Professional Documents
Culture Documents
1
What is Facility Layout?
• Customer satisfaction
2
Five Types of Facility Design Projects
Facility Layout
3
Layout
Layout
4
Impact of Poor Plant Layout
• High material handling costs
• Cycle and lead time delays
• High WIP inventories
• Lower quality
• Product damage
• Safety and morale problems
• Poor equipment utilization
• Congested aisles
• Wasted floor space
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5
Layout Procedures
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Layout Procedures
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6
Apple’s Plant Layout Procedure
In “planning for and preparing the layout,” Reed recommended that the
following steps be taken in his “systematic plan of attach”:
1. Analyze the product to be produced.
2. Determine the process required to manufacture the product.
3. Prepare layout planning charts.
4. Determine work stations.
5. Analyze storage area requirements.
6. Establish minimum aisle widths.
7. Establish office requirements.
8. Consider personnel facilities and services.
9. Survey plant services.
10. Provide for future expansion.
7
Algorithmic Approaches
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Product Layout
Analysis
1, Flow of Materials 2, Activity Relationships
3, Relationship Diagram
Search
7, Modifying Considerations 8, Practical Limitations
Selection
10, Evaluation
Input Data/Activities
9
Sources for Data:
Most of the information concerning the types of
parts and assemblies that will produced will come
from documents that you learned about in PP&S
design. These documents include:
Parts Lists
Bill of Material
Process Flow Chart
Process Map
Routing Sheets
Assembly Chart
Operations Process Chart
Assembly Precedence Diagram
Production Schedule
10
Example 1
REL chart:
Example 1 (Cont,)
5 8 7
10 9 6
4 2 3
Activity Relationship
1
Diagram
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11
Example (Cont,)
5 8 7
(500) (200) (575)
9
(500) 6
10 (75)
(1750)
4 2 3
(350) (125) (125)
1
Space Relationship (1000)
Diagram
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Example (Cont,)
5 8 7 5 8 7
(500) (200) (575) (500) (200) (575)
6 6
(75) (75)
9
(500) 9
(500)
10 2 (125) 10
3 (125)
(1750) (1750)
2 3
(125) (125)
1
(1000)
4 4 1
(350) (350) (1000)
Alternative 2 Alternative 1
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12
Systematic Layout Planning—
Example 2: Reasons for Closeness
Code Reason
1 Type of customer
2 Ease of supervision
3 Common personnel
4 Contact necessary
6 Psychology
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13
Systematic Layout Planning--Example
Relating Reasons and Importance
Area
From To
2 3 4 5 (sq, ft,)
I U A U
1, Credit department 100
6 -- 4 --
U I A
2, Toy department 400
-- 1 1,6
U X
3, Adult books department 300
-- 1
X
4, Camera department 100
1
1 E 3
I 4 U U
2 5
A
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14
Systematic Layout Planning--
Example
Initial and Final Layouts
5 2 4 2
3 20 ft
3 1 5 1 4
50 ft
Relationship Diagramming
REL chart:
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15
Relationship Diagramming
10 U I U I A U U E 5 10 8
5 U I U U U U U U
10 U I U I U U E
9
8 U O U U U U U
5 U I U U U U U
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Relationship Diagramming
5 10 8 5 10 8
- The 5th one to enter is 7
1 9 7
3 2 6
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Relationship Diagramming
5 10 8
10
(1750)
1
(1000)
1 9 7
3 (125)
7
3 2 6 9 (575)
(500)
6
2 (125) (75)
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Relationship Diagramming
• Final alternative
4
5 (350) 8
(500) (200)
1 10 7
(1000) (1750) (
5
7
5
3 (125) )
9 6
(500) (75)
2 (125)
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Graph-based Approach
• Keys:
– A node (O) represents a department
– An arc ( ___ ) represent a relationship
• A weight is assigned to each relationship (Closeness Rating Rel-Chart):
• Rules:
– No arc intersection is allowed
– Dimensional specifications are not considered
– The scores are very sensitive to the numerical weights assigned
– The scores do not represents distances
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18
Graph-Based Construction Method
• Strategy: iteration is based on inserting a new node
• Step -1: Largest weight-pair departments
20
3 4
1 8 10 18
12 13
2 12 13 25
(Best)
5 0 2 2
3 4
20
