Facility Layout

1. 6 Facility Layout Slides prepared by Laurel Donaldson Douglas College

2. Describe the basic plant/facility layout types. Solve simple assembly line balancing problems. Develop simple process (functional) layouts. LO 1 LO 2 LO 3

3. Types of Layout • Assembly Line Balancing • Designing Process Layouts

4. Layout • Layout: the arrangement of departments, work centers, equipment, etc. • want to have smooth movement (of work, people, materials, info) through the system

5. Basic Layout Types • Product layout • arranges production resources linearly according to the progressive steps by which a product is made • Process layout • arranges production resources together according to similarity of function

6. Product (Line) Layout • Used for Repetitive or Continuous Processing • More common for goods than services Raw materials or customer Station 2 Station 3 Station 4 Finished item Station 1 Material and/or labour Material and/or labour Material and/or labour Material and/or labour

7. Product Layout (Assembly Line) Standardized processing operations to achieve smooth, rapid, high-volume flow • Standardized product/service • allows continuous processing and • specialization of labour & equipment • Product demand is stable • enough to justify high investment in specialized equipment • Divide work into series of tasks • by technological processing requirements • Can use fixed path material handling • conveyors

8. Advantages: Efficient and Easy to Use High degree of labour & equipment utilization = lower cost per unit Minimal work-in-process inventories Simplified accounting, purchasing and inventory control Easier training and supervision Disadvantages: Inflexible Higher equipment cost Dull, repetitive jobs = stress, low morale Lack of flexibility in product or production rates Work stoppage at any point ties up the whole operation Product (Line) Layouts

9. Assembly Lines Lucy at the Chocolate Factory

10. Process (Functional) Layout • Used for Intermittent processing • Job Shop or Batch Processes • Common in Services

11. Process (Functional) Layout

12. Process (Functional) Layout Advantages: Flexibility • Less vulnerable to shutdown(from mechanical failure or absenteeism) • Lower maintenance costs(and reduced investment in spare parts) • Disadvantages: Inefficiency • Scheduling can be difficult (= low equipment utilization rates) • Setup, material handling, and labour and costs can be high • Increased work-in-process inventory

13. Cellular Layout • Cellular layout • Layout in which machines are grouped into a cell that can process items that have similar processing requirements • Group technology • The grouping into part families of items with similar design (size, shape and function) or manufacturing (type and sequence of operations required) characteristics

14. 222 222 222 Mill 111 444 333 222 444 Grind 333 Assembly 111 333 111 222 444 Drill Gear cutting 333 111 111 111 333 444 Lathes Heat treat Comparison of functional and cellular layouts Functional Layout

15. Gear cut Heat treat Lathe Mill Drill 111 111 Heat treat Mill Drill Grind 222 222 Assembly Heat treat 333 Lathe Mill Grind 333 Gear cut 444 444 Mill Drill Comparison of functional and cellular layouts Cellular Layout

16. Cellular Layouts • Benefits: • faster processing time and reduced setup times • increased capacity • less material handling and work-in-process inventory • Conversion is a major undertaking • Three primary methods: • visual inspection, • examination of design and production data, • and production flow sequence and routing analysis.

17. Other Layout Types • Warehouse layouts • Important consideration: frequency of order • Retail layouts • Important consideration: traffic flow • Office layouts • Objective: optimize the physical transfer of information or paperwork • New trend: create an image of openness (low rise partitions)

18. Fixed Position Layouts • Layout in which the product or project remains stationary, and workers, materials, and equipment are moved as needed. • Nature of the product dictates this type of layout • Weight • Size • Bulk • Large construction projects

19. process of assigning tasks to workstations so that the workstations have approximately equal time requirements. Design Product Layouts: Line Balancing

20. Line Balancing Procedure Acceptable efficiency? Repeat if NO

21. Cycle time is the maximum time allowed at each workstation to complete its set of tasks on a unit. Cycle Time

22. Line Balancing Formulas

23. 0.1 min. 1.0 min. A Simple Precedence Diagram a b c d e 0.7 min. 0.5 min. 0.2 min. Precedence Diagram • Tool used in line balancing to display elemental tasks and sequence requirements

24. 0.1 min. 1.0 min. a b c d e 0.7 min. 0.5 min. 0.2 min. Example 1: Assembly Line Balancing • Arrange tasks into three workstations. • Use a cycle time of 1.0 minute • Assign tasks in order of the most number of followers

25. 0.1 min. 1.0 min. a b c d e 0.7 min. 0.5 min. 0.2 min. Example 1 Solution

26. Line Balancing Rules • Assign the task with longest time • Assign the task with the most followers Some Heuristic (intuitive) Rules:

27. WS 1 WS 2 0.1 min. 1.0 min. a b WS 3 c d e 0.7 min. 0.5 min. 0.2 min. Example 1 Solution

28. c d a b e f g h Example 2 0.2 0.1 0.3 0.8 0.6 • Arrange tasks into four workstations. • Use a cycle time of 1.0 minute • Assign tasks in order of the most number of followers (then longest time) 1.0 0.4 0.3

29. Station 1 Station 2 Station 3 Station 4 b a e g h f c d Solution to Example 2

30. Variable Task Times: Solutions

31. 30/hr. 30/hr. 30/hr. 30/hr. 1 min. 1 min. 2 min. 1 min. 2 min. 30/hr. 30/hr. 60/hr. 60/hr. 1 min. 1 min. 1 min. Bottleneck Parallel Workstations 30/hr. 30/hr. 2 min. Bottleneck Workstation

32. Treatment of Bottlenecks

33. Process (Functional) Layout Design • Arrange work centers so as to minimize transportation cost, distance or time • Difficult to optimize • General rule: • Locate departments with high interdepartmental flow as close as possible

34. Designing Process (Functional) Layouts Information Requirements: • List of departments • Projection of work flows • Distance between locations • cost per unit of distance to move loads • List of special considerations • Location of entrances, elevators • Need to be close (or far) from others • Reinforced flooring, room dimensions, etc

35. Designing Process Layouts Tools Block Diagramming QUANTITATIVE Minimize Non-Adjacent Loads Relationship Diagramming NON-QUANTITATIVE Based on Intuitive Preferences

36. Example: Process Layout Design • Distance between locations (metres) • Loads between departments (per day)

37. 30 170 100 1 2 3 A B C Example: Interdepartmental Work Flowsfor Assigned Departments

38. Closeness ratings - Muther Grid • Muther suggests the following list of reasons for closeness: • Use same equipment or facilities • Share the same personnel • Sequence of work flow • Ease of communication • Unsafe or unpleasant conditions • Similar work performed

39. Learning Checklist • Process • Discuss considerations for make or buy decisions • Compare intermittent vs. repetitive processes • Discuss issues in automation • Describe the steps in production process design • Be able to draw a process flow diagram • Facility Layout • List the different types and key considerations in each • Describe advantages/disadvantages of product, process and cellular layouts • Create a precedence diagram, calculate cycle time, idle time and efficiency, balance a line • Use tools to create a process layout