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Production Plant Layout (1)Production Plant Layout (1)
Facility Layout Problem: designFacility Layout Problem: design
problemproblem
locations of activitieslocations of activities
dimensionsdimensions
configurationsconfigurations
No overall algorithm existsNo overall algorithm exists
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Design problem
Greenfield Location of one
new machine
Production Plant Layout (2)Production Plant Layout (2)
Reasons:Reasons: new productsnew products
changes in demandchanges in demand
changes in product designchanges in product design new machinesnew machines
bottlenecksbottlenecks
too large bufferstoo large buffers
too long transfer timestoo long transfer times
Production Plant Layout (2)Production Plant Layout (2)
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DesignDesign
Layout
Product
Logistics Process
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Production Plant Layout (3)Production Plant Layout (3)
Goals (examples):Goals (examples):
minimal material handling costsminimal material handling costs
minimal investmentsminimal investments
minimal throughput timeminimal throughput time
flexibilityflexibility
efficient use of spaceefficient use of space
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Production Plant Layout (4)Production Plant Layout (4)
Restrictions:Restrictions:
legislation on employees workinglegislation on employees working
conditionsconditions present building (columns/waterworks)present building (columns/waterworks)
Methods:Methods:
Immer: The right equipment at the rightImmer: The right equipment at the rightplace to permit effective processingplace to permit effective processing
Apple: Short distances and short timesApple: Short distances and short times
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Goals Production Plant LayoutGoals Production Plant Layout
Plan for the preferred situation in thePlan for the preferred situation in the futurefuture
Layout must support objectives of the facilityLayout must support objectives of the facility
No accurate dataNo accurate data layout must be flexiblelayout must be flexible
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Search
Analysis
Systematic Layout PlanningSystematic Layout Planning
Muther (1961)Muther (1961)
0 Data gathering
10 Evaluation
4 Space
requirements
5 Space
available
6 Space relationship
diagram
1 Flow 2 Activities
3 Relationshipdiagram
7 Reasons to
modify8 Restrictions
9 Layout alternatives
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0 - Data gathering (1)0 - Data gathering (1)
Source: product designSource: product design
BOMBOM
drawingsdrawings
gozinto (assembly) chart, see fig 2.10gozinto (assembly) chart, see fig 2.10
redesign, standardizationredesign, standardization simplificationssimplifications
machines
product design
sequence of assembly operations
layout (assembly) line
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0 - Data gathering (2)0 - Data gathering (2)
Source: Process designSource: Process design make/buymake/buy
equipment usedequipment used process timesprocess times
operations process chartoperations process chart (fig 2.12)(fig 2.12)
assembly chartassembly chart
operationsoperations
precedence diagramprecedence diagram
(fig 2.13)(fig 2.13)
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0 - Data gathering (3)0 - Data gathering (3)
Source: Production schedule designSource: Production schedule design
logistics: where to produce, how muchlogistics: where to produce, how much
product mixproduct mix marketing: demand forecastmarketing: demand forecast
production rateproduction rate
types and number of machinestypes and number of machines continuous/intermittentcontinuous/intermittent
layoutlayout scheduleschedule
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1/2 - Flow and Activity Analysis1/2 - Flow and Activity Analysis
Flow analysis:Flow analysis:
Types of flow patternsTypes of flow patterns
Types of layoutTypes of layout
flow analysis approachesflow analysis approaches
Activity relationship analysisActivity relationship analysis
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1/2 - Flow analysis and activity1/2 - Flow analysis and activity
analysisanalysisFlow analysisFlow analysis
quantitative measure of movementsquantitative measure of movements
between departments:between departments:
material handling costsmaterial handling costs
Activity analysisActivity analysis
qualitative factorsqualitative factors
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Flow analysisFlow analysis
Flow of materials, equipment andFlow of materials, equipment and
personnelpersonnel
Raw material Finished product
layout facilitates this flowlayout facilitates this flow
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Types of flow patternsTypes of flow patterns
P = receivingP = receiving
S = shippingS = shipping
R S
R S
R
S
long line
Horizontal transportHorizontal transport
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LayoutLayout
volumes of productionvolumes of production
variety of productsvariety of products
volumes: what is the right measure ofvolumes: what is the right measure of
volume from a layout perspective?volume from a layout perspective?