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9
1 9 8 10 27 12
13
(Best)
1
5 7 0 9 16 8 10
3 4
20
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Graph-Based – Step 4
1 2 3 4 2
5 0 7 0 2
Faces Total 9 7
1-2-3 7
12 13
1-2-4 9 5
0
(best) 2
1-3-4 2 1
8 10
2-3-4 9
(best) 3 4
20
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20
Adjacency Graphs – Version B
Arc Weight
5
0 1-5 0
7 2-5 7
1
9 1-2 9
2
10
1-4 10
13
2-4 13
12
4 2-3 12
20 3-4 20
3
Total 71
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Arc Weight
12 2 13
1-2 9
1-3 8
9 7
1-4 10
0 1-5 0
1 5
8 2-3 12
2-4 13
2
10 2-5 7
3 3-4 20
20 4 4-5 2
Total 81
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21
Pair-wise exchange method
• Improvement: redesign of an existing
facility ( new machine, expansion of
storage, …
• Objective: Minimize the total cost of
MH
– Min MH cost
n n
min z X ij Cij
i 1 j 1
• X=Number of moves
• C: cost of a move Xij
• Procedure:
1 2 3 4
– Example: ( 4 departments with equal
size) 1 - 10 15 20
– Existing layout and 2 - 10 5
3 - 5
1 2 3 4
4 -
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Pair-wise exchange method
• TC1234 = 125 (existing layout cost)
• TC2134 = (10)(1)+(15)(1)+(20)(2)+(10)(2)+(5)(3)+(5)(1) =105
• TC3214 = 95 Feasible exchange pair is 1-3
• TC4231 = 120
• TC1432 = 105
• TC1324 = 120
• TC1243 = 125
Iteration 1 leads to the following layout
Iteration 2
• TC3214 = 95 (1st iteration layout cost) 3 2 1 4
• TC1234 = 125
• TC3241 = 110
• TC2314 = 90 Feasible exchange pair is 2-3
• TC
Iteration 2 leads to the following layout
2 3 1 4 ٤٥
SLP Example
• XYZ inc, has a facility with 6 depts, (A,B, C, D, E, and F), A summary of
the processing sequence for 10 products and the weekly production
forecasts for the products, and areas are given in the tables below:
Dimension Weekly
(ft*ft) products Processing
Production
Seq,
A 40 x 40
1 ABCDEF 960
B 45 x 45
2 ABCBEDCF 1,200
C 30 x 30
3 ABCDEF 720
D 50 x 50
4 ABCEBCF 2,400
E 60 x 60
5 ACEF 1,800
F 50 x 50
6 ABCDEF 480
7 ABDECBF 2,400
1. F – To Chart 8 ABDECBF 3,000
2. Block laying diagramming using SLP 9 ABCDF 960
3. Developing a block laying using
10 ABDEF 1,200
Relationship diagramming
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a)Construct the F – T Chart
A B C D E F
A-B = 960 + 1,200 + 720 + 2,400
+ 480 + 2,400 + 3,000 + 960 + A X 13,320 1,800 0 0 0
B 0 X 11,400 6,600 4,920 5,400
1,200
C 0 6,600 X 2,400 4,200 3,600
= 13,320 D 0 3,000 1,200 X 5,040 960
B-A = 0 E 0 5,400 7,800 1,200 X 5,160
B-C = 960 + 1,200 + 720 + 2,400 F 0 0 0 0 0 X
A E I
O A
B U
A U
Rel. Chart: A E I O U
C E U
A B C D E F O E U
A - A U U U U D E I
B - A E E I I O
C - O E O
E U
D - I U
I
E - I
F
F -
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1st to enter is B (two As’) B
A
A
2nd to enter is C (E & O) B C
B U
A U
3rd to enter is A (A effect) A B C
C E U
4th to enter is E E F O E U
A B C D
D E I
5th to enter is D E A U U U
I O
B E E I
C O E O E U
6th to enter is F A B C
I
D E D F F
A U U
F
B E I
A B C C O O
D E E I I
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Relationship Diagram
F
A O
E U
A B C I
D E
Block Diagram
F
A B F
I O
C
AA B A C
E E
U E E E D
D I
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25
Pairwise Exchange Example
Given:
4-equal size departments are
A B C D
Served by an AGV on a
Linear bidirectional track
As shown. Each machine
block
Is 30X30 ft. The product
routine
Information and required
production
Are given. Determine
arrangement
based on the pairwise
exchange
1 BDCAC 300
method. Assume P/D point
as shown in the figure. 2 BDAC 700
3 DBDCAC 900
4 ABCA 200
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D -
CBAD = 507,000
DBCA = 435,000
ABCD = 372,000
B A C D
CABD = 351,000
DACB = 468,000
Find Arrangement BACD
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Graph-based Approach Example
The ABC cooling and heating company manufactures several different types of air
conditioners. 5 departments are involved in the processing required for the products. A
summary of the processing sequence required for the 5 major products and weekly
production volumes for the products are shown in the table below along with the department
area. Based on the graph-based approach construction method, develop a block layout
3 ACE 50 C 1000
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4) the 5th department to enter is C but where? A 250 0 250 A 250 0 350 600
.
