LAYOUT

1. LAYOUT MARCH 2013

2. Layout : Definition • Layout: thephysicalarrangment of • machines, • equipment, • workstations, • People, and • Materialhandlingequipment. Prepared by: Asst. Prof. Dr. Nevra AKBILEK

3. What is facilitylayout • The final layout plan is theendresult of Facility Design. • An efficient layout of facilities can reduce operational cost and contribute tothe overall production efficiency (Tomkins et al 2003). • Locationorarrangement of everythingwithin & aroundbuildings. Prepared by: Asst.Prof.Dr. Nevra AKBILEK

4. What is facilitylayout • Facility layout includes all types of facilities:plants, warehouses, distributioncenters, officebuildings, hospitals,… • Plant layout is focused on production plants • The layout of a facility is an important factorin determining the overall efficiency andeffectiveness of the production or serviceoperations. • A poor layout can result in inefficient workflows, unhappy workers, unsafe workingconditions, and less capacity to carry out theoperational mission of the facility Prepared by: Asst. Prof. Dr. Nevra AKBILEK

5. Objectives of FacilityLayout • Minimize investment in equipment • Minimize production time • Minimize materialhandlingcost • Maximizeutilization of space, equipment,andpeople. • Maintainflexibility of arrangementandoperation. • Providesafetyandcomforttoemployees. • Customersatisfaction • Efficientflow of information, material, andpeople. • Maximizeemployee morale andsafety Prepared by: Asst. Prof. Dr. Nevra AKBILEK

6. FacilityLayoutInputs Facilitylayoutrequires the following inputs: • Specification of objectives of the system in terms of output and flexibility. • Estimation of product or service demand on the system. • Processing requirements in terms of number of operations and amount of flow between departments and work centers. • Space requirements for the elements in the layout. • Space availability within the facility itself. Prepared by: Asst. Prof. Dr. Nevra AKBILEK

7. Typesof Facility Design Projects • New facility • New Product • Design changes • Costreduction • Retrofit Prepared by: Asst. Prof. Dr. Nevra AKBILEK

8. FacilityLayoutReasons • A layout problem may be to • determinethelocationfor a newmachine, • develop a newlayoutfor an existingproductionplant, • develop a layoutfor a newproductionplant, • etc. • A layout problem mayarisesdueto • changes in thedesign of a product, • additionordeletion of a product • change in thedemand of a product • changes in thedesign of theprocess • additionordeletion of a process • replacement of equipment Prepared by: Asst. Prof. Dr. Nevra AKBILEK

9. Layout Developinglayoutestablishesthephysicalrelationshipsbetweenactivities. • So, whichcomesfirst, thematerialhandlingsystemorthefacilitylayout? • Both • Thelayoutandthehandlingsystemshould be designedsimultaneously Prepared by: Asst. Prof. Dr. Nevra AKBILEK

10. Impact of PoorPlantLayout • High materialhandlingcosts • Cycleandlead time delays • High WIP Inventories • Lowerquality • Product damage • Safetyand morale problems • Poorequipmentutilization • Congestedaisle • Wastedfloorspace Prepared by: Asst. Prof. Dr. Nevra AKBILEK

11. LayoutProcedure • Thecomplexity of design problem requiresthat a sequentialprocess be used. • Forthisreason, werecommendthat a number of alternativehandlingsystems be developedandappropriatelayout be designedforeach. Prepared by: Asst. Prof. Dr. Nevra AKBILEK

12. LayoutProcedures • Apples’sPlantLayoutProcedure (20 stepsprocedure) • Reed’sPlantLayoutProcedure (10 stepsprocedure) Layout Planning Chart Prepared by: Asst.Prof.Dr. Nevra AKBILEK

13. Apple’sPlantLayoutProcedure • Procurethebasicdata • Analyzethebasicdata • Design theproductiveprocess • Plan thematerialflowpattern • Consider the general material handling plan. • Calculate equipment requirements. • Plan individual workstations. • Select specific material handling equipment. • Coordinate groups of related operations. • Design activityrelationships. • Determine storage requirements. • Plan service and auxiliary activities. • Determine space requirements. • Allocate activities to total space. • Consider building types. • Construct master layout. • Evaluate, adjust, and check the layout with the appropriate persons. • Obtain approvals. • Install the layout. • Follow up on implementation of the layout.

14. Reed's Plant Layout Procedure • Analyze the productto be produced. • Determine the process required to manufacture the product. • Prepare layout planning charts. • Flow process, including operations, transportation, storage, and inspections. • Standard times for each operation. • Machine selection and balance. • Manpower selection and balance. • Material handling requirements. • Determine workstations. • Analyze storage area requirements. • Establish minimum aisle widths. • Establish office requirements. • Consider personnel facilities and services. • Survey plant services. • Provide for future expansion.

