Plant layout,Factors influencing plant layout,Types and principles of plant layout
Production management- Layout types
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Transcript of Production management- Layout types
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Ground rules
Arrive on time.
Turn your cell phone off.
Do not leave class early without okaying it with the lecturer in advance.
80% attendance is compulsory
Participate actively.
Submit one page summary of the lecture.
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Layout decisions
NNC Pushpamali
Dept. of Management of Technology
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Intended learning outcomes
Recognize the strategic importance of layout decisions
Identify the factors concerned in layout decisions
Evaluate different types of layout
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Strategic Importance of Layout Decisions
• One of the key decisions that determines the long-run efficiency of operations.
• It established an organization’s competitive priorities in regard to capacity, processes, flexibility, and cost as well as quality of work life, customer contact and image.
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The objective of layout strategy is to develop an effective and efficient layout that will meet the firm’s competitive requirements.
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Layout Design Considerations
Higher utilization of space, equipment, and people
Improved flow of information, materials, or people
Improved employee morale and safer working conditions
Improved customer/client interaction
Flexibility
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Layout decisions include the best placement of machines (in production settings), offices and desks (in office settings) or service centers (in settings such as hospitals or department stores)
An effective layout facilities the flow of materials, people, and information within and between areas.
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Types of Layout
1. Office layout
2. Retail layout
3. Warehouse layout
4. Fixed-position layout
5. Process-oriented layout
6. Work-cell layout
7. Product-oriented layout
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Types of Layout
1. Office layout: Positions workers, their equipment, and spaces/offices to provide for movement of information
2. Retail layout: Allocates shelf space and responds to customer behavior
3. Warehouse layout: Addresses trade-offs between space and material handling
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Types of Layout
4. Fixed-position layout: Addresses the layout requirements of large, bulky projects such as ships and buildings
5. Process-oriented layout: Deals with low-volume, high-variety production (also called job shop or intermittent production)
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Types of Layout
6. Work cell layout: Arranges machinery and equipment to focus on production of a single product or group of related products
7. Product-oriented layout: Seeks the best personnel and machine utilizations in repetitive or continuous production
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Good Layouts Consider
Material handling equipment
Capacity and space requirements
Environment and aesthetics
Flows of information
Cost of moving between various work areas
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Office Layout
Grouping of workers, their equipment, and spaces to provide comfort, safety, and movement of information
Movement of information is main distinction
Typically in state of flux due to frequent technological changes
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https://www.google.lk/search?q=office+relationship+chart&espv=2&biw=1024&bih=599&tbm=isch&imgil=OopO8KUhWLKI6M%253A%253BJpMt7GIHB4Nv-M%253Bhttp%25253A%25252F%25252Fwww.slideshare.net%25252Fshilpijain23%25252Flayout-
strategies&source=iu&pf=m&fir=OopO8KUhWLKI6M%253A%252CJpMt7GIHB4Nv-M%252C_&usg=__2gITO01__eUogCemyXt_yB-BECY%3D&ved=0CCQQyjdqFQoTCJ_drvvJ9sgCFUiclAod7E4AoQ&ei=V-A5Vt_VEMi40gTsnYGICg#imgrc=gluv_bCVJI64vM%3A&usg=__2gITO01__eUogCemyXt_yB-BECY%3D
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Office relationship chart
https://www.google.lk/search?q=office+relationship+chart&espv=2&biw=1024&bih=599&tbm=isch&imgil=OopO8KUhWLKI6M%253A%253BJpMt7GIHB4Nv-M%253Bhttp%25253A%25252F%25252Fwww.slideshare.net%25252Fshilpijain23%25252Flayout-strategies&source=iu&pf=m&fir=OopO8KUhWLKI6M%253A%252CJpMt7GIHB4Nv-
M%252C_&usg=__2gITO01__eUogCemyXt_yB-BECY%3D&ved=0CCQQyjdqFQoTCJ_drvvJ9sgCFUiclAod7E4AoQ&ei=V-A5Vt_VEMi40gTsnYGICg#imgrc=49JgSWU39GkTxM%3A&usg=__2gITO01__eUogCemyXt_yB-BECY%3D
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Supermarket Retail Layout
Objective is to maximize profitability per square foot of floor space
Sales and profitability vary directly with customer exposure to the products
Greater the rate of exposure, the greater the sales and the higher the return on investment
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Five Helpful Ideas for Supermarket Layout
1. Locate high-draw items around the periphery of the store
2. Use prominent locations for high-impulse and high-margin items
3. Distribute power items to both sides of an aisle and disperse them to increase viewing of other items
4. Use end-aisle locations
5. Convey mission of store through careful positioning of lead-off department
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Retail Slotting
Manufacturers pay fees to retailers to get the retailers to display (slot) their product
Contributing factors
Limited shelf space
An increasing number of new products
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Servicescapes
1. Ambient conditions - background characteristics such as lighting, sound, smell, and temperature
2. Spatial layout and functionality - which involve customer circulation path planning, aisle characteristics, and product grouping
3. Signs, symbols, and artifacts - characteristics of building design that carry social significance
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Warehousing and Storage Layouts
Trade-off between handling cost and costs associated with warehouse space.
