Facility Layout: Eng. Alexander Aragón Ch. M.SC

564201
Facility Layout
Eng. Alexander Aragón Ch. M.Sc.
Department of Operations and Systems - DOS
Faculty of Engineering
Class
2021-03
www.alexanderaragon.co
Art. 57° Res. CA. 666 Dic. 17 / 2020

«Student Regulations»
Art. 9° Res. CA. 6602 Oct. 30 / 2017
«Code of Ethics»
Personería jurídica, Res. No. 0618, de la Gobernación del Valle del Cauca, del 20 de febrero de 1970. Universidad Autónoma de Occidente, Res. No. 2766, del Ministerio de Educación Nacional, del 13 de noviembre de 2003, Acreditación Institucional de Alta Calidad, Res. No. 16740, del 24 de agosto de 2017, con vigencia hasta el 2021. Vigilada MinEducación.
Module 1
Production and Services Processes
Session 2
Operations Software – 35
Product / Service Characterization – 36
Process Characterization – 37
The Supply Chain – 38
Process Types – 39
Distribution types – 40
Advantages and disadvantages of the types of Distribution – 47
Design of Process – 56
Video – 57
Review Activity – 58
Assessment Activity – 59
Glosary – 60
References Session 1 – 61
34
/-\\ 2021-03. Didactic support material – Eng. Alexander Aragón Ch. (www.alexanderaragon.co) – Universidad Autónoma de Occidente 564201 - Facility Layout
Operations Software
The POM/QM For Windows (Production and Operation Management/Quantitative Methods) application of academic
type, allows various useful analyzes for the Facility Layout course.
There are two versions, Excel QM and QM For Windows.
The direct download link from the Pearson publisher is:
QM For Windows v.4.0
QM For Windows v.5.2
35
Product / Service Characterization
It is necessary to know well the product to be manufactured or service to be provided in the facility to be designed. The
productive processes are also Internal Supply Chains that must be synchronized, with the External Supply Chain.
The Bill of Materials (BOM) provides key information for

Production Planning.
GOLA-Cola
(2 days)
Cola Syrup Can 350 mL

(1 day) (2 days)
Sugar Caramel Color Phosporic Acid Painting

(1 day) (1 day) (2 days) (3 days)
Main Lyquid
(1 day)
Carbonated Sodium
Caffeine
Water benzonate
(3 days)
(1 day) (2 days)
What Student Outcomes are involved in

this concepts?
36
Process Characterization
In the same way, it is required to know how the product is manufactured or the service is provided. Necessary
equipment, labor, support services, etc.
Operations process charts and other diagrams provide details

about process activities.

this concepts?
37
The Supply Chain
The facility connects with the environment, in what we call the Supply Chain, with suppliers and customers.
Identify here some of the key elements in supply chain operations:
Suppliers Supplier GOLA-Cola Distribution Retailers
Transport Bottles Organization Storage Departmen stores
Sugars Cans Production Wholesalers Small shops
Colorants
Phosphoric Acid
Flavorings Consumidor
Caffeine
80
100
150
125
170
84

this concepts?
38
Process Types
Different types of process distribution are appropriate for different combinations of volume and variety1:
Low Volume High
Intermittent
Flow
Fixed Position
Regular flow becomes more feasible

Distribution
High
Functional
Distribution
Cellular
Distribution
Product
Distribution
Variety
Low
Continuous
flow
Regular flow becomes more important

1. Poker (Bavaria) | 42 Ferrari (Rojal) 3. Big Building (Free PNG Pictures) | 4. Pencil (Rojal)
39
Distribution types
Distribution and location decisions depend on whether it is a Production Environment, Office Environment or Service Environment, which
facilitates the flow of materials, people and information for which various approaches have been developed2:
Fixed position distribution (or Project3)
Study the physical distribution requirements for large projects such as ships, airplanes, buildings.
Discuss its characteristics.
5. AIDAprima Cruise Ship Construction & Christening (MK timelapse GmbH)

40
Distribution types
Process or service-oriented distribution (intermittent)
For productions of low volume and high variety (or customization), it is also known as production workshop, by Order or Job Shop4, each
product or service follows a particular sequence of operations.
A hospital follows this type.
6. FSJ Hospital Project (Energetic City)

