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FACILITY LAYOUT
Process Layout
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Facility Layout
A Layout problem may be to
determine the location for a new machine,
develop a new layout for an existingproduction plant,
develop a layout for a new production
plant,
etc.
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Facility Layout
Facility layout can be defined as the processby which the placement of departments,workgroups within departments,workstations, machines, and stock-holdingpoints within a facility are determined.
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A Layout problem may arise due to changes in the design of a product,
addition or deletion of a product,
change in the demand of a product, changes in the design of the process,
addition or deletion of a process,
obsolescence/replacement of equipment,
frequent accidents,
changes in legal/environmental regulations,
competitive cost reduction, etc.
Facility Layout
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Objectives of Facility Layout
Reduce congestion that impedes movement of peopleor material
Minimize material handling costs
Provide safety and comfort to employees
Utilize labour efficiently Increase morale
Utilize available space effectively and efficiently
Provide ease of supervision
Facilitate co-ordination and face-to-face communication
Minimize investment in equipment
Minimize production time
Maintain flexibility of arrangement and operation
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Basic Layout Types
Product or Line Layouts - uses standardizedprocessing operations to achieve smooth,high-volume flow
Process or Functional Layouts - can handlevaried processing requirements
Project or Fixed-Position - the product orproject remains stationary, and workers,materials, and equipment are moved as needed
Cellular Layouts
Combination Layouts
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Process Layout: Interdepartmental Flow
GivenThe flow (number of moves) to and from all
departments
The cost of moving from one department to
another
The existing or planned physical layout of the
plant
DetermineThe best locations for each department,
where best means maximizing flow, while
minimizing costs
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Graphic Approaches to Layout
Planning
1 2
5
3
64Facility Outline Locations
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Graphic Approaches to Layout
Planning
From
No. of Moves to
A B C D E F
A - 7 - - - 5B - - - 4 10 -
C - 7 - - 2 -
D - - 8 - - -E 4 - - - - 3
F - 6 - - 10 -
From-To or Travel Chart
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Graphic Approaches to Layout
Planning
Deptt. A B C D E FNo. oflinks
3 5 3 2 5 4
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Graphic Approaches to Layout
Planning
Deptt. A B C D E FNo. oflinks
3 5 3 2 5 4
Number of Links or Number of Moves?
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Graphic Approaches to Layout
Planning
A 7
F
B D
E C10
4
2
5 10 8
6
7
4
3
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Graphic Approaches to Layout
Planning
A B
E
D
CFA Possible Facility Layout
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Process Layout: Systematic LayoutPlanning
Numerical flow of items between workcentres
Can be impractical to obtain
Does not account for the qualitative factors that may
be crucial to the placement decision
Systematic Layout Planning
Accounts for the importance of having each
department located next to every other department Is also guided by trial and error
Switching workcentres then checking the resultsof the closeness score
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Muthers
SystematicLayout
Planning
Input Data and
Activities
1. Flow of Materials2. Activity
Relationships
3. Relationship Chart
4. Relationship
Diagram
5. Space Requirement 6. Space Available
7. Space Relationship
Diagram
8. ModifyingConsiderations 9. PracticalLimitations
10. Develop
Alternative Layouts
11. Evaluation
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Example of Systematic Layout Planning:
Relating Reasons and Importance
From
1. Credit department
2. Toy department
3. Wine department
4. Camera department
5. Candy department
6
I
--
U
4
E
--
U
--
U
1
I
1,6
A
--
U
1
X
1
X
To2 3 4 5
Area
(sq. ft.)
100
400
300
100
100
Closeness rating
Reason for rating
Letter
Number
Relationship Chart or REL Chart
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Example of Systematic Layout Planning:
Relating Reasons and Importance
From
1. Credit department
2. Toy department
3. Wine department
4. Camera department
5. Candy department
6
I
--
U
4
A
--
U
--
U
1
I
1,6
A
--
U
1
X
1
X
To2 3 4 5
Area
(sq. ft.)
100
400
300
100
100
Closeness rating
Reason for rating
Note here
that the (1)
Credit Dept.
and (4)
CameraDept. are
given a high
rating of A.Letter
Number
Note here that
the (2) Toy Dept.
and the (5)Candy Dept. are
given a high
rating of A.
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Example of Systematic Layout Planning:
Reasons for Closeness
Code
1
2
3
4
5
6
Reason*
Type of customer
Ease of supervision
Common personnel
Contact necessary
Share same price
Psychology
* Others may be used
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Example of Systematic Layout Planning:Initial Relationship Diagram
1
2
4
3
5
X X
E
A
I
The number of lines
here represent paths
required to be taken in
transactions between
the departments. The
more lines, the more
the interaction betweendepartments.
Note here again, Depts. (1) and(2) are linked together, and
Depts. (2) and (5) are linked
together by multiple lines or
required transactions.
I
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Example of Systematic Layout Planning:
Initial and Final Layouts
1
2 4
3
5
Initial Layout
Ignoring space and
building constraints
2(400)
5(100) 1(100) 4(100)
3
(300)
50 ft
20 ft
Final Layout
Adjusted by square
footage and building
size
Note in the
Final Layout
that Depts.
