Facility Layout

IPE 4111

Afia Ahsan
Lecturer
MPE, AUST
Facility Layout

Layout refers to the specific configuration of physical facilities in

an organization.
The configuration of departments, work centers, and equipment,
with particular emphasis on movement of work (customers or
materials) through the system.
Objective of layout strategy is to develop an effective and efficient
layout that will meet the firm’s competitive requirements.
Importance of Layout Decisions
❑ Requires substantial investments of money and effort
❑ Involves long-term commitments
❑ Has significant impact on cost and efficiency of short-term
operations
Objective of Layout Design

❖ Facilitate attainment of product or service quality

❖ Use workers and space efficiently
❖ Avoid bottlenecks
❖ Minimize unnecessary material handling costs
❖ Eliminate unnecessary movement of workers or materials
❖ Minimize production time or customer service time
❖ Design for safety
Basic Layout Types
1. Product layout
2. Process layout
3. Fixed-Position layout
4. Combination layout/Cellular layout
Product layout

➢ Layout that uses standardized processing operations to

achieve smooth, rapid, high-volume flow
➢ Equipment or work processes are arranged according to
progressive steps by which product is made
➢ Organized around products or families of similar high-
volume, low-variety products
➢ Example: Chemical or production plants.
Process layout
➢ Layout that can handle varied processing requirements
➢ similar equipment or functions are grouped together
➢ To deal with low-volume, high-variety production
➢ Each product/service undergoes a different sequence of
operations
➢ Example: Hospitals
Fixed-Position Layout

➢ Layout in which the product or project remains stationary,

and workers, materials, and equipment are moved as
needed
➢ Deal with large, bulky projects
➢ Example: ship & building, construction projects
Cellular Layouts

Cellular Production
Layout in which machines are grouped into a cell that can
process items that have similar processing requirements

Group Technology
The grouping into part families of items with similar design or
manufacturing characteristics
Design Product Layouts: Line Balancing
❖ Line Balancing is the process of assigning tasks to workstations in
such a way that the workstations have approximately equal time
requirements.
❖ The goal is to obtain workstations with well balanced workload.
❖ Need to match the output rate with desired plan.
Line Balancing in Product Layouts
1. Central problem in product layout is to balance the output at
each workstation along the production line
2. Line Balancing is the process of assigning tasks to workstations in
such a way that the workstations have approximately equal time
requirements
 Cycle time
❑ Cycle time is the maximum time allowed at each workstation to
complete its set of tasks on a unit.
❑ Time between successive units coming off end of the line
 General Procedure for Line Balancing
➢ Determine precedence relationships – the order in which tasks must be performed in the assembly process.
Total work time available
➢ Calculate Cycle time , C= Units required
Total of all task time
➢ Determine minimum number of workstations, N =
Cycle time
➢ Determine the candidate list which includes the following tasks

➢ The task whose immediate predecessors have been assigned to a workstation

➢ The task for which adequate time is available at the workstation

➢ Decision rule: Primary rule: Assign task with the longest processing time

Secondary rule: Assign task with greatest no of followers

For tie, choose arbitrarily.

➢ After task assignment, determine idle time = Cycle time-sum of time already assigned tasks

➢ Continue until all tasks have been assigned to workstations.

Sum of all task times
➢ Determine efficiency = X 100%
No of Actual Workstations X Cycle time
 Line Balancing (Example 1)
There are 240 productive minutes available per day. The production schedule
requires to complete 600 units each day. Arrange the work activities into workstations
to balance the assembly line.
0.2
Immediate
Task Time (Min)
Predecessor 0.1 0.3
A. Press out sheet of
- 0.1
fruit
B. Cut into strips A 0.2
C. Outline fun shapes A 0.4
D. Roll up and package B, C 0.3
0.4
 Line Balancing (Example 1)
There are 240 productive minutes available per day. The production schedule
requires to complete 600 units each day. Arrange the work activities into workstations
to balance the assembly line.
Immediate
Task Time (Min)
Predecessor
A. Press out sheet of fruit - 0.1
B. Cut into strips A 0.2
C. Outline fun shapes A 0.4
D. Roll up and package B, C 0.3

𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑇𝑖𝑚𝑒 𝑎𝑣𝑎𝑖𝑎𝑏𝑙𝑒 𝑝𝑒𝑟 𝑑𝑎𝑦 240

𝐶𝑦𝑐𝑙𝑒 𝑇𝑖𝑚𝑒 = = = 0.4 𝑚𝑖𝑛/𝑢𝑛𝑖𝑡
𝑂𝑢𝑡𝑝𝑢𝑡 𝑛𝑒𝑒𝑑𝑒𝑑 𝑝𝑒𝑟 𝑑𝑎𝑦 600

𝑇𝑜𝑡𝑎𝑙 𝑡𝑎𝑠𝑘 𝑡𝑖𝑚𝑒 0.1 + 0.2 + 0.4 + 0.3

𝑁𝑚𝑖𝑛 = = = 2.5 ≈ 3
𝐶𝑦𝑐𝑙𝑒 𝑇𝑖𝑚𝑒 0.4
Line Balancing (Example 1)

Cycle Time = 0.4 min/unit

Station Candidate List Task Assigned Task Time Total Time Idle Time
Number
1 A A 0.1 0.1 0.3
B B 0.2 0.3 0.1
2 C C 0.4 0.4 0
3 D D 0.3 0.3 0.1
 Line Balancing (Example 1)

𝑇𝑜𝑡𝑎𝑙 𝑇𝑎𝑠𝑘 𝑇𝑖𝑚𝑒

𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 =
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐴𝑐𝑡𝑢𝑎𝑙 𝑆𝑡𝑎𝑡𝑖𝑜𝑛𝑠 × 𝐶𝑦𝑐𝑙𝑒 𝑇𝑖𝑚𝑒

0.1+0.2+0.4+0.3
=
3 𝑆𝑡𝑎𝑡𝑖𝑜𝑛𝑠 ×0.4

= 83.33%
Line Balancing (Exercise 1)
There are 500 productive minutes available per day. The production schedule
requires to complete 65 units each day. Arrange the work activities into workstations
to balance the assembly line.
Immediate
Task Time (Min)
Predecessor

A - 5
B A 3
C B 4
D B 3
E C 4
F C 1
G D, E, F 4
H G 7
THANK
YOU