facility layout
TRANSCRIPT
1
Manufacturing Facility Layouts
2
Materials Handling
The central focus of most manufacturing layouts is to
minimize the cost of processing, transporting, and
storing materials throughout the production system.
Materials used in manufacturing include:
Raw material
Purchased components
Work-in-progress
Finished goods
Packaging material
Maintenance, repair, and operating supplies
3
Materials Handling
A materials-handling system is the entire network of
transportation that:
Receives material
Stores material in inventories
Moves material between processing points
Deposits the finished products into vehicles for delivery to customers
4
Materials Handling
Material-Handling Principles
Move directly (no zigzagging/backtracking)
Minimize human effort required
Move heavy/bulky items the shortest distances
Minimize number of times same item is moved
MH systems should be flexible
Mobile equipment should carry full loads
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Materials Handling
Material-Handling Equipment
Automatic transfer devices
Containers/pallets/hand carts
Conveyors
Cranes
Elevators
Pipelines
Turntables
AGVS
6
Basic Layout Forms
Process
Product
Cellular
Fixed-Position
Hybrid
7
Process (Job Shop) Layouts
Equipment that perform similar processes are
grouped together
Used when the operations system must handle a wide
variety of products in relatively small volumes (i.e.,
flexibility is necessary)
8
Characteristics of Process Layouts
General-purpose equipment is used
Changeover is rapid
Material flow is intermittent
Material handling equipment is flexible
Operators are highly skilled
9
Characteristics of Process Layouts
Technical supervision is required
Planning, scheduling and controlling functions are
challenging
Production time is relatively long
In-process inventory is relatively high
10
Product (Assembly Line) Layouts
Operations are arranged in the sequence required to
make the product
Used when the operations system must handle a
narrow variety of products in relatively high volumes
Operations and personnel are dedicated to producing
one or a small number of products
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Characteristics of Product Layouts
Special-purpose equipment are used
Changeover is expensive and lengthy
Material flow approaches continuous
Material handling equipment is fixed
Operators need not be as skilled
12
Characteristics of Product Layouts
Little direct supervision is required
Planning, scheduling and controlling functions are
relatively straight-forward
Production time for a unit is relatively short
In-process inventory is relatively low
13
Cellular Manufacturing Layouts
Operations required to produce a particular family
(group) of parts are arranged in the sequence required
to make that family
Used when the operations system must handle a
moderate variety of products in moderate volumes
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Characteristics of Cellular Manufacturing
Relative to Process Layouts
Equipment can be less general-purpose
Material handling costs are reduced
Training periods for operators are shortened
In-process inventory is lower
Parts can be made faster and shipped more quickly
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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
16
Fixed-Position Layouts
Product remains in a fixed position, and the
personnel, material and equipment come to it
Used when the product is very bulky, large, heavy or
fragile
17
Hybrid Layouts
Actually, most manufacturing facilities use a
combination of layout types.
An example of a hybrid layout is where departments
are arranged according to the types of processes but
the products flow through on a product layout.
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New Trends in Manufacturing Layouts
Designed for quality
Designed for flexibility - to quickly shift to different
product models or to different production rates
Cellular layout within larger process layouts
Automated material handling
U-shaped production lines
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New Trends in Manufacturing Layouts
More open work areas with fewer walls, partitions, or
other obstacles
Smaller and more compact factory layouts
Less space provided for storage of inventories
throughout the layout
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Planning Manufacturing Facility Layouts
Two Categories of Software Tools
Computer aided design (CAD)
Allows 3-D, full-color views of facility design
Allows virtual walk-throughs
Ex. – ArchiCAD, AutoSketch, AutoCAD
Computer simulation
Can simulate proposed system layout in operation and measure its performance
Ex. – ProModel, VisFactory, SIMPROCESS
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Process and Warehouse Layouts
Product Layouts
Cellular Manufacturing Layouts
Planning Manufacturing Facility Layouts
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Planning Manufacturing Facility Layouts
Process Layouts
Primary focus is on the efficient flow of materials
The wide variety of potential product routings through the facility can be evaluated using computer simulation
Warehouse Layouts
Primary focus is the fast storage and retrieval of inventory items
Decisions about aisle size/placement and location of each inventory item can be evaluated using computer simulation
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Planning Manufacturing Facility Layouts
Product Layouts
Primary focus is on the analysis of production lines
The goal of the production line analysis is to:
Determine how many workstations to have
Determine which tasks to assign to which workstation
Minimize the number of workers & machines used
Provide the required amount of capacity
Line balancing is a key part of the analysis
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Planning Cellular Manufacturing Layouts
Cell Formation Decision
Which machines are assigned to manufacturing
cells
Which parts will be produced in each cell
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Planning Cellular Manufacturing Layouts
Fundamental Requirements for Parts to be Made in
Cells
Demand for the parts must be high enough and
stable enough that moderate batch sizes of the
parts can be produced periodically.
Parts must be capable of being grouped into parts
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 to be the
exceptional parts?
If inadequate capacity is available to produce all the
parts in cells, which parts should be made outside the
cells?
