JTM3023: INDUSTRIAL ENGINEERING

FACILITIES LAYOUT

WHAT IS FACILITIES LAYOUT?

THE ARRANGEMENT OF MACHINES, DEPARTMENTS, WORKSTATIONS, STORAGE AREAS, AISLES AND COMMON AREAS WITHIN THE EXISTING OR PROPOSED FACILITY.

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DISCUSSION 1
What type of layout(s) would be appropriate for: Hospital Electronic assembly A university Bank Home construction Airports

a. b.

c.
d. e.

f.

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OBJECTIVE OF LAYOUT DECISIONS

TO ENSURE A SMOOTH FLOW OF WORK, MATERIAL, PEOPLE AND INFORMATION THROUGH THE SYSTEM

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Good Layouts Consider

1. Material handling equipment 2. Capacity and space requirements

3. Environment and aesthetics

4. Flows of information

5. Cost of moving between various work areas

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Why layout decision is important?

Requires substantial investments of money and effort Involves long-term commitments Has significant impact on cost and efficiency of short-term operations

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The Need for Layout Decisions

Inefficient operations
For Example:

High Cost Bottlenecks

Changes in the design of products or services

Accidents
The introduction of new products or services

Safety hazards
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The Need for Layout Designs (Contd)

Changes in environmental or other legal requirements

Changes in volume of output or mix of products Morale problems

Changes in methods and equipment

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Patterns of flow

General flow pattern

(a) Straight

(d) L flow (b) U flow

(c) S flow (e) circular flow

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BASIC LAYOUTS
Process / Functional layouts Product layouts / Assembly lines Fixed position layouts Cellular layouts

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PROCESS LAYOUTS

Group similar activities together in departments or work centres according to the process of function they perform Job shops or batch productions

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Process Layout
Milling Assembly & Test Grinding

Drilling

Plating

Process Layout - work travels to dedicated process centers

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Process-Oriented Layout
Patient A - broken leg ER triage room Surgery

Emergency room admissions

Patient B - erratic heart pacemaker Laboratories

Radiology

ER Beds

Pharmacy

Billing/exit

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Figure 9.3

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PRODUCT LAYOUT

Arrange activities in a line according to the sequence of operation that need to be performed to assemble a particular product. Mass production

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A Flow Line for Production or Service

Flow Shop or Assembly Line Work Flow

Raw materials or customer Material and/or labor

Statio n 1 Material and/or labor

Station 2 Material and/or labor

Station 3 Material and/or labor

Station 4

Finished item

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A U-Shaped Production Line

In

4 5

Workers

6
Out

10

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FIXED-POSITION LAYOUT

The items being worked on remains stationary. Workers, materials and equipments are moved about as needed. Specialised for project production in which product produced is too fragile, bulky or heavy to move.

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CELLULAR LAYOUTS

Group dissimilar machines into work centres (called cells) that process families of parts with similar shapes or processing requirements. Batch production Simplify process layout

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Cellular Manufacturing Layout

-1111

Lathe Mill

Drill

Heat treat Heat treat Heat treat Drill

Gear -1111 cut

222222222

Mill

Drill

Grind - 2222

3333333333

Lathe Mill

Grind - 3333

44444444444444

Mill

Gear - 4444 cut

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Assembly

DISCUSSION 3
What type of layout(s) would be appropriate for:
a. b.

c.
d. e.

Grocery store Home construction Electronic assembly A university Airport

f. g.

h.
i.

j.

Bank Classroom Parking lot Human resources department Office of product designers
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Advantages and disadvantages

Fixed position layout
Very high product and mix flexibility.

Process layout
High product and mix flexibility. Relatively robust in the case of disruptions.

Cell layout
Can give good compromise. Fast throughput.

Product layout
Low unit costs for high volume. Opportunities for specialization of equipment.

Advantages

Product/customer not moved. High variety of tasks for staff.

Group work can result in good Easy to supervise. motivation.

Very high unit costs.

Disadvantages

Can be costly to rearrange existing Can have very high layout. Not very robust to Scheduling space work in progress. disruption. and activities can Can need more be difficult. Complex flow. plant. Work can be very repetitive.

Low utilization.

Can have low mix flexibility.

