Facilities Planning - Unit 04 Layout Types: Manufacturing

1. Facilities Planning - Unit 04Layout Types: Manufacturing

2. Hierarchy of Facility PlanningLayout Design Facility Location Structural Design Facility Planning Facility Design Layout Design Handling System Design Source for Figure: Tompkins and White, Facilities Planning, 2nd edition, Wiley Layout Types: Manufacturing - 2

3. Layout Design • Facility layout means planning: • for the location of all machines, utilities, employee workstations, customer service areas, material storage areas, aisles, restrooms, lunchrooms, internal walls, offices, and computer rooms • for the flow patterns of materials and people around, into, and within buildings Layout Types: Manufacturing - 3

4. Layout DesignPlanning for required Spaces and Areas • Equipment • Work stations • Material storage • Rest/break areas • Utilities • Eating areas • Aisles • Offices Layout Types: Manufacturing - 4

5. Layout Design – Introduction Characteristics of the Facility Layout Decision • Location of these various areas impacts the flow through the system. • The layout can affect productivity and costs generated by the system. • Layout alternatives are limited by • the amount and type of space required for the various areas • the amount and type of space available • the operations strategy Layout Types: Manufacturing - 5

6. Basic Layout Types • Product Layouts • Process Layouts • Fixed-position layouts • Cellular/Group technology layouts Layout Types: Manufacturing - 6

7. High Medium Low Product Planning Department Product Layout Volume Product Family Planning Department Fixed Location Layout Process Layout Group Technology Layout Fixed Materials Location Planning Department Process Planning Department Low Medium High Variety Basic Layout TypesProduct Volume vs. Product Variety Layout Types: Manufacturing - 7

8. Warehouse Storage Lathe Press Grind Weld Assembly Paint Types of LayoutFixed Position Layout Layout Types: Manufacturing - 8

9. Types of LayoutFixed Position Layout Layout in which the product or project remains stationary, and workers, materials, and equipment are moved as needed. Examples: • Large construction projects (buildings, power plants, dams) • Shipbuilding, production of large aircraft • Rockets used to launch space missions Layout Types: Manufacturing - 9

10. Types of LayoutFixed Position Layout: Advantages • Material movement is reduced. • Promotes job enlargement by allowing individuals or teams to perform the “whole job”. • Continuity of operations and responsibility results from team. • Highly flexible; can accommodate changes in product design, product mix, and product volume. • Independence of production centers allowing scheduling to achieve minimum total production time. Layout Types: Manufacturing - 10

11. Types of LayoutFixed Position Layout: Limitations • Increased movement of personnel and equipment. • Equipment duplication may occur. • Higher skill requirements for personnel. • General supervision required. • Cumbersome and costly positioning of material and machinery. • Low equipment utilization. Layout Types: Manufacturing - 11

12. Warehouse Assembly Press Mill Lathe Bend Lathe Drill Drill Lathe Drill Grind Drill Drill Storage Types of LayoutProduct Type Layout Layout Types: Manufacturing - 12

13. Types of LayoutProduct Type Layout - Requirements • Standardized product • High production volume • Stable production quantities • Uniform quality of raw materials & components Layout Types: Manufacturing - 13

14. Types of LayoutProduct Type Layout - Assumptions • Volume is adequate for high equipment utilization • Product demand is stable enough to justify high investment in specialized equipment • Product is standardized or approaching a phase of its life cycle that justifies investment in specialized equipment • Supplies of raw materials and components are adequate and of uniform quality ensure they will work with specialized equipment Layout Types: Manufacturing - 14

15. Types of LayoutProduct Type Layout - Advantages • Since the layout corresponds to the sequence of operations, smooth and logical flow lines result. • Since the work from one process is fed directly into the next, small in-process inventories result. • Total production time per unit is short. • Since the machines are located so as to minimize distances between consecutive operations, material handling is reduced. • Little skill is usually required by operators at the production line; hence, training is simple, short, and inexpensive. • Simple production planning control systems are possible. • Less space is occupied by work in transit and for temporary storage. Layout Types: Manufacturing - 15