Material handling cost: incoming transport, storage, outgoing transport,: equipment, people, material, supervision, insurance and depreciation
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Cross-Docking
Materials are moved directly from receiving to shipping and are not placed in storage in the warehouse
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Fixed-Position Layout
Product remains in one place
(a ship, a highway, a bridge, a house, an operating table)
Workers and equipment come to site
Complicating factors
Limited space at site
Different materials required at different stages of the project
Volume of materials needed is dynamic
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Process oriented layout
Can simultaneously handle a variety of products or services.
When making products with different requirements or when handling customers, patients or clients with different needs.
Most common tactic is to arrange department or work centers so as to minimize the costs of material handling
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e.g.
Walters company management wants to arrange the six departments of its factory in a way that will minimize interdepartmental material handling costs. (They make an initial assumption that each department is 20*20 feet and that the building is 60 feet long and 40 feet wide
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Construct a from-to-matrix
https://books.google.lk/books?id=wUHzc8JtZzUC&pg=PA319&lpg=PA319&dq=Walters+company+management+wants+to+arrange+the+six+departments+of+its+factory+in+a+way+that+will+mi
nimize+interdepartmental+material+handling+costs.+(They+make+an+initial+assumption+that+each+department+is+20*20+feet+and+that+the+building+is+60+feet+long+and+40+feet+wide&s
ource=bl&ots=EGMdjuDSTD&sig=rIVOMm4jnfkqniQt6uBEHGan9t8&hl=en&sa=X&ved=0ahUKEwjy59fU76XJAhUCH5QKHcd9DdkQ6AEIGzAA#v=onepage&q&f=false
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Determine the space requirement
https://books.google.lk/books?id=wUHzc8JtZzUC&pg=PA319&lpg=PA319&dq=Walters+company+management+wants+to+arrange+the+six+departments+of+its+factory+in+a+way+that+will+mi
nimize+interdepartmental+material+handling+costs.+(They+make+an+initial+assumption+that+each+department+is+20*20+feet+and+that+the+building+is+60+feet+long+and+40+feet+wide&s
ource=bl&ots=EGMdjuDSTD&sig=rIVOMm4jnfkqniQt6uBEHGan9t8&hl=en&sa=X&ved=0ahUKEwjy59fU76XJAhUCH5QKHcd9DdkQ6AEIGzAA#v=onepage&q&f=false
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Develop an initial schematic diagram
https://books.google.lk/books?id=wUHzc8JtZzUC&pg=PA319&lpg=PA319&dq=Walters+company+management+wants+to+arrange+the+six+departments+of+its+factory+in+a+way+that+will+mi
nimize+interdepartmental+material+handling+costs.+(They+make+an+initial+assumption+that+each+department+is+20*20+feet+and+that+the+building+is+60+feet+long+and+40+feet+wide&s
ource=bl&ots=EGMdjuDSTD&sig=rIVOMm4jnfkqniQt6uBEHGan9t8&hl=en&sa=X&ved=0ahUKEwjy59fU76XJAhUCH5QKHcd9DdkQ6AEIGzAA#v=onepage&q&f=false
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Determine the cost of this layout
Adjacent dept. $1
Non adjacent dept. $2
($ 570)
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https://books.google.lk/books?id=wUHzc8JtZzUC&pg=PA319&lpg=PA319&dq=Walters+company+management+wants+to+arrange+the+six+departments+of+its+factory+in+a+way+that+will+mi
nimize+interdepartmental+material+handling+costs.+(They+make+an+initial+assumption+that+each+department+is+20*20+feet+and+that+the+building+is+60+feet+long+and+40+feet+wide&s
ource=bl&ots=EGMdjuDSTD&sig=rIVOMm4jnfkqniQt6uBEHGan9t8&hl=en&sa=X&ved=0ahUKEwjy59fU76XJAhUCH5QKHcd9DdkQ6AEIGzAA#v=onepage&q&f=false
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By trial and error, improve the layout
$ 480
https://books.google.lk/books?id=wUHzc8JtZzUC&pg=PA319&lpg=PA319&dq=Walters+company+management+wants+to+arrange+the+six+departments+of+its+factory+in+a+way+that+will+mi
nimize+interdepartmental+material+handling+costs.+(They+make+an+initial+assumption+that+each+department+is+20*20+feet+and+that+the+building+is+60+feet+long+and+40+feet+wide&s
ource=bl&ots=EGMdjuDSTD&sig=rIVOMm4jnfkqniQt6uBEHGan9t8&hl=en&sa=X&ved=0ahUKEwjy59fU76XJAhUCH5QKHcd9DdkQ6AEIGzAA#v=onepage&q&f=false
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workcells
An arrangement of machines and personnel that focus on making a single product or family of related products.
