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Part b

Part b. Facility Layout. Computerized Layout Solutions. Classification A Construction Algorithm C ORELAP , A LDEP , P LANET Improvement Algorithm C RAFT Classification B Relationship Diagramming Based C ORELAP , A LDEP From-To Chart (Block Diagramming) Based P LANET , C RAFT.

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Part b

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  1. Part b Facility Layout

  2. Computerized Layout Solutions • Classification A • Construction Algorithm • CORELAP, ALDEP, PLANET • Improvement Algorithm • CRAFT • Classification B • Relationship Diagramming Based • CORELAP, ALDEP • From-To Chart (Block Diagramming) Based • PLANET,CRAFT

  3. CRAFT Example • Consider a facility with four departments A, B, C, and D. The initial layout and dimensions of each department area are given in the diagram (a). The distance and flow information for this initial layout are given in matrices (b) and (c). Develop an improved layout using the two-way exchange procedure. • Please Note in CRAFT: • Distances are measured from the centroid of the area. • Two-Way Interchanges imply that departments with common boundaries and/or same areas can be switched.

  4. CRAFT Example

  5. CRAFT Example (cont.)

  6. CRAFT Example (cont.)

  7. CRAFT Example (cont.)

  8. CRAFT Example (cont.) • Possible Two-Way Interchanges: • AB • AC • AD • BD • CD

  9. CRAFT Example (cont.)

  10. CRAFT Example (cont.)

  11. CRAFT Example (cont.)

  12. CRAFT Example (cont.)

  13. CRAFT Example (cont.) • Next, possible Two-Way Interchanges: • AB • AC • AD • BC • BD (Takes it to the initial layout; can be ignored) • CD

  14. CRAFT Example (cont.)

  15. CRAFT Example (cont.) • Next, possible Two-Way Interchanges: • AB (Takes it to the previous layout; can be ignored) • AC • AD • BC • CD

  16. CRAFT Example (cont.)

  17. CRAFT Example (cont.)

  18. Service Layouts • Usually process layouts due to customers needs • Minimize flow of customers or paperwork • Retailing tries to maximize customer exposure to products • Computer programs consider shelf space, demand, profitability • Layouts must be aesthetically pleasing

  19. Designing Product Layouts • Product layouts or assembly lines • Develop precedence diagram of tasks • Jobs divided into work elements • Assign work elements to workstations • Try to balance the amount work of each workstation

  20. Hybrid Layouts • Cellular layouts • Flexible Manufacturing Systems • Mixed Model Assembly Lines

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

  22. 4 6 7 9 5 8 2 10 12 1 3 11 Original Process Layout Assembly A B C Raw materials

  23. Part Routing Matrix MACHINES PARTS 1 2 3 4 5 6 7 8 9 10 11 12 A x x x x x B x x x C x x x D x x x x x E x x x F x x x G x x x x H x x x

  24. Part Routing MatrixReordered To Highlight Cells MACHINES PARTS 1 2 4 8 10 3 6 9 5 7 11 12 A x x x x x D x x x x x F x x x C x x x G x x x x B x x x H x x x E x x x

  25. Cellular Layout Solution

  26. Advantages Of Cellular Layouts • Reduced material handling and transit time • Reduced setup time • Reduced work-in-process inventory • Better use of human resources • Easier to control • Easier to automate

  27. Disadvantages Of Cellular Layouts • Inadequate part families • Poorly balanced cells • Expanded training and scheduling of workers • Increased capital investment

  28. Flexible Manufacturing Systems • Automated machining operations • Automated material handling • Automated tool changers • Computer controlled system • Designed around size of parts processed & average processing time for parts • Can process wide variety of items quickly

  29. FMS Layouts

  30. Open Field FMS Layout

  31. Mixed Model Assembly Lines • Produce multiple models in any order on one assembly line • Issues in mixed model lines • line balancing • U-shaped line • flexible workforce • model sequencing

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