varietyvariety high/low commonalityhigh/low commonality
layout typelayout type
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Types of layoutTypes of layout
Fixed product layoutFixed product layout
Product layoutProduct layout
Group layoutGroup layout
Process layoutProcess layout
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Fixed product layoutFixed product layout
ProcessesProcesses product (e.g. shipbuilding)product (e.g. shipbuilding)
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Product layout (flow shop)Product layout (flow shop)
Production line according to theProduction line according to the
processing sequence of the productprocessing sequence of the product
High volume productionHigh volume production
Short distancesShort distances
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Process layout (Job shop)Process layout (Job shop)
All machines performing a particularAll machines performing a particular
process are grouped together in aprocess are grouped together in a
processing departmentprocessing department Low production volumesLow production volumes
Rapid changes in the product mixRapid changes in the product mix
High interdepartmental flowHigh interdepartmental flow
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Group layoutGroup layout
Compromise between product layoutCompromise between product layout
and process layoutand process layout
Product layouts for product familiesProduct layouts for product families cells (cellular layout)cells (cellular layout)
Group technologyGroup technology
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Production volume and product varietyProduction volume and product varietydetermines type of layoutdetermines type of layout
group layout process layout
product variety
production
volume
product
layout
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Layout determinesLayout determines
material handlingmaterial handling
utilization of space, equipment andutilization of space, equipment and
personnel (table 2.2)personnel (table 2.2)
Flow analysis techniquesFlow analysis techniques
Flow process chartsFlow process charts product layoutproduct layout
From-to-chartFrom-to-chart process layoutsprocess layouts
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Activity relationship analysisActivity relationship analysis
Relationship chart (figure 2.24)Relationship chart (figure 2.24)
Qualitative factors (Qualitative factors (subjective!subjective!))
Closeness rating (A, E, I, O, U or X)Closeness rating (A, E, I, O, U or X)
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3 - Relationship diagrams3 - Relationship diagrams
Construction of relationships diagrams:Construction of relationships diagrams:
diagrammingdiagramming
Methods, amongst others: CORELAPMethods, amongst others: CORELAP
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Relationship diagram (1)Relationship diagram (1)
Spatial picture of the relationshipsSpatial picture of the relationships
between departmentsbetween departments
Constructing a relation diagram oftenConstructing a relation diagram oftenrequires compromises.requires compromises.
What is closeness? 10 or 50 meters?What is closeness? 10 or 50 meters?
See figure 2.25See figure 2.25
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Relationship diagram (2)Relationship diagram (2)
PremisePremise:: geographicgeographic proximityproximity reflects thereflects the
relationshipsrelationships
Sometimes other solutions:Sometimes other solutions: e.g. X-rating because of noisee.g. X-rating because of noise acousticalacoustical
panels instead of distance separationpanels instead of distance separation
e.g. A rating because of communicatione.g. A rating because of communication
requirementrequirement computer network instead of proximitycomputer network instead of proximity
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Graph theory based approachGraph theory based approach
closeclose adjacentadjacent
department-nodedepartment-node
adjacent-edgeadjacent-edge
requirement: graph is planarrequirement: graph is planar
(no intersections)(no intersections)
region-faceregion-face
adjacent faces: share a common edgeadjacent faces: share a common edge
graphgraph
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Primal graphPrimal graph dual graphdual graph
Place a node in each facePlace a node in each face
Two faces which share an edge joinTwo faces which share an edge join
the dual nodes by an edgethe dual nodes by an edge
Faces dual graph correspond to theFaces dual graph correspond to the
departments in primal graphdepartments in primal graph
block layout (plan) e.g. figure 2.39block layout (plan) e.g. figure 2.39
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Graph theoryGraph theory
Primal graph planarPrimal graph planar dual graphdual graph
planarplanar
Limitations to the use of graph theory:Limitations to the use of graph theory:it may be an aid to the layout designerit may be an aid to the layout designer
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CORELAPCORELAP
Construction algorithmConstruction algorithm
Adjacency!Adjacency!
Total closeness rating = sum ofTotal closeness rating = sum of
absolute values for the relationshipsabsolute values for the relationships
with a particular department.with a particular department.