16. Types of LayoutProduct Type Layout - Limitations • A breakdown of one machine may lead to a complete stoppage of the line that follows that machine. • Since the layout is determined by the product, a change in product design may require major alternations in the layout. • The “pace” of production is determined by the slowest machine. • Supervision is general, rather than specialized. • Comparatively high investment is required, as identical machines (a few not fully utilized) are sometimes distributed along the line. Layout Types: Manufacturing - 16

17. Warehouse Paint Assembly Lathe Drill Weld Mill Drill Grind Lathe Mill Mill Lathe Mill Paint Grind Assembly Lathe Weld Storage Types of LayoutProcess Type Layout Layout Types: Manufacturing - 17

18. Types of LayoutProcess Type Layout • Process type layouts can handle varied processing requirements • The layouts feature departments or other functional groupings in which similar kinds of activities are performed • Examples: Machine shops usually have separate departments for milling, grinding, drilling, and so on • Different products may present quite different processing requirements and sequences of operations Layout Types: Manufacturing - 18

19. Milling Assembly Test Grinding Plating Drilling Process Layout - work travels to dedicated process centers Types of LayoutProcess Type Layout Layout Types: Manufacturing - 19

20. Types of LayoutProcess Type Layout - Advantages • A high degree of flexibility exists relative to equipment or manpower allocation for specific tasks. • Comparatively low investment in machines is required. • The diversity of tasks offers a more interesting and satisfying occupation for the operator. Layout Types: Manufacturing - 20

21. Types of LayoutProcess Type Layout - Limitations • Since longer flow lines usually exist, material handling is more expensive. • Production planning and control systems are more involved. • Total production time is usually longer. • Comparatively large amounts of in-process inventory result. • Space and capital are tied up by work in process. • Because of the diversity of the jobs in specialized departments, higher grades of skill are required. Layout Types: Manufacturing - 21

22. Types of LayoutProcess Layout vs. Product Layout Layout Types: Manufacturing - 22

23. Warehouse Grind Press Drill Grind Assembly Drill Weld Assembly Lathe Grind Press Mill Lathe Paint Drill Drill Assembly Assembly Storage Types of LayoutGroup Technology/Cellular/Product Family Layout Layout Types: Manufacturing - 23

24. Types of LayoutGroup Technology vs. Cellular Manufacturing • Group Technology (GT) is a management philosophy that attempts to group products with similar design or manufacturing characteristics, or both. • Cellular Manufacturing (CM) is an application of GT that involves grouping machines based on the parts manufactured by them. • The main objective of CM is to identify machine cells and part families simultaneously, and to allocate part families to machine cells in a way that minimizes the intercellular movement of parts. Layout Types: Manufacturing - 24

25. Assembly 4 7 9 6 8 5 12 2 10 3 1 11 A B C Raw materials Original Process Layout Types of LayoutGroup Technology/Cellular Layout – Example A (page 1) Layout Types: Manufacturing - 25

26. Machines Parts 1 2 3 4 5 6 7 8 9 10 11 12 A x x x x x B x 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 Original Part Routing Matrix Types of LayoutGroup Technology/Cellular Layout – Example A (page 2) Layout Types: Manufacturing - 26

27. 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 x H x x x E x x x Reordered Part Routing Matrix Types of LayoutGroup Technology/Cellular Layout – Example A (page 3) Layout Types: Manufacturing - 27

28. Assembly 9 8 10 12 11 Cell 1 Cell 3 Cell 2 4 6 7 2 1 3 5 A B C Raw materials Revised Cellular Layout Types of LayoutGroup Technology/Cellular Layout – Example A (page 4) Layout Types: Manufacturing - 28

29. Types of LayoutGroup Technology/Cellular Layout – Example B (page 1) Unorganized Parts Layout Types: Manufacturing - 29

30. Types of LayoutGroup Technology/Cellular Layout – Example B (page 2) Process Flows before the Use of GT Cells Layout Types: Manufacturing - 30

31. Types of LayoutGroup Technology/Cellular Layout – Example B (page 3) Transition from Process Layout Grouping parts into families that follow a common sequence of steps. Identifying dominant flow patterns of parts families as a basis for location or relocation of processes. Physically grouping machines and processes into cells. Layout Types: Manufacturing - 31

