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Plant Layout Reasons for Redesigning Layout
Objectives
be able to determine some of the main
reasons for redesign layout
be able to discuss the major factors that need
to be considered
be able to describe basic types of layout
be able to apply line balancing
Examples and Assignment
Factors Need to be Considered
Capacity and space requirements – machines,
personnel, equipment allowance
Selection of material handling equipment –
conveyor belt, AGV
Environment and aesthetics – Lighting,
Temperature
Flow of information - arrangement
Cost of moving between work areas
Safety aspects – hazard areas
Inefficient operations – bottlenecks
Accident or safety hazards
Introduction of new product or change of
current product design
Change in volumes, mix outputs
Change in process, method or equipments
Change in environmental or legal requirements
Basic Types of Layout
1. Process Layout or Functional Layout
or Process-Oriented Layout
2. Product Layout or Product-Oriented
Layout
3. Fixed Position Layout
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Process Layout Example of Process Layout

All operations of similar nature are grouped
together in the same department or part of Lathe Milling Drill
the factory
Variety High, Volume Low – job shop, small
batch production Assembly Grinding
Permits flexibility in production, involved skill
workers
Disadvantages – operate with high level of work Raw Material Finished Goods
Inspection
in progress, throughput time is high, cost of Storage Storage
material handling is high

Product Layout Example of Product Layout

Arrange activities in a line according to the
sequence of operations of a particular product Workers
Each product has own line specifically design to
meet requirements
Flow orderly and efficient, more automated
Components Move to
Suitable for mass production or repetitive, feed into inspection
stable demand conveyor
Machines
Variety Low, Volume High

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Fixed Layout Example of Fixed Layout

Product remains stationary for entire
production cycle Workers Raw Materials
Product produces too fragile, bulky or heavy
to move e.g. ship, house, aircraft
SHIP
Equipment, workers, materials and other
resources are brought to the production site
Highly skilled workers, low equipment Equipment Tools
utilization

Line Balancing Steps in Line Balancing

To allocate a group of tasks to a workstation and
to determine an optimal set up of workstations
Cycle time is the time any two successive units
coming off the end of the line.
Each workstation may consists of a number of
tasks
Large number of combinations may be possible
but need to choose the optimum solution
Draw up a diagram of the relationships among the
tasks; circle for tasks and arrow for relationship
Determine the required Cycle Time.
Cycle time
The maximum time allowed at each workstation to
complete its set of tasks on a unit
Cycle time also establishes the output rate of a line
CT = Production Time per day (in min)
Output per day (in units)

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Derive the Min Number of Workstation

N = Sum of times for all tasks Calculate the Output Rate
Output Rate = Operating time per day
C
CT
Assign tasks into workstation based on the rule
Bottleneck : the longest task act as a constraints
Add the task if total station time is less than the cycle time
and the predecessors of the task are already done
Tasks should be assigned in the N workstations Minimum cycle time = the longest task

Calculate the Efficiency of the Line Maximum cycle time = the sum of the task time
Efficiency = Sum of times for all tasks x 100%
N x CT

Bottleneck Workstation Line Balancing Rules

30/hr. 30/hr. 30/hr. 30/hr.
1 min. 1 min. 2 min. 1 min.
Some Heuristic (intuitive) Rules:
Bottleneck Assign tasks in order of most following tasks or
Parallel Workstations most followers.
Count the number of tasks that follow
2 min. 30/hr.
30/hr.
Assign tasks in order of greatest positional
60/hr.
1 min. 1 min. 1 min. 60/hr. weight or longest processing time
30/hr.
2 min. 30/hr. Positional weight is the sum of each task’s time and
Parallel Workstations the times of all following tasks.
6-15

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Example
Cycle Time = Production Time per day (in min)
Output per day (in units)
The tasks shown in Task Immediate Task Time = 440 min per day
the table are to be Follower (min) 275 unit per day
assigned to A C 0.3 = 1.6 min per unit
workstations. B D 0.6
No. of Workstation = Sum of times for all tasks
Management has C E 0.4 Cycle Time
designed an output D F 1.2 = 4.2 min = 2.6 ≈ 3 workstations
rate of 275 units E G 0.2 1.6 min
per day. Assume F H 0.6 Efficiency = Sum of times for all tasks x 100 %
440 minutes are G H 0.1 NxC
available per day. H I 0.5 = 4.2 min x 100% = 87.5 %
I End 0.3 1.6 x 3

1.8 min 1.5 min 1.1 min 0.9 min 0.8 min 0.3 min 1.8 min 1.5 min 1.1 min 0.9 min 0.8 min 0.3 min

A C E G H I A C E G H I

0.3 min 0.4 min 0.2 min 0.1 min 0.5 min 0.3 min 0.3 min 0.4 min 0.2 min 0.1 min 0.5 min 0.3 min

3.2 min 2.6 min 1.4 min 3.2 min 2.6 min 1.4 min

B D F B D F

0.6 min 1.2 min 0.6 min 0.6 min 1.2 min 0.6 min

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Time Task Idle 1.8 min 1.5 min 1.1 min 0.9 min 0.8 min 0.3 min
Assign
Workstation Remain Eligible Time Time
Task A C E G H I
(min) (min) (min)
1 1.6 A, B B 0.6
0.3 min 0.4 min 0.2 min 0.1 min 0.5 min 0.3 min