=j
iji rTCR
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CORELAP - stepsCORELAP - steps
1.1. sequence of placements ofsequence of placements of
departmentsdepartments
2.2. location of departmentslocation of departments
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CORELAP step 1CORELAP step 1
First department:First department:
Second department:Second department:
X-relationX-relation last placed departmentlast placed department
A-relation with first. If noneA-relation with first. If none E-relationE-relation
with first, etceterawith first, etcetera
ii
TCRmax
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CORELAP step 2CORELAP step 2
Weighted placement valueWeighted placement value
1st
8
1
2 3
7 6
5
4
2nd
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4 - Space requirements4 - Space requirements
Building geometry or building siteBuilding geometry or building site
space availablespace available
Desired production rate, distinguish:Desired production rate, distinguish: Engineer to order (ETO)Engineer to order (ETO)
Production to order (PTO)Production to order (PTO)
Production to stock (PTS)Production to stock (PTS)
marketing forecastmarketing forecast productionsproductions
quantitiesquantities
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4 - Space requirements4 - Space requirements
Equipment requirements:Equipment requirements:
Production rateProduction rate number of machinesnumber of machines
requiredrequired
Employee requirementsEmployee requirements
rate
machine operators
machines employees
assembly
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Space determinationSpace determination
Methods:Methods:
1. Production center1. Production center
2. Converting2. Converting
4. Standards4. Standards
5. Projection5. Projection
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4 - Space determination (1)4 - Space determination (1)
1. Production center1. Production center
for manufacturing areasfor manufacturing areas
machinemachinespace requirementsspace requirements
2. Converting2. Converting
e.g. for storage arease.g. for storage areas present space requirementpresent space requirement spacespace
requirementsrequirements
non-linear function of production quantitiynon-linear function of production quantitiy
# machines per operator
# assembly operatorsSpace requirements
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4 - Space determination (2)4 - Space determination (2)
4.4. Space standardsSpace standards
standardsstandards
5.5. Ratio trend and projectionRatio trend and projection
e.g. direct labour hour, unit producede.g. direct labour hour, unit produced
Not accurate!Not accurate!
Include space for:Include space for:
packaging, storage, maintenance, offices, aisles,packaging, storage, maintenance, offices, aisles,inspection, receiving and shipping, canteen, toolinspection, receiving and shipping, canteen, tool
rooms, lavatories, offices, parkingrooms, lavatories, offices, parking
factor
space
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Deterministic approach (1)Deterministic approach (1)
n = # machines per operator (non-integer)n = # machines per operator (non-integer)
a = concurrent activity timea = concurrent activity time
t = machine activity timet = machine activity time b= operatorb= operator
ba
tan
+
+='
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Deterministic approach (2)Deterministic approach (2)
( )
+
+=
bam
taTc
TTcc = cycle time= cycle time
a = concurrent activity timea = concurrent activity time
t = machine activity timet = machine activity time
b = operator activity timeb = operator activity time
m = # machines per operatorm = # machines per operator
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Deterministic approach (3)Deterministic approach (3)
( )m
TmCCmTC c21)( +=
TC(m) = cost per unit produced as a function of mTC(m) = cost per unit produced as a function of m
CC11 = cost per operator-hour= cost per operator-hour
CC22 = cost per machine-hour= cost per machine-hour
Compare TC(n) and TC(n+1) for n < n < n+1Compare TC(n) and TC(n+1) for n < n < n+1
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Designing the layout (1)Designing the layout (1)
Search phaseSearch phase
Alternative layoutsAlternative layouts
Design process includesDesign process includes Space relationship diagramSpace relationship diagram
Block planBlock plan
Detailed layoutDetailed layout
Flexible layoutsFlexible layouts
Material handling systemMaterial handling system
PresentationPresentation
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Designing the layout (2)Designing the layout (2)
Relationship diagram + spaceRelationship diagram + space
space relationship diagramspace relationship diagram
(see fig 2.56)(see fig 2.56)
Different shapesDifferent shapes
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9 Layout alternatives9 Layout alternatives
Alternative layouts by shifting theAlternative layouts by shifting the
departments to other locationsdepartments to other locations
block plan, also shows e.g.block plan, also shows e.g.
columns and positions of machinescolumns and positions of machines
(see fig 2.57)(see fig 2.57)
selection
detailed design
detailed design
selection
or
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Flexible layoutsFlexible layouts
FutureFuture
Anticipate changesAnticipate changes
2 types of expansion:2 types of expansion:
1.1. sizessizes
2.2. number of activitiesnumber of activities
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Material handling systemMaterial handling system
Design in parallel with layoutDesign in parallel with layout
PresentationPresentation
CAD templates 2 or 3 dimensionalCAD templates 2 or 3 dimensional
simulationssimulations
selling the layout (+ evaluation)selling the layout (+ evaluation)
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10 Evalution (1)10 Evalution (1)
Selection and implementationSelection and implementation best layoutbest layout
cost of installation + operating costcost of installation + operating cost comparecompare futurefuture costs for both the new and thecosts for both the new and the
old layoutold layout
other considerationsother considerations