41
Distribution types
Office Distribution
It is specific for operations in business environments, where it is important to facilitate the movement of information.
What can you identify in the teachers' offices?
7. Interior 3D Animation of Modern Open Plan Office (3D Design Bureau)

42
Distribution types
Store Distribution
Allocation of spaces for shelves, gondolas and respond to customer behavior.

It is known that the higher the product exposure rate, the higher the sales. The use of marketing techniques and product location is
required.
Have you seen the Merchandising lab?
8. Buzz 3D virtual store flythrough (Buzz 3D)

43
Distribution types
Warehouse Distribution (Distribution Centers)
Consider storage spaces and minimize costs for material handling. Inventory storage and control techniques are important (ABC
Classification, for example).
The University has a General Warehouse and each laboratory has a smaller one.
Do you know their locations?
9. Warehouse 3D Animation (Derf Fil)

44
Distribution types
Product Oriented Distribution
It seeks the best use of people and equipment in repetitive and continuous production of high volume and low variety (manufacturing
and assembly lines), also known as Flow-Shop.
Very common in the manufacturing environment.
Do you remember the conveyor belt in the operations workshop?
10. Plant Layout Animation - 10s lag (GSAe)

45
Distribution types
Plant distribution decisions include the most optimal placement of machines, offices and desks or
service centers. An effective distribution seeks to facilitate the flow of materials, people and
information within and between areas2.
The selection of the type of distribution is linked to the type or structure of the process3, and
therefore, defines the general pattern of the workflow4.
Fixed position distribution Process or service oriented Office Distribution
(or Project) distribution (intermittent)
Store Distribution Warehouse Distribution Product Oriented Distribution

(Distribution Centers) (repetitive - continuous)
46
Advantages and disadvantages of the types of Distribution
Functional Distribution, by Processes, Flexible Flow, Job-Shop or Intermittent Production
Recommended for batch production. Machines that perform similar operations are grouped in one location as
"departments“5. It is typical when there is a high variety of references to produce but with few volumes per batch.
When the product, information or customer flows throughout the operations, they will take a “route” between activities
according to their requirements1. [Milling machines ]
Intensive Care
[Adjustment ] [Winches ]
Diagnostic Imaging Surgery
[Painting ]
Recovery room
Emergency
[Orders ]
Billing
[Delivery ]
47
Functional Distribution, by Processes, Flexible Flow, Job-Shop or Intermittent Production
Some advantages and disadvantages of this type of distribution:
Advantages: Disadvantages:
1. Less machinery is required, and they are 1. Extensive movements can occur reducing the
better used. efficiency in displacement and its costs.
2. Greater flexibility in equipment and personnel 2. Possibly the movement of materials could not
is achieved. be automated without adding high costs.
3. Less investment in equipment. 3. Process time is extended by reducing
4. Greater use of the facilities. inventory turnover and increasing the product
5. High degree of flexibility in process.
6. Ease of acquiring knowledge about the 4. Low productivity due to the number of
functions of each department. preparations.
7. General purpose equipment is less expensive 5. Longer cycle times
and requires less maintenance in contrast to 6. It requires more space and capital.
specialized equipment. 7. Greater difficulty in programming activities
(Prioritization or order).
48
Product Distribution, repetitive, in line or assembly / manufacturing lines, Flow Shop.
Machines and other auxiliary services are located according to the product's processing sequence. It is adequate when the
volume of production of a product is high and therefore, a configuration of this type allows to achieve an efficient flow of
materials at a lower cost per unit. It use special purpose machines.
Typical examples: Automotive Assembly, Self Service Cafes

