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Technical Note 6 Facility Layout

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  1. Technical Note 6Facility Layout • Facility Layout and Basic Formats • Process Layout • Layout Planning • Assembly Line balancing • Service Layout

  2. Facility Layout Defined Facility layout can be defined as the process by which the placement of departments, workgroups within departments, workstations, machines, and stock-holding points within a facility are determined. This process requires the following inputs:

  3. Basic Production Layout Formats • Process Layout • Product Layout • Group Technology (Cellular) Layout • Fixed-Position Layout

  4. Process-Oriented Layout • Design places departments with large flows of material or people together • Dept. areas have similar processes • Used with process-focused processes • Examples © 1995 Corel Corp.

  5. Product-Oriented Layout • Facility organized around product • Design minimizes line imbalance • Types: Fabrication line; assembly line • Examples © 1984-1994 T/Maker Co.

  6. Cellular Layout - Group Technology (Work Cells) • Special case of process-oriented layout • Consists of different machines brought together to make a product • Temporary arrangement only • Group Technology Benefits:

  7. Group Technology:Transition from Process Layout 1. Grouping parts into families that follow a common sequence of steps. 2. Identifying dominant flow patterns of parts families as a basis for location or relocation of processes. 3.

  8. Fixed-Position Layout • Design is for stationary project • Workers & equipment come to site • Complicating factors • Limited space at site • Examples © 1995 Corel Corp. © 1995 Corel Corp. © 1995 Corel Corp.

  9. Fixed Position Layout Question: What are our primary considerations for a fixed position layout? Answer:

  10. Retail Service Layout • Goal--maximize net profit per square foot of floor space. • Servicescapes

  11. Layout Solution

  12. Station 1 Station 2 Station 3 Minutes per Unit 6 7 3 Assembly Lines Balancing Concepts Question: Suppose you load work into the three work stations below such that each will take the corresponding number of minutes as shown. What is the cycle time of this line? Answer:

  13. Example of Line Balancing • You’ve just been assigned the job a setting up an electric fan assembly line with the following tasks: Task Time (Mins) Description Predecessors A 2 Assemble frame None B 1 Mount switch A C 3.25 Assemble motor housing None D 1.2 Mount motor housing in frame A, C E 0.5 Attach blade D F 1 Assemble and attach safety grill E G 1 Attach cord B H 1.4 Test F, G

  14. Example of Line Balancing: Structuring the Precedence Diagram Task Predecessors Task Predecessors A None E D B A F E C None G B D A, C H E, G A B G H E C D F

  15. 2 1 1 1.4 A B G H C D E F 3.25 1.2 .5 1 Example of Line Balancing: Precedence Diagram Question: Which process step defines the maximum rate of production? Answer:

  16. Example of Line Balancing: Determine Cycle Time Question: Suppose we want to assemble 100 fans per day. What would our cycle time have to be? Answer:

  17. Example of Line Balancing: Determine Theoretical Minimum Number of Workstations Question: What is the theoretical minimum number of workstations for this problem? Answer: