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IE 419 Work Design: Productivity and Safety Dr. Andris Freivalds Class #9

IE 419 Work Design: Productivity and Safety Dr. Andris Freivalds Class #9. IE 419 Work Design: Productivity and Safety Dr. Andris Freivalds Class #9. Plant Layout ( Operations Analysis Step #8, pp. 110-118).

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IE 419 Work Design: Productivity and Safety Dr. Andris Freivalds Class #9

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  1. IE 419 Work Design:Productivity and Safety Dr. Andris Freivalds Class #9 IE 419

  2. IE 419 Work Design:Productivity and Safety Dr. Andris Freivalds Class #9 IE 419

  3. Plant Layout(Operations Analysis Step #8, pp. 110-118) Plant Layout = arrangement of machines (or areas) to permit most direct flow of material, at lowest cost, with minimum handling Four types: • Fixed (static) position • Product (straight line) • Process (functional) • Group layout IE 419

  4. Fixed (Static) Layout • Product doesn’t move • All equipment, tools, operators brought to it • Examples: IE 419

  5. Advantages: Flow = Inventory = Production time/unit= Material handling time = Operator training = Disadvantages: Breakdown of one machine = Product change = Pace set by = Capital costs = Repetitive injuries = Product (Straight Line) Layout:Flow minimized for a given product by processing sequence IE 419

  6. Advantages: Utilization of machines = Flexibility = Capital costs = Diversity of tasks = Disadvantages: Material handling = Paperwork = Inventory = Production time/unit = Operator training = Process (Functional) Layout:Grouping of machinery by similar function IE 419

  7. Group Layout:Group of operators assembles product completely • Flexibility vs. training • Increased job satisfaction • Decrease in repetitive motion disorders • SAAB Malmö plant IE 419

  8. Flow Analyses Examine flow of a product using: • Flow process chart • Flow diagram • Travel chart IE 419

  9. Flow (String) Diagram:Pictorial plan of flow, using lines, arrows IE 419

  10. Flow (String) Diagram – 2(Improved Layout) IE 419

  11. Travel (From-to) Chart • Matrix format • From-vertical • To-horizontal • Cell value is amount of flow • Indicates which areas should be adjacent IE 419

  12. Systematic Layout Planning • Muther (1973) → Muther’s SLP • Goal: two areas with high, logical relationship should be close together • Chart relationship (flow, functional) • Establish space requirements • Diagram activity relationships • Diagram space relationships • Evaluate alternative arrangements • Detail selected layout, install IE 419

  13. 1) SLP Relationship Ratings IE 419

  14. Ex: Layout for Dorben Co. • SLP Relationship Ratings • Space requirements • Floor loading • Overhead clear • Water/drains • Compressed air • Power (220,440) IE 419

  15. 3) Diagram Activity Relationships IE 419

  16. 4) Diagram Space Relationships(Spatial representation) IE 419

  17. 4) Diagram Space Relationships(Compress to floor plan) IE 419

  18. 5) Evaluating Alternatives • List important factors • Flexibility, ease of expansion, • Effectiveness of flow, ease of material handling • Safety, ease of supervision • Aesthetics, appearance • Weigh relative importance (0-10 max) • Rate alternatives by each factor (4,3,2,1,0) • Multiply ratings by weights • Sum products and compare totals • Largest = best IE 419

  19. IE 419

  20. 6) Detail Final Layout (Install) • Power, utilities • Storage space • Material handling equipment IE 419

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