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Hybrid Layouts

Hybrid Layouts. Cellular Layouts By Maria Roig. Hybrid Layouts. Hybrid layouts modify and/or combine some aspects of product and process layouts. Three hybrid layouts: Cellular layouts (presented by Maria Roig) Flexible manufacturing systems (presented by Brian Barnes)

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Hybrid Layouts

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  1. Hybrid Layouts Cellular Layouts By Maria Roig

  2. Hybrid Layouts • Hybrid layouts modify and/or combine some aspects of product and process layouts. • Three hybrid layouts: • Cellular layouts (presented by Maria Roig) • Flexible manufacturing systems (presented by Brian Barnes) • Mixed-model assembly lines (presented by Brian Barnes)

  3. Hybrid Layouts: Cellular layouts • Cellular layouts group dissimilar machines into work centers (called cells) that process families of parts with similar shapes or requirements. • Combines the flexibility of a process layout with the efficiency of a product layout.

  4. Hybrid Layouts: Cellular layouts Characteristics of the process: • Cells are arranged in relation to each other so that material movement is minimized. • Large machines that cannot be split among cells are located near to the cells that use them (point of use) • The layout of machines within each cell resembles a small assembly line. • Adjustments can be used to arrange the machines within the cell. • Computer programs can be used to locate cells.

  5. Hybrid Layouts: Cellular layouts • Example: • Machines are grouped by function into four distinct departments. • Component parts manufactured in the process layout section of the factory are later assembled into a finished product on the assembly line. • The parts follow different flow paths through the shop. • Three representative routings, for parts A, B, and C. • Workers are skilled within a single department and can operate more than one machine at a time.

  6. Hybrid Layouts: Cellular layouts • Notice: • The distance that each part must travel before completion • the irregularity of the part routings • Amount of “paperwork” needed to direct the flow of each individual part and to confirm that the right operation has been performed Original Process Layouts

  7. Hybrid Layouts: Cellular layouts • In its current form, there is no apparent pattern to the routings. • PRODUCT FLOW ANALYSIS (PFA) reorders part routing matrices to identify families of parts with similar processing requirements. If we reorder the matrix listing which parts have four machines in common, three... Part Routing Matrix

  8. Hybrid Layouts: Cellular layouts Revised Layout with Three Cells Part Routing Matrix Reordered to Highlight Cells

  9. Advantages: Reduced material handling and transit time Reduced setup time Reduced work-in-process inventory Better use of human resources multifunctional workers Easier to control Easier to automate Disadvantages: Inadequate part families Poorly balanced cells Expanded training and scheduling of workers Increased capital investment Hybrid Layouts: Cellular layouts

  10. Hybrid Layouts: Cellular layouts • Questions?

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