32. Types of LayoutGroup Technology/Cellular Layout – Example B (page 4) Grouping parts into families Layout Types: Manufacturing - 32

33. Types of LayoutGroup Technology/Cellular Layout – Example B (page 5) Process flows after the Use of GT Cells Layout Types: Manufacturing - 33

34. Gear cut Heat treat Lathe Mill Drill AAAA AAAA Heat treat Mill Drill Grind BBBB BBBBBBBBB Assembly Heat treat CCCC CCCCCCCCCC Lathe Mill Grind Gear cut DDDD Mill Drill DDDDDDDDDDDDDD Types of LayoutGroup Technology/Cellular Layout Related topic: Mixed model Assembly/manufacturing Layout Types: Manufacturing - 34

35. A family of related grocery items A family of similar parts Types of LayoutGroup Technology/Cellular Layout Grouping parts into families Layout Types: Manufacturing - 35

36. Types of LayoutGroup Technology vs. Cellular Manufacturing Layout Types: Manufacturing - 36

37. High Medium Low Product Planning Department Product Layout Volume Product Family Planning Department Fixed Location Layout Process Layout Group Technology Layout Fixed Materials Location Planning Department Process Planning Department Low Medium High Variety Basic Layout TypesProduct Volume vs. Product Variety Layout Types: Manufacturing - 37

38. Types of LayoutProcess (Functional) Layout vs. Cellular Layout Layout Types: Manufacturing - 38

39. Direction of part movement within cell A Manufacturing Cell with Worker Paths HM VM Paths of three workers moving within cell Material movement VM Worker 3 L Worker 2 G L Final inspection Key: S = Saw L = Lathe HM = Horizontal milling machine VM = Vertical milling machine G = Grinder Finished part S Worker 1 Out In Types of Layout - Example Layout Types: Manufacturing -39 Layout Types: Manufacturing - 39

40. Types of Layout - Example Manufacturing Cell Animated Picture Layout Types: Manufacturing - 40

41. Types of Layout - Example Manufacturing Cell An example of a hybrid layout Layout Types: Manufacturing - 41

42. Types of Layout - Example Automated Manufacturing Cell An example of a hybrid layout Layout Types: Manufacturing - 42

43. Types of Layout - Example Flexible Manufacturing Cell An example of a hybrid layout Layout Types: Manufacturing - 43

44. Work Cell Assembly or Production line-oriented arrangement of machines and personnel in what is ordinarily a process-oriented facility. Cells can be formed on a temporary basis. Example: job shop with rearranged machinery and personnel to produce 30 unique control panels Focused Work A permanent assembly-line-oriented arrangement of machines and personnel in what is ordinarily a process-oriented facility Center Example: manufacturing of pipe brackets at a shipyard A permanent facility to produce a product or component in a product-oriented facility Focused Factory Example: a plant to produce window mechanisms for automobiles Types of LayoutWork Cell, Focused Work Center, and Focused Factory Layout Types: Manufacturing - 44

45. Principles of a Good LayoutManufacturing • Straight-line Flow Pattern when possible • Backtracking kept to a Minimum • Predictable Production Time • Little In-process materials storage • Open Floor plans so everyone can see what is going on • Bottlenecks under control • Workstations close together • Minimum of material handling • Easy adjustment to changing conditions Layout Types: Manufacturing - 45

46. New Trends in Manufacturing Layouts • Designed for quality and flexibility • Ability to quickly shift to different product models or to different production rates • Cellular layout within larger process layouts • Automated material handling • U-shaped production linesuse to better accomplish flow control • 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 Layout Types: Manufacturing - 46

47. Wrap-UpWorld-Class Practices • 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 Layout Types: Manufacturing - 47

48. Wrap-upAttaining Lean Production • Focus on inventory reduction • Build systems that help employees • Reduce space requirements • Develop close relationships with suppliers • Educate suppliers • Eliminate all but value-added activities • Develop the workforce • Make jobs more challenging • Set sights on perfection! Layout Types: Manufacturing - 48