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Volume-variety characteristics
Low Low Fixed position layout Process layout VOLUME High

VARIETY

Cell layout

Low

Product layout

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Design process Layout: Relationship Chart

Value
1

Closeness
Absolutely necessary Especially important Important Ordinary OK Unimportant Not desirable

A
2 3 U 4 A I I I I I I A E O U E A O U I U O O 5 6 7 8 9

President Chief Technology Officer Engineers area Secretary

A O A O

E I O U X

Office entrance
X

E
U

Central files
O

U
O X A E

Equipment cabinet
U

Photocopy equipment
E

Storage room
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Figure 9.1
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Relationship diagram Exercise

Meat Me, is a franchised chain of fast food burger restaurants. A new restaurant is being located in a growing suburban community. Each restaurant has the following departments:
Cooking burgers 2. Cooking fries 3. Packing and storing burgers 4. Drink dispensers 5. Counter servers 6. Drive-up server Develop a relationship diagram of the restaurant.
1.
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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.

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Objectives

To obtain task grouping that represent approximately equal time requirement. To minimise idle time and bottleneck along the line.

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Cycle Time

Cycle time is the maximum time allowed at each workstation to complete its set of tasks on a unit.

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Assembly-Line Balancing
Objective is to minimize the imbalance between machines or personnel while meeting required output Starts with the precedence relationships
1. Determine cycle time 2. Calculate theoretical minimum number of workstations 3. Balance the line by assigning specific tasks to workstations
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Copier Example
Performance Time Task (minutes) A 10 B 11 C 5 D 4 E 12 F 3 G 7 H 11 I 3 Total time 66 Task Must Follow Task Listed Below A B B A C, D F E G, H
This means that tasks B and E cannot be done until task A has been completed

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Copier Example
Performance Time Task (minutes) A 10 B 11 C 5 D 4 E 12 F 3 G 7 H 11 I 3 Total time 66 Task Must Follow Task Listed Below A B B A C, D F E G, H

10

11

B
4

G
3

12

11

E
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H
Figure 9.13
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Copier Example
Performance Time Task (minutes) A 10 B 11 C 5 D 4 E 12 F 3 G 7 H 11 I 3 Total time 66 Task Must Follow Task Listed Below 480 available mins per day 40 units required

workstations

A Production time B available per day Cycle B time = Units required per day A = 480 / 40 5 C, D = 12 minutes per unit C F 10 11 3 7 n E for taskF i A Time B G Minimum G, H i=1 4 number of =
Cycle D time
12 11

= 66 / 12 E H = 5.5 or 6 stations
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Figure 9.13

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Line-Balancing Heuristics Copier Example

1. Longest task time Choose the available task with 480 available Performance Task Must Follow the longest task time mins per day Time Task Listed Task (minutes) 40 task units required 2. Most following tasks Below Choose the available with the largest number of following A 10 Cycle time = 12 mins tasks B 11 A Minimum = 5.5 or 6 C 3. Ranked 5 positional B workstations Choose the available task for D B weight 4 which the sum of following task E 12 A times is the longest 5 F 3 C, D Choose the available C task with G 4. Shortest 7 task time F 10 11 3 7 the shortest task time H 11 E A B G F I 5. Least number 3 G, H of Choose the available 4 task with 3 following the least number ofD following Total time 66 tasks I 12 11 tasks
E
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H Table 9.4
Figure 9.13
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Copier Example
Performance Time Task (minutes) A 10 B 11 Station C 5 2 D 4 11 E 10 12 F A B 3 G 7 H 11 I 3 12 Station Total time 66 E 1
Station 3

Task Must Follow Task Listed Below A 5 B C B A C, D 4 F D E G, H

480 available mins per day 40 units required Cycle time = 12 mins Minimum workstations = 5.5 or 6
3 7

F
Station 4

I
11
Station 6

H
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Station 5

Figure 9.1433

Copier Example
Performance Time Task (minutes) Task Must Follow Task Listed Below 480 available mins per day 40 units required

A 10 Cycle time = 12 mins B 11 A Minimum C 5 B workstations = 5.5 or 6 D 4 B E 12 A F 3 C, D Task times G 7 F Efficiency = (actual number of H 11 E workstations) x (largest cycle time) I 3 G, H = 66 minutes / (6 stations) x (12 minutes) Total time 66 = 91.7%
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