selling the layoutselling the layout assess and reduce resistanceassess and reduce resistance
anticipate amount of resistance for eachanticipate amount of resistance for eachalternativealternative
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10 Evalution (2)10 Evalution (2)
Causes of resistance:Causes of resistance: inertiainertia
uncertaintyuncertainty loss of job contentloss of job content
Minimize resistance byMinimize resistance by
participationparticipation
stagesstages
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ImplementationImplementation
InstallationInstallation
planningplanning
Periodic checks after installationPeriodic checks after installation
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Systematic Layout PlanningSystematic Layout Planning0 Data gathering
10 Evaluation
Analysis
Search
Selection
4 Spacerequirements 5 Spaceavailable
6 Space relationship
diagram
1 Flow 2 Activities
3 Relationship
diagram
7 Reasons to
modify8 Restrictions
9 Layout alternatives
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Systematic Layout PlanningSystematic Layout Planning0 Data gathering
10 Evaluation
Analysis
Search
Selection
4 Spacerequirements 5 Spaceavailable
6a Space relationship
diagram
1 Flow 2 Activities
3 Relationship
diagram
7 Reasons to
modify8 Restrictions
9 Layout alternatives
6b Analytical analyses
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Automatic Guided Vehicles (AGVs)Automatic Guided Vehicles (AGVs)
Unmanned vehicle for in-plant transportation onUnmanned vehicle for in-plant transportation onmanufacturing and assembly areasmanufacturing and assembly areas
Two types of guidanceTwo types of guidance free rangingfree ranging
dead reckoning + lasers or transpondersdead reckoning + lasers or transponders
path restrictedpath restricted induction wires in the floorinduction wires in the floor
AGVAGV fork lift truck with RF-communicationfork lift truck with RF-communication
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Design and operational control of anDesign and operational control of an
AGV systemAGV systemAGV systemAGV system
track layouttrack layout
number of AGVsnumber of AGVs operational controloperational control
Traffic control: zonesTraffic control: zones
max. throughputmax. throughputcapacitycapacity
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Track layoutTrack layout
infrastructureinfrastructure
location of pick-up and drop-off stationslocation of pick-up and drop-off stations
buffer sizesbuffer sizes
congestion/blockingcongestion/blocking
tandem configurationtandem configuration
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Determination of number of AGVsDetermination of number of AGVs
h
timetravelemptytotaltv
AGVsi j
ijij +
=
)min(
#
5 x
6 x
4 x LP-problem(i.e. a classical TP)
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Operational transportation controlOperational transportation control
Job controlJob control
(routing and scheduling of transportation tasks)(routing and scheduling of transportation tasks)
Traffic controlTraffic control
Traffic rulesTraffic rules
Goal: minimize empty travel + waiting timeGoal: minimize empty travel + waiting time
Single load:Single load: Performance indicators:Performance indicators:- Throughput- Throughput- Throughput times- Throughput times
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Operational controlOperational control
production controlproduction control transportation controltransportation control flow shopflow shop
job shopjob shop
centralized controlcentralized control
all tasks are concurrently consideredall tasks are concurrently considered
or decentralized controlor decentralized control FEFS: AGV looks for work (suited for tandem configuration)FEFS: AGV looks for work (suited for tandem configuration)
think-aheadthink-ahead combine tasks to routescombine tasks to routes
or no think-aheador no think-ahead
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Relations between the issuesRelations between the issues
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Combination 1Combination 1
Separated/no think-aheadSeparated/no think-ahead centralized controlcentralized control
on-line priority rules:on-line priority rules:
1.1. transportation task assignmenttransportation task assignmenttasks wait, ortasks wait, or
2.2. idle vehicle assignmentidle vehicle assignmentidle vehicles waitidle vehicles wait
Ad 1: push/pull (JIT), e.g. FCFS, MOQRSAd 1: push/pull (JIT), e.g. FCFS, MOQRS
PushPush sometimes shop lockingsometimes shop locking
Ad 2: NV, LIVAd 2: NV, LIV
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Combination 3Combination 3
Separated/think-ahead (1)Separated/think-ahead (1) Centralized controlCentralized control
a. without time windowsa. without time windows Only routingOnly routing
Minimize empty travel time by simulated annealing:Minimize empty travel time by simulated annealing:
2 options:2 options:
determine optimal route each time a new taskdetermine optimal route each time a new taskarrivesarrives
problem: a task may stay at the end of the routeproblem: a task may stay at the end of the route Periodic controlPeriodic control
time horizon (length?)time horizon (length?)
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Combination 3Combination 3
Separated/think-ahead (2)Separated/think-ahead (2) Centralized controlCentralized control
b. with time horizonsb. with time horizons
Simulated annealingSimulated annealing
machine 1
machine 2
machine 3
machine 1
machine 2
machine 3
machine 1
machine 2
machine 3
loaded trip
empty trip
loaded trip
empty trip
loaded trip
empty trip
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Combination 4Combination 4
Integrated/think-aheadIntegrated/think-aheadAGVs ~ parallel machinesAGVs ~ parallel machines
empty travel time ~ change-over timeempty travel time ~ change-over time
transportation time ~ machine timetransportation time ~ machine time
Shop-floor schedulingShop-floor scheduling
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Basic conceptBasic concept
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Case studyCase study
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