15. Muther’sSystematicLayout Planning • Flow of materials • Activity relationships • Relationshipdiagram • Space requirements & Space available • Space relationshipdiagram • Modifyingconsiderations • Practicallimitations • Developlayoutalternatives • Evaluation Prepared by: Asst. Prof. Dr. Nevra AKBILEK

16. SystematicLayout Planning Procedure Prepared by: Asst. Prof. Dr. Nevra AKBILEK

17. Basic ProductionLayoutFormats Depending on process • Process Layouts-ProcessDepartments • Product Layouts-Productionlinedepartments • HybridLayout ( Product familydepartments-Group Technology (Cellular) Layout) • Fixed-Position Layout –Fixedmateriallocationdepartments • Service Layout Depending on product Prepared by: Asst. Prof. Dr. Nevra AKBILEK

18. Product Layout(straight‐line) Advantages 1. Since the layout corresponds to the sequence of operations,smooth , simple, directand logical flow lines result. 2. Since the work from a process is fed directly into the nextone, small in-process inventories result. 3. Total production time per unit is short. Prepared by: Asst.Prof.Dr. Nevra AKBILEK

19. Product Layout Advantages 4. Since the machines are located so as to minimize distancesbetween consecutive operations, material handling isreduced. 5. Little skill is usually required by operators at the productionline; hence, training is simple, short, and inexpensive. 6. Simple production planning control systems are possible. 7. Less space is occupied by work in transit and for temporarystorage. Prepared by: Asst.Prof.Dr. Nevra AKBILEK

20. Product Layout Limitations 1. A breakdown of one machine may lead to acomplete stoppage of the line that follows thatmachine. 2. Since the layout is determined by the product, achange in product design may require majoralternationsin thelayout. 3. The “pace” of production is determined by theslowestmachine. 4. Supervision is general, rather than specialized. 5. Comparatively high investment is required, asidentical machines (a few not fully utilized)aresometimes distributed along the line. Prepared by: Asst.Prof.Dr. Nevra AKBILEK

21. An army induction centre with uses product layout Waiting area Waiting area Lecture theatre Blood test Doctor Doctor Record personal history and medical details X-ray Uniform issuing area Blood test Doctor Doctor X-ray Blood test Doctor Doctor Uniform store X-ray

22. ProcessLayout(functional) Advantages 1. Better utilization of machines can result;consequently, fewer machines are required. 2. A high degree of flexibility exists relative toequipment or man power allocation for specifictasks. 3. Comparatively low investment in machines isrequired. Prepared by: Asst.Prof.Dr. Nevra AKBILEK

23. ProcessLayout 4. The diversity of tasks offers a more interesting andsatisfying occupation for the operator. 5. Specialized supervision is possible. Prepared by: Asst.Prof.Dr. Nevra AKBILEK

24. ProcessLayout Limitations 1. Since longer flow lines usually exist, materialhandlingis moreexpensive. 2. Production planning and control systems are moreinvolved. 3. Total production time is usually longer. 4. Comparatively large amounts of in-processinventoryresult. 5. Space and capital are tied up by work in process. 6. Because of the diversity of the jobs in specializeddepartments, higher grades of skill are required. Prepared by: Asst.Prof.Dr. Nevra AKBILEK

25. Loan books in subject order On-line and CD-ROM access room Study desks To journal sack Company reports Current journals Enquiries Reference section Reserve collection Store room Counter staff Copying area Entrance Exit An example of a process layout in a library showing the path of just one customer Prepared by: Asst.Prof.Dr. Nevra AKBILEK

26. Fixed Product Layout Advantages 1. Material movement is reduced. 2. Promotes job enlargement by allowingindividuals or teams to perform the “whole job”. 3. Continuity of operations and responsibilityresultsfromteam. Prepared by: Asst.Prof.Dr. Nevra AKBILEK

27. Fixed Product Layout 4. Highly flexible; can accommodate changes inproduct design, product mix, and productvolume. 5. Independence of production centers allowingscheduling to achieve minimum total production time. Prepared by: Asst.Prof.Dr. Nevra AKBILEK

28. Fixed Product Layout Limitations 1. Increased movement of personnel andequipment. 2. Equipment duplication may occur. 3. Higher skill requirements for personnel. 4. General supervisionrequired. 5. Cumbersome and costly positioning of materialandmachinery. 6. Lowequipmentutilization. Prepared by: Asst.Prof.Dr. Nevra AKBILEK