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Planning Cellular Manufacturing Layouts
Cell Formation Procedure
1. Form the Parts-Machines Matrix.
2. Rearrange the Rows.
Place the machines that produce the same parts in adjacent rows.
3. Rearrange the Columns.
Place the parts requiring the same machines in 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 high
performance cars and trucks. Maxx has implemented
a group technology program in its shop and now must
formulate the manufacturing 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 Formulation – Original Matrix
1 2 3 4 5 6
X X X
X X X X
X X
X X
X X X
A
B
C
D
E
Parts
Machines
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Example: Maxx Superchargers
Cell Formulation – Rows Rearranged
1 2 3 4 5 6
X X X
X X X
X X
X X
X X X X
A
E
D
C
B
Parts
Machines
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Example: Maxx Superchargers
Cell Formulation – Columns Rearranged
3 5 6* 1 2 4
X X X
X X X
X X
X X
X X X X
A
E
D
C
B
Parts
Machines
* exceptional part
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Example: Maxx Superchargers
Cell Formulation – Summary
2 manufacturing cells (MC1, MC2) will be used.
Parts 3 and 5 will be produced in MC1 on
machines A and E.
Parts 1, 2 and 4 will be produced in MC2 on
machines B, C and D.
Part 6 is an exceptional part that cannot be
produced within a single cell.
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Service Facility Layouts
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Characteristics of Services
There may be a diversity of services provided
There are three dimensions to the type of service:
Standard or custom design
Amount of customer contact
Mix of physical goods and intangible services
There are three types of service operations:
Quasi manufacturing operations: Kitchen area of Fast Food Restaurant
Customer-as-Participant: ATM, Dept. stores or Fast Food Restaurant
Customer-as-Product: hair salons, medical clinics, hospitals, tailors
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Characteristics of Service Facility Layouts
The encounter between the customer and the service
must be provided for.
The degree to which customer-related features must
be provided varies with the amount of customer
involvement and customer contact.
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Planning Service Facility Layouts
Quasi-Manufacturing Services
Several topics previously discussed under
Manufacturing Layouts are relevant here:
Principles of material handling
CAD and simulation software
Line balancing
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Planning Service Facility Layouts
Customer-as-Participant & Customer-as-Product
An important element is providing for customer
waiting lines
Amount of space needed for service counters
and waiting customers
Placement of waiting lines in overall layout
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Planning Service Facility Layouts
For many service operations, layouts are like process
layouts in manufacturing
The departments of hospitals are grouped and located
according to their processes
In some cases, closeness ratings are used to reflect the
desirability of having one department near another
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Using Closeness Ratings
to Develop Service Facility Layouts
Start Let m = 1 and n = 6.
Identify dept. pairs with CR of m.
Develop layout with dept. pairs iden-
tified in Step 2 adjacent to one another.
Identify dept. pairs with CR of n.
Fit the dept. pairs identified in Step 4
into the trial layout from Step 3.
Step 1
Step 2
Step 3
Step 4
Step 5
Examine the trial layout from Step 5.
If any CRs of dept. pairs are violated,
rearrange depts. to comply with CRs.
Step 6
Does
m = 3 and n = 4
?
Stop
Let m = m + 1
and n = n - 1.
No
Yes
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Using Closeness Ratings
to Develop Service Facility Layouts
Typical Closeness Ratings
Closeness Meaning
Rating of Rating
1 Necessary
2 Very Important
3 Important
4 Slightly Important
5 Unimportant
6 Undesirable
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Example: AG Advertising
Using Closeness Ratings
AG Advertising is moving into a new office suite
having seven large, roughly equal size rooms, one for
each department of the firm. Lisa, the manager, must
now assign each department to a room. She has
developed a grid of closeness ratings (on the next
slide) for the 21 unique pairs of departments.
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Example: AG Advertising
5
6
4
4
2
3 3
5
4
1
2 6
2 4
3 3
1 6 5
1 2
Closeness Ratings Grid
Dept. A
Dept. B
Dept. C
Dept. D
Dept. E
Dept. F
Dept. G
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Example: AG Advertising
Unassigned Rooms of Office Suite
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Layout Satisfying All Pairings of
Departments with 1 Closeness Ratings
CR = 1
B – D
B – F
C – G
Example: AG Advertising
B D
F C G
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Trying to satisfying all pairings of departments with
6 closeness ratings, we see that Dept. C needs to be
moved.
CR = 1 CR = 6
B – D A – D
B – F B – C
C – G
Example: AG Advertising
B D
F G C
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Example: AG Advertising
Layout Satisfying All Pairings of Departments with 6
Closeness Ratings (note that we swapped Dept. D and
Dept. F)
CR = 1 CR = 6
B – D A – D
B – F B – C
C – G
B F A
D E G C
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Wrap-Up: World-Class Practice
Strive for flexibility in layouts
Multi-job training of workers
Sophisticated preventive-maintenance programs
Flexible machines
Empowered workers trained in problem solving
Layouts small and compact
Services follow the above practices plus incorporate
customer needs in design
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End of Chapter 5, Part B