Facility Layout 16.11.09

FACILITY LAYOUT 16.11.2009

What Is Layout Planning • Layout planning is determining the best physical arrangement of resources within a facility • Two broad categories of operations: – Intermittent processing systems – Continuous processing systems 

7 A -3

Facility Layout Facility layoutcan be defined as the process by which the placement of departments, workgroups within departments, workstations, machines, and stock-holding points within a facility are determined This process requires the following inputs: 

– Specification of objectives of the system in terms of output and flexibility – Estimation of product or service demand on the system – Processing requirements in terms of number of operations and amount of flow between departments and work centers – Space requirements for the elements in the layout – Space availability within the facility itself

Each process type (project, job shop, cell, assembly line, continuous) has it corresponding basic layout Determine the best layout (one that minimizes flow*distance, or flow*unit flow cost, …, maximizes throughput, …) 

Objectives of facility layout Minimize material handling costs Utilize space efficiently Utilize labor efficiently Eliminate bottlenecks Facilitate communication and interaction between workers, between workers and their supervisors, or between workers and customers § Reduce manufacturing cycle time or customer service time § ü § § § § §

Objectives of facility layout § Eliminate waste or redundant movement § Facilitate the entry, exit, and placement of material, products, or people § Incorporate safety and security measures § Promote product and service quality § Encourage proper maintenance activities § Provide a visual control of operations or activities § Provide flexibility to adapt to changing conditions ü

Basic Layout Types

TY

Basic Layout Types n

Product Layout —

—

n

Process Layout — —

n

Layout that uses standardized processing operations to achieve smooth, rapid, highvolume flow Linear arrangement of workstations to produce a specific product Layout that can handle varied processing requirements Centers/machines grouped by process they perform

Fixed Position Layout —

—

Layout in which the product or project remains stationary; workers, materials, and equipment are moved as needed Used in projects where the product cannot be

Hybrid Layouts n Cellular layouts – group machines into machining cells

n Flexible manufacturing systems – automated machining & material handling systems

n Mixed-model assembly lines – produce variety of models on one line

Layout Types Grinding

Forging

Lathes

Painting

Welding

Drills

Office

Milling machines

Foundry

Station 1

Station 2

Station 3

(a) Layout of a job shop

Station 4

(b) Layout of a production line

9

Manufacturing Process Layout Lathe Department

Milling Department

Drilling Department

L

L

M

M

D

D

D

D

L

L

M

M

D

D

D

D

L

L

G

G

G

P

L

L

G

G

G

P

L

L

Grinding Department Receiving and Shipping

Painting Department

A

A Assembly

A

Hybrid Layout § Cellular layouts § Group machines into machining cells § Flexible manufacturing systems § Automated machining & material handling systems

§ Mixed-model assembly lines § Produce variety of models on one line

§ 11

Hybrid Layout: Group Technology One Worker, Multiple Machines Machine 1

Machine 2

Machine 3

Materials in

Finished goods out

Machine 5

Machine 4 12

Group Technology Lathing

L

L

Milling

L

L

M

Drilling

M

M

D

D

D

D

M Grinding

L

L

L

L

Receiving and shipping

M

M

Assembly A

A

A

A

G

G

G

G

G

G

Group Technology Lathing

L

L

Milling

L

L

M

Drilling

M

M

D

D

D

D

M Grinding

L

L

L

L

Receiving and shipping

M

M

Assembly A

A

A

A

G

G

G

G

G

G

( a ) Jumbled flows in a job shop without GT cells

Group Technology Lathing

L

L

Milling

L

L

M

Drilling

M

M

D

D

D

D

M Grinding

L

L

L

L

Receiving and shipping

M

M

Assembly A

A

A

A

G

G

G

G

G

G

( a ) Jumbled flows in a job shop without GT cells

Group Technology Lathing

L

L

Milling

L

L

M

Drilling

M

M

D

D

D

D

M Grinding

L

L

L

L

Receiving and shipping

M

M

Assembly A

A

A

A

G

G

G

G

G

G

( a ) Jumbled flows in a job shop without GT cells

Group Technology L

L

M

L

G

M

Assembly area A

Cell 2

Cell 1 Receiving

D

G

A

G

Cell 3 L

M

D

Shipping

( b ) Line flows in a job shop with three GT cells

Group Technology L

L

M

L

G

M

Assembly area A

Cell 2

Cell 1 Receiving

D

G

A

G

Cell 3 L

M

D

Shipping

( b ) Line flows in a job shop with three GT cells

Group Technology L

L

M

L

G

M

Assembly area A

Cell 2

Cell 1 Receiving

D

G

A

G

Cell 3 L

M

D

Shipping

( b ) Line flows in a job shop with three GT cells

Group Technology L

L

M

L

G

M

Assembly area A

Cell 2

Cell 1 Receiving

D

G

A

G

Cell 3 L

M

D

Shipping

( b ) Line flows in a job shop with three GT cells

Cellular Layout 1. Identify families of parts with similar flow paths 2. Group machines into cells based on part families 3. Arrange cells so material movement is minimized 4. Locate large shared machines at point of use

HM VM Worker 3

VM L

Worker 2

G

L Final inspection

• S

Worker 1

In

Finished part

Out 21

Designing Flexible-Flow Layout 1.Gather Information – – – –

Space requirement Available space Closeness factors Other considerations



2.Develop block plan – distance measure – Calculating a weighted-distance score 

3.Design a detailed layout 22

Cell characteristics

e of values for the number of people (1-6) and workstations (1-10) and its own entran

aid out in a U-layout to simplify and minimize material movement.

wn inspection and work scheduling.

a family of similar parts that requires similar machines, or workstations, in the cell.(1)

Examples of cells 1.Machining center 2. 3.Single operator, multiple machines 4. 5.Single- robot automated cell 6. 7.Multiple machines, multiple operators 8. 9.Multiple robots, automated cell 10. 11.Assembly cell

Advantages of cells • The tangible advantages of manufacturing cells are due to the proximity of all machines required to make a family of parts.(1) 

• This reduces the total distance required to be traveled by the batches of parts in the family. • • Manufacturing cells are the first step in the implementation of Computer-Aided Design, Computer-Aided Manufacturing, Flexible Manufacturing Systems

Disadvantages of cells 

• Need for high investment in machine installation and re-layout

• • Lack of flexibility in handling demand changes, product mix changes, infrequent ordering of parts, variable lo sizes

• • Imbalance of utilization of machines and labor 

• Lack of a comprehensive cell formation method 

• Data collection and analysis is time-consuming

•

Examinations Of Layouts Could Result From: n Bottlenecks n Quality Problems n High Scrap Rates n Accidents & Safety Hazards n Absenteeism n Turnover n Complaints & Morale Problems

Production Methods Which is more efficient? 2

Operation 1

3

4

This?

5

6

7 Finished Product

11

10

9

8

Production Methods Or this? 1a

Operation 1

1b

2a

3a

3b

1c

2b

3c

1d

2c

3d

Finished product

Production Methods Or this?

Finished Product

Finished Product

Finished Product

Production Methods • Answer – it could be any of them! • The design of the production space can influence: – Output levels – Factor use – Efficiency – Cost levels – Quality assurance procedures

•

Common Reasons For Redesign Of Layouts n Changes In Design Of Products/services n Introduction Of New Products/services n Changes In Technology/equipment n Changes In Volume Or Mix Of Outputs n Improvements In Work Methods n Compensation For Learning Curve Effect n Compliance With Environmental Or Legal Regulations

THANK YOU FOR YOUR ATTENTION