29. HybridLayout 2 basic types of hybrid layouts: 1.Group/Cellular layout: tries to combine the bestfeatures of process and product layouts 2.Combinations of fixed position layouts andprocessorproductlayouts Prepared by: Asst.Prof.Dr. Nevra AKBILEK

30. 1.Group Layout Advantages 1. Bygrouping, highermachineutilizations. 2. Team attitude and job enlargement tend tooccur. 3. Compromise between product layout andprocess layout, with associated advantages. Prepared by: Asst.Prof.Dr. Nevra AKBILEK

31. 1.Group Layout 4. Supports the use of general purposeequipment. 5. Shorter travel distances and smoother flow linesthan for process layout. Prepared by: Asst.Prof.Dr. Nevra AKBILEK

32. 1.Group Layout Limitations 1. General supervisionrequired. 2. Higher skill levels required of employees than forproductlayout. 3. Compromise between product layout and processlayout, withassociatedlimitations. 4. Depends on balanced material flow through thecell; otherwise, buffers and work-in-processstoragearerequired. 5. Lower machine utilization than for process layout. 6. Decreasetheopportunitytousespecialpurposeequipment Prepared by: Asst.Prof.Dr. Nevra AKBILEK

33. Books and videos Sports shop Menswear Footwear Entrance Perfume & jewellery Elevators Confectionery, newspaper, magazines and stationery Women’s clothes Luggage and gifts Entrance The ground floor plan of a department store showing the sports goods shop-within-a-shop retail ‘cell Prepared by: Asst.Prof.Dr. Nevra AKBILEK

34. Comparison of Layouts Prepared by: Asst.Prof.Dr. Nevra AKBILEK

35. Comparison of Layouts Prepared by: Asst.Prof.Dr. Nevra AKBILEK

36. Line layout cafeteria Cell layout buffet Fixed-position layout service restaurant Desert buffet Starter buffet Main course buffet Service line Preparation Oven Process layout kitchen Cool room Freezer Grill Vegetable prep A restaurant complex with all four basic layout types

37. Selecting a layout type

38. Product volume versus variety Product Volume versus Product Variety in Production System Design Volume of Production Variety of Products

39. Volume-varietylayoutclassification Quantity (Volume) Product Layouts FixedPosition Layouts Process Layouts Mixed Layouts Number of Different Products (Variety) Prepared by: Asst. Prof. Dr. Nevra AKBILEK

40. Low High Flow is intermittent Volume Fixed-position layout High Process layout Regular flow more feasible Cell layout Variety Product layout Flow becomes continuous Low Regular flow more important Volume-variety relationship(flow)

41. The nature of the basic layout types Manufacturing B asic layout Service process types types process types Fixed Project processes Project processes Professional position layout services Jobbing processes Process layout Service shops Batch pro cesses Cell layout Mass services Mass processes Product layout Continuous processes

42. Basic layouttypes • Project process(fixedposition) • Job Shop(Process Layout) • Group Technology(Batch Processing Characteristics-Cell layout) • Production Line(MassProduction) Prepared by: Asst.Prof.Dr. Nevra AKBILEK

43. (a) (b) Fixed-position Costs Costs Process Cell Product ? ? ? ? Use cell Use process Use product Use fixed-position Volume Volume Use product Use cell or product Use process or cell or product Use process or cell Use process Use fixed-position or process Use fixed-position (a) The basic layout types have different fixed and variable cost characteristics which seem to determine which one to use. (b) In practice the uncertainty about the exact fixed and variable costs of each layout means the decision can rarely be made on cost alone Consider total cost

44. Detailed design of a layout

45. Process layout design: • When cost of traveling is important: • Collecting information such as: • number of loads per day • cost per distance traveled • When process relationship is important • Relationship chart

46. (a) LOADS/DAY Collecting information in process layout (b) LOADS/DAY If direction is not important, collapses to

47. A 30 B - 30 60 C - 20 - 30 D 80 40 E Collecting information in process layout (c) LOADS/DAY (d) LOADS/DAY Or alternatively

48. UNIT COST/DISTANCE TRAVELLED Collecting information in process layout (e) (f) LOADS/DAY If cost of flow differs between work centers, combine with

49. Collecting information in process layout (g) DAILY COST/DISTANCE TRAVELLED To give

50. Collecting information in process layout (h) (i) DAILY COST/DISTANCE TRAVELLED DAILY COST/DISTANCE TRAVELLED If direction is not important, collapses to