3.2 min 2.6 min 1.4 min

B D F

0.6 min 1.2 min 0.6 min

Time Task Idle 1.8 min 1.5 min 1.1 min 0.9 min 0.8 min 0.3 min
Assign
Workstation Remain Eligible Time Time
Task A C E G H I
(min) (min) (min)
1 1.6 A, B B 0.6
0.3 min 0.4 min 0.2 min 0.1 min 0.5 min 0.3 min
1.0 A, D A 0.3
3.2 min 2.6 min 1.4 min

B D F

0.6 min 1.2 min 0.6 min

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Time Task Idle 1.8 min 1.5 min 1.1 min 0.9 min 0.8 min 0.3 min
Assign
Workstation Remain Eligible Time Time
Task A C E G H I
(min) (min) (min)
1 1.6 A, B B 0.6
0.3 min 0.4 min 0.2 min 0.1 min 0.5 min 0.3 min
1.0 A, D A 0.3
0.7 C, D C 0.4 3.2 min 2.6 min 1.4 min

B D F

0.6 min 1.2 min 0.6 min

Time Task Idle 1.8 min 1.5 min 1.1 min 0.9 min 0.8 min 0.3 min
Assign
Workstation Remain Eligible Time Time
Task A C E G H I
(min) (min) (min)
1 1.6 A, B B 0.6
0.3 min 0.4 min 0.2 min 0.1 min 0.5 min 0.3 min
1.0 A, D A 0.3
0.7 C, D C 0.4 3.2 min 2.6 min 1.4 min

0.3 D, E E 0.2 B D F

0.6 min 1.2 min 0.6 min

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Time Task Idle 1.8 min 1.5 min 1.1 min 0.9 min 0.8 min 0.3 min
Assign
Workstation Remain Eligible Time Time
Task A C E G H I
(min) (min) (min)
1 1.6 A, B B 0.6
0.3 min 0.4 min 0.2 min 0.1 min 0.5 min 0.3 min
1.0 A, D A 0.3
0.7 C, D C 0.4 3.2 min 2.6 min 1.4 min

0.3 D, E E 0.2 B D F
0.1 D,G G 0.1 0
0.6 min 1.2 min 0.6 min

Time Task Idle 1.8 min 1.5 min 1.1 min 0.9 min 0.8 min 0.3 min
Assign
Workstation Remain Eligible Time Time
Task A C E G H I
(min) (min) (min)
1 1.6 A, B B 0.6
0.3 min 0.4 min 0.2 min 0.1 min 0.5 min 0.3 min
1.0 A, D A 0.3
0.7 C, D C 0.4 3.2 min 2.6 min 1.4 min

0.3 D, E E 0.2 B D F
0.1 D,G G 0.1
2 1.6 D D 1.2 0.6 min 1.2 min 0.6 min

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Time Task Idle 1.8 min 1.5 min 1.1 min 0.9 min 0.8 min 0.3 min
Assign
Workstation Remain Eligible Time Time
Task A C E G H I
(min) (min) (min)
1 1.6 A, B B 0.6
0.3 min 0.4 min 0.2 min 0.1 min 0.5 min 0.3 min
1.0 A, D A 0.3
0.7 C, D C 0.4 3.2 min 2.6 min 1.4 min

0.3 D, E E 0.2 B D F
0.1 D,G G 0.1
2 1.6 D D 1.2 0.6 min 1.2 min 0.6 min

0.4 F - - 0.4

F = 0.6 min, cannot fit !!

1.8 min 1.5 min 1.1 min 0.9 min 0.8 min 0.3 min Time Task Idle
Assign
Workstation Remain Eligible Time Time
A C E G H I
Task
(min) (min) (min)
1 1.6 A, B B 0.6
0.3 min 0.4 min 0.2 min 0.1 min 0.5 min 0.3 min 1.0 A, D A 0.3
3.2 min 2.6 min 1.4 min 0.7 C, D C 0.4
B D F 0.3 D, E E 0.2
0.1 D,G G 0.1
0.6 min 1.2 min 0.6 min 2 1.6 D D 1.2
0.4 F - - 0.4
3 1.6 F F 0.6

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1.8 min 1.5 min 1.1 min 0.9 min 0.8 min 0.3 min Time Task Idle
Assign
Workstation Remain Eligible Time Time
A C E G H I
Task
(min) (min) (min)
1 1.6 A, B B 0.6
0.3 min 0.4 min 0.2 min 0.1 min 0.5 min 0.3 min 1.0 A, D A 0.3
3.2 min 2.6 min 1.4 min 0.7 C, D C 0.4
B D F 0.3 D, E E 0.2
0.1 D,G G 0.1
0.6 min 1.2 min 0.6 min 2 1.6 D D 1.2
0.4 F - - 0.4
3 1.6 F F 0.6
1.0 H H 0.5
0.5 I I 0.3
0.2 - - - 0.2

Result of Line Balancing Tutorial

A C E G H I

B D F
Workstation 3
Workstation 1

Workstation 2

Total Idle time is 0.6 min.

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Let’s Recap!
What are the main reasons for redesigning a
new layout?
List few factors that should be considered in
designing a layout
Describe 3 types of basic layout
What are the steps in line balancing?

Assignment

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