B 0 400 400 C 0 50 350 400
C 0 50 50
A E B Total
A D E Total A D B Total C 250 50 350 650
C 250 0 50 300 C 250 0 350 600
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Graph-based Approach Example
D
Adjacency Graph
E C B
Block Layout
D
C A E
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Impact of Changes
• Expansion
– Mirror image expansion: simple, free
of bottlenecks and limited to one time
expansion
– Straight line flow expansion:
Unlimited, simple, low add on cost
building but hard to selectively expand
some departments
– T-shape expansion
– U-Shape expansion
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Computer Aided Layout
a) Distance-Based Approach
f: flow number between i and j n n
d: distance from i and j MinZ fdc ij ij ij
c: cost of moving one unit from i to j i 1 j 1
i and j: departments
n: number of departments
b) Adjacency-Based Approach
1) Z= adjacent score
n n
f: flow number between i and j
x: adjacency score
MaxZ f ij xij
i 1 j 1
= 1 if i and j are adjacent
= 0 otherwise
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b) Distance-Based Approach n n n n
2) Z* = Relative efficiency or Efficiency Max* f ij xij / f ij
rating i 1 j 1 i 1 j 1
0 < Z* < 1
as Z* 1 all the departments are adjacent
Cij = 1 for the same MH equipment
3) Z^ = Relative efficiency or Efficiency rating
for –ve values of relationships
Cij = 1 for the same MH equipment
+F: positive Rel. group of Depts.
- F: negative Rel. group of Depts.
n n n n n n n n
Max^ ( fij xij F fij (1 xij F )) /( fij F f ij F )
i 1 j 1 i 1 j 1 i 1 j 1 i 1 j 1
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30
Computer Aided Layout
1 2 3 4 5
1 2 3 4 5
1 - 1 1 0 0
1 - 5 0 4 -3
2 - 1 0 0
2 - 6 -1 2
3 - 1 1
3 - -6 0
4 - 1
4 - 3
5 -
5 -
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b) Calculate Z*
n
1 3 4
f = 5 +0+4-3+6-1+2-6+0+3 = 10
ij
j 1
2 5
n n
f
i 1 j 1
ij xij = f12*X12 + f13*X13 + f14*X14 +
f15*X15 + f23*X23 + f24*X24 + f25*X25
+ f34*X34 + f35*X35 + f45*X45
= 1*5 +1*0 +4*0+ -3*0 +6*1+
-1*0 + 2*0 + -6*1 + 0*1 1 2 3 4 5 1 2 3 4 5
+3*1 = 8 1 - 5 0 4 -3 1 - 1 1 0 0
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Computer Aided Layout
c) Calculate Z^
n
f (+ve) = 5 +0+4+6+2+0+3 = 20
ij
j 1
n F (-ve): (1,5), (2,4), (3,4)
f (-ve) = -3-1-6 = -10
ij
j 1 F (+ve): the rest
n n
x (+ve) = f12*X12 + f13*X13 +
fi 1 j 1
ij
Discrete:
- Area of each department is rounded to the
nearest integer
- Grid size affects the resolution and the
computation time
Continuous
- No grid
- More difficult
- Restricted to rectangular shape
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