3. Milling
4. Painting 2. Turning
5. Assembly and Inspection
1. Raw Materials
6. Delivery
49
Product Distribution, repetitive, in line or assembly / manufacturing lines, Flow Shop.
Advantages: Disadvantages :
1. The product flow is smoothed. 1. Failures in a machine or station, you can stop
2. The inventory in process is smaller. the entire production line.
3. The cycle time is less. 2. Changes in product design require major
4. Lower costs in material handling. changes in distribution.
5. Production is simplified and its planning and 3. The production rate is controlled by
control is easier. bottlenecks.
6. Less space is occupied both for work in transit 4. High investment in equipment is required.
and for temporary storage. 5. Little flexibility, since changes in products will
7. Lower material handling costs thanks to the require modifications in the installation.
use of automated systems. 6. Possible work stress due to repetitive tasks.
8. Line balancing that eliminates bottlenecks.
9. Short manufacturing cycle thanks to
continuous flow.
10. Requires less skilled labor.
50
Cellular Distribution, Manufacturing / Production Cells or Technological Grouping.
Assigns different machines to work cells for the manufacture of similar products. It is a derivation of Distribution By
Product and Functional Distribution (Job Shop)6.
In effect, they are small distributions per product.
Product Cell 2
Product Cell 1
Painting
Product Cell 3
Raw Materials
Delivery
51
Advantages : Disadvantages :
1. It can increase the standardization and 1. It is not feasible for all situations, especially if
rationalization of components. the products differ in some aspect.
2. There is reliability in the estimates. 2. May require more skilled labor.
3. Operation and effective productivity of the 3. It will require investment in equipment and
machines. machinery.
4. Improves customer service.
5. Decrease overproduction times.
6. It reduces work in process and material
movements.
7. Decrease cost overruns.
The detailed design of the Cellular Distribution is difficult, given its mixed configuration, and
because of the detailed analysis of the product families and the resources necessary for their
consideration1
52
To design such a distribution, these steps are considered6:
1. Group products into families that follow a common sequence of activities. It may require the support of computer systems for the explosion of materials.
2. Identify the dominant flow patterns of product families (parts).
3. Group machines and processes in cells.
4. Pieces that do not correspond to a particular family, should be placed in a new cell, called “Remaining Cell”
Original distribution Cell Distribution
Milling
Drills Mills
machines
(Ta) (M) Cell 1
Raw Materials
(F)
Assembly
Heat Cell 2
Raw Materials
Winches Lever Cut
treatment
Assembly
(To) (Cp)
(Tc)
Parte
Family Cell 3
Process Route Matrix
Parts Milling Heat
Winches Drills Mills Lever Cut To
family machines treatment
Raw
Assembly
Materials Cell 4
53
Fixed Distribution or by Projects.
They have a relatively small number of units to produce, given their large size or volume, so distributions are designed
around the product6.
The challenge to overcome is the convergence of many resources (materials, tools, people, machinery) towards a common
point, the assembly or manufacture of the product.
Final assembly Pre assembly
o Manufacturing (Cell)
Pre assembly
o Manufacturing (Cell)
Raw Materials
Raw Materials
54
Fixed Distribution or by Projects.
Advantages : Disadvantages :
1. It contributes to the specialization and 1. High investment in equipment for material

updating of the workforce. handling.
2. Workers identify with the process and 2. Little literature related to quantitative
product, encouraging pride in being part of it. distribution techniques.
3. High flexibility 3. High complexity in the planning and
4. Low capital investment in distribution. programming of activities.
55
Design of Process
Indeed, industrial engineers design or redesign processes by selecting the necessary technical and human resources, the
appropriate type of process, and the ideal spaces and conditions.
What Student Outcomes are involved in the design of a Process?
3. Milling
4. Painting 2. Turning
5. Assembly and Inspection
1. Raw Materials
6. Delivery
56
Video
Let's look at a good example of a facility, in the assembly line of the Airbus Beluga in Toulouse, France:
Pay special attention to logistics, facilities and equipment for

material handling and risks. Airbus uses this aircraft, as a material handling equipment.
11. In the making: Airbus’ first BelugaXL

57
Review activity
Now, we are going to review some concepts using your mobile phone. Scan the QR code or visit www.kahoot.it and wait for the access
code.
58
Assessment activity
For next class, create a mind map of key concepts about this topics:
1. Characteristics of the production systems and their respective distribution.

2. From video Plant Layout Tutorial - Chapter 10: Service businesses.
Title: Plant Layout Tutorial - Chapter 10: Service businesses

Posted by: Invest Northern Ireland
Duration: 3:23
Language: English (you can activate subtitles)
From this information, we will do a quiz test in the last 10 minutes of class.
59
Glosary
Incorporate in this Glossary page, at least 5 terms or acronyms used in this session, with their respective definitions. You will need for
incorporating it in the final report.
60
References Session 2:
1. SLACK, Nigel. Operations Management. Pearson. 7 Ed. 2013, 764 p.