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https://books.google.lk/books?id=wUHzc8JtZzUC&pg=PA319&lpg=PA319&dq=Walters+company+management+wants+to+arrange+the+six+departments+of+its+factory+in+a+way+that+will+mi
nimize+interdepartmental+material+handling+costs.+(They+make+an+initial+assumption+that+each+department+is+20*20+feet+and+that+the+building+is+60+feet+long+and+40+feet+wide&s
ource=bl&ots=EGMdjuDSTD&sig=rIVOMm4jnfkqniQt6uBEHGan9t8&hl=en&sa=X&ved=0ahUKEwjy59fU76XJAhUCH5QKHcd9DdkQ6AEIGzAA#v=onepage&q&f=false
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Staffing and Balancing workcells
1. Takt time: pace (frequency) of production units necessary to meet customer orders.
= Total work time available/ units required
2. Number of operators required
= Total operation time required/ takt time
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e.g.
Stepehn Hall’s company makes auto mirrors. The major customer is the Honda plant nearby. Honda expects 600 mirrors delivered daily, and the work cell producing the mirrors is scheduled for 8 hours.
Determine the takt time and the number of workers required.
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Cont.…
Total operation time required is 140 seconds.
Assemble= 50 seconds
Paint= 45 seconds
Test= 10 seconds
Label= 20 seconds
Pack for shipping= 15
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answer
Takt time: (8 hour* 60 minutes)/ 600 units= 480/600= 0.8 minutes= 48 seconds
Workers required: 140/48 = 2.92
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Product- oriented layout
Are organized around products or families of similar high-volume, low-variety products. Repetitive production and continous production
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McDonald’s Assembly Line
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Developing a precedence diagram for an assembly
line Boeing wants to develop a
precedence diagram for an electrostatic wing component that require a total assembly time of 66 minutes.
Staff gather tasks, assembly times and sequence requirements for the component as below.
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480 productive minutes production schedule requires that 40 units
Task Assembly time
(minutes)
Task must follow
task listed below
A 10 -
B 11 A
C 5 B
D 4 B
E 12 A
F 3 C,D
G 7 F
H 11 E
I 3 G,H
TOTAL TIME 66
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https://books.google.lk/books?id=wUHzc8JtZzUC&pg=PA319&lpg=PA319&dq=Walters+company+management+wants+to+arrange+the+six+departments+of+its+factory+in+a+way+that+will+mi
nimize+interdepartmental+material+handling+costs.+(They+make+an+initial+assumption+that+each+department+is+20*20+feet+and+that+the+building+is+60+feet+long+and+40+feet+wide&s
ource=bl&ots=EGMdjuDSTD&sig=rIVOMm4jnfkqniQt6uBEHGan9t8&hl=en&sa=X&ved=0ahUKEwjy59fU76XJAhUCH5QKHcd9DdkQ6AEIGzAA#v=onepage&q&f=false
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Steps
Cycle time (The maximum time that a product is allowed at each station)=
production time available per day ÷ units required per day
Minimum number of workstation=
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Cycle time= 480 m/ 40 units
= 12 minutes/ unit
Minimum number of workstation= Total task time/ cycle time= 66/12= 5.5 or 6 stations
© 2011 Pearson Education
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https://books.google.lk/books?id=wUHzc8JtZzUC&pg=PA319&lpg=PA319&dq=Walters+company+management+wants+to+arrange+the+six+departments+of+its+factory+in+a+way+that+will+mi
nimize+interdepartmental+material+handling+costs.+(They+make+an+initial+assumption+that+each+department+is+20*20+feet+and+that+the+building+is+60+feet+long+and+40+feet+wide&s
ource=bl&ots=EGMdjuDSTD&sig=rIVOMm4jnfkqniQt6uBEHGan9t8&hl=en&sa=X&ved=0ahUKEwjy59fU76XJAhUCH5QKHcd9DdkQ6AEIGzAA#v=onepage&q&f=false
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Heizer, J., & Render, B., Operation Management, Global Edition, Pearson
https://mrtashfeen.wikispaces.com/file/view/Layout+Decisions.ppt