(1) and (5)are not both
placed
directly next
to Dept. (2).
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Computerised Layout Planning
Construction ProgrammesComputerised Relationship Layout Planning
(CORELAP)
Automated Layout Design Programme (ALDEP) Plant Layout Analysis and Evaluation Technique
(PLANET)
Improvement ProgrammesComputerised Relative Allocation of FacilitiesTechnique (CRAFT)
Computerised Facilities Design (CFD)
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Cellular Manufacturing Layouts
Operations required to produce a particularfamily (group) of parts are arranged in thesequence required to make that family
Used when the operations system must handle amoderate variety of products in moderatevolumes
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Characteristics of Cellular Manufacturing
Relative to Process Layouts
Equipment can be less general-purpose
Material handling costs are reducedTraining periods for operators are shortened
In-process inventory is lower
Parts can be made faster and shipped morequickly
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Characteristics of Cellular Manufacturing
Relative to Product Layouts
Equipment can be less special-purpose
Changeovers are simplified Production is easier to automate
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Manufacturing Cell:Benefits
1. Better human relations
2. Improved operator expertise
3. Less in-process inventory and material
handling
4. Faster production setup
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Manufacturing Cell:
Transition from Process Layout
1. Grouping parts into families that follow acommon sequence of steps
2. Identifying dominant flow patterns of partsfamilies as a basis for location or relocationof processes
3. Physically grouping machines and processesinto cells
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Cell 3
L M G G
Cell 1 Cell 2
Assembly
areaA A
L M DL
L MShipping
D
Receiving
G
Create Manufacturing Cells
Line flows in a job shop with three GT cells
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One Worker, Multiple Machines
Materials in
Machine
2Machine
1
Machine
5
Finished
goods out
Machine
4
Machine
3
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Planning Cellular Manufacturing
Layouts
Cell Formation Decision
Which machines are assigned tomanufacturing cells
Which parts will be produced in each cell
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Planning Cellular Manufacturing
Layouts
Fundamental Requirements for Parts to beMade in Cells
Demand for the parts must be high enoughand stable enough that moderate batch sizesof the parts can be produced periodically.
Parts must be capable of being grouped intoparts families.
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Planning Cellular Manufacturing
Layouts
More-Complex Issues to be Resolved
If all the parts cannot be cleanly divided
between cells, how will we decide which are tobe the exceptional parts?
If inadequate capacity is available to produce all
the parts in cells, which parts should be madeoutside the cells?
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Planning Cellular Manufacturing
LayoutsCell Formation Procedure
1. Form the Parts-Machines Matrix.2. Rearrange the Rows.
Place the machines that produce the sameparts in adjacent rows.
3. Rearrange the Columns.
Place the parts requiring the same machinesin adjacent columns.4. Use the rearranged parts-machines matrix to
identify cells, the machines for that cell and the
parts that will be produced in that cell.
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Example: Maxx Superchargers
Cell Formulation
Maxx produces superchargers for highperformance cars and trucks. Maxx hasimplemented a group technology program in itsshop and now must formulate themanufacturing cells. Maxx has identified six
parts that meet the requirements for CM.The parts-machines matrix on the next slide
identifies the 6 parts and 5 machines on which
the parts are presently produced.
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Example: Maxx Superchargers
Cell FormulationOriginal Matrix
1 2 3 4 5 6X X X
X X X X
X X
X XX X X
A
B
C
DE
Parts
Machines
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Example: Maxx Superchargers
Cell FormulationRows Rearranged
1 2 3 4 5 6
X X XX X X
X X
X X
X X X X
AE
D
C
B
Parts
Machines
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Example: Maxx Superchargers
Cell FormulationColumns Rearranged
3 5 6* 1 2 4
X X XX X X
X X
X X
X X X X
AE
D
C
B
Parts
Machines
* exceptional part
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Example: Maxx Superchargers
Cell FormulationSummary
2 manufacturing cells (MC1, MC2) will be used.
Parts 3 and 5 will be produced in MC1 on machinesA and E.
Parts 1, 2 and 4 will be produced in MC2 onmachines B, C and D.
Part 6 is an exceptional part that cannot be producedwithin a single cell.
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Planning Cellular Manufacturing
LayoutsExerciseMachi
nesParts
1 2 3 4 5 6 7 8
A X X
B X XC X X X
D X X
E X X
F X X X
G X
H X X X
I X X
l i C ll l f i
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Machines
Parts
3 5 8 1 4 2 6* 7
B X X
C X X XF X X X
D X X
G X
I X X
A X X
E X X
H X X X
Planning Cellular Manufacturing
LayoutsExercise
Pl i C ll l M f i
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Cell FormulationSummary
3 manufacturing cells (MC1, MC2, MC3) will be used.
Parts 3, 5 and 8 will be produced in MC1 on machines B, C
and F. Parts 1, and 4 will be produced in MC2 on machines D, G
and I.
Parts 2, 6 and 7 will be produced in MC3 on machines A, Eand H.
Part 6 is an exceptional part that cannot be produced within asingle cell.
A second machine F needs to be purchased or else it needs tobe moved between MC1 and MC3.
Planning Cellular Manufacturing
LayoutsExercise
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