2. RENDER, Barry & HEIZER, Jay. Administración de la Producción. Pearson Educación, México. 2007. 472 p.
3. KRAJEWSKI, Lee. Administración de operaciones, procesos y cadena s de valor. Pearson Prentice-Hall. 8 Ed. 2008. 754 p.
4. STEVENSON, William J. Operations Management. McGraw-Hill Irwin. 7 ed. 2012. 945 p.
5. KUMAR, S. Anil. Operations Management. New Age International. 2009. 290 p.
6. CHASE, Richard et al. Operations Management for Competitive Advantage. McGraw-Hill Higher Education, 2000 - 864 p.
Material compiled by Alexander Aragón Ch. For academic use only.
Copyright notice: This presentation may contain copyrighted material cited in the sources consulted; Other material may conform to the uses allowed under the Multimedia guidelines and exemptions for academic use in Copyright laws in some
countries or under Creative Commons licensing. Use for other pourposes is prohibited.
Images: | 1, 2, Universidad Autónoma de Occidente | 1, Bavaria | 2, 4, www.pngall.com | 3, https://freepng.pictures/ | 2. Renderpeople https://renderpeople.com/es/free-3d-people/
Icons: Graphic Resources SL (www.flaticon.com)
YouTube Videos: 5-10 Standard Licensing | 11, Airbus
This work is covered under the Creative Commons Attribution-Share Alike 3.0 Unported License. To see a copy of this license, visit http://creativecommons.org/licenses/by-sa/3.0/deed.es.
/-\\ Last Update: July 28, 2021.
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564201

Art. 57° Res. CA. 666 Dic. 17 / 2020

There are two versions, Excel QM and QM For Windows.

The direct download link from the Pearson publisher is:

QM For Windows v.4.0

QM For Windows v.5.2

The Bill of Materials (BOM) provides key information for

Cola Syrup Can 350 mL

Sugar Caramel Color Phosporic Acid Painting

What Student Outcomes are involved in

Operations process charts and other diagrams provide details

What Student Outcomes are involved in

What Student Outcomes are involved in

Regular flow becomes more feasible

Regular flow becomes more important

Fixed position distribution (or Project3)

Discuss its characteristics.

5. AIDAprima Cruise Ship Construction & Christening (MK timelapse GmbH)

A hospital follows this type.

6. FSJ Hospital Project (Energetic City)

What can you identify in the teachers' offices?

7. Interior 3D Animation of Modern Open Plan Office (3D Design Bureau)

Allocation of spaces for shelves, gondolas and respond to customer behavior.

Have you seen the Merchandising lab?

8. Buzz 3D virtual store flythrough (Buzz 3D)

Do you know their locations?

9. Warehouse 3D Animation (Derf Fil)

Very common in the manufacturing environment.

Do you remember the conveyor belt in the operations workshop?

10. Plant Layout Animation - 10s lag (GSAe)

Store Distribution Warehouse Distribution Product Oriented Distribution

Some advantages and disadvantages of this type of distribution:

Typical examples: Automotive Assembly, Self Service Cafes

5. Assembly and Inspection

Some advantages and disadvantages of this type of distribution:

In effect, they are small distributions per product.

Some advantages and disadvantages of this type of distribution:

To design such a distribution, these steps are considered6:

Original distribution Cell Distribution

Some advantages and disadvantages of this type of distribution:

1. It contributes to the specialization and 1. High investment in equipment for material

5. Assembly and Inspection

Pay special attention to logistics, facilities and equipment for

11. In the making: Airbus’ first BelugaXL

1. Characteristics of the production systems and their respective distribution.

Title: Plant Layout Tutorial - Chapter 10: Service businesses

1. SLACK, Nigel. Operations Management. Pearson. 7 Ed. 2013, 764 p.

Material compiled by Alexander Aragón Ch. For academic use only.

Images: | 1, 2, Universidad Autónoma de Occidente | 1, Bavaria | 2, 4, www.pngall.com | 3, https://freepng.pictures/ | 2. Renderpeople https://renderpeople.com/es/free-3d-people/

Icons: Graphic Resources SL (www.flaticon.com)

YouTube Videos: 5-10 Standard Licensing | 11, Airbus

/-\\ Last Update: July 28, 2021.

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