Professional Documents
Culture Documents
Chapter 6
Limitations
Personel-equipment moves Equipment duplicates Greater skill Close control& coordination Increased space & greater work-in-process
Product Layout
Advantages
Smooth, simple, direct flow Small work-in-process inv. Short production time/unit Reduced material handling Less skill Easy production control
Limitations
Line stoppage Product design changes
Slowest station paces the line
Group Layout
Advantages
Limitations
By grouping, higher machine Greater labor skills for team utilizations Balancing individual cells Smoother flow lines and Unbalanced flow may result shorter travel distances in work-in-process Team spirit and job enlargement
Process Layout
Advantages
Limitations
Increased machine utilization Increased material handling General purpose equipment Complicated production control Highly flexible Increased work-in-process Diversity of tasks Longer production lines Higher skills required
Relationship diagram
QAP???
Problems
6.12 Suppose five departments labeled A through E are located as shown in the layout below. Given the corresponding flow-between chart, compute the efficiency rating for the layout.
A C D E B
A A B C D E
B 5
C 0 6
D E 4 -1 -6 -3 2 0 3
5
6 7
Assembly
Plating Shipping
8000 4
12000 6 12000 6
Dr. Muzaffer Kapanoglu-Copyright 2005
5.
Select the second dept. to enter the layout. Select the third department to enter the layout Select the fourth department to enter the layout Place dept. n similar to 3rd and 4th steps.
4
5 5 5 5
2
6 6 7 7
2
6 6 7 7
2
6 6 7 7
To From
1
-
2
10 -
3
15 10 -
4
20 5 5 -
To From
1 -
2 1
3 2
4 3
1 2 3 4
2
3 4
1
-
2
1 -
2-3-1-4
Local best Global best: 90 (1-2;2-4;3-3;4-1) (By using QAP in Lingo)
Total Weight:63
Total Weight: 71
Rel-chart
CRAFT
(Computerized Relative Allocation of Facilities Technique) 1963-Armour, Buffa, Vollman Improvement-type algorithm
Initial solution Rectilinear distances between department centroids CostxDistances All-possible two-way and three-way department exchanges Determine the best exchange (that yields the best reduction in the layout cost)
CRAFT
Updates the layout according to the best exchange-calculates layout efficiency Exchanges departments that either adjacent or equal in area. If the area is not equal, the algorithm may result in split department.
6.24Consider four departments labeled A, B, C, and D. Each department is represented by a 1X1 square. The following data are given:
Location of department A is fixed. Answer the following questions using CRAFT with two-way exchanges only. a. List all the department pairs that CRAFT would consider exchanging. (Do not compute their associated cost.) b. Compute the actual cost of exchanging departments C and D. c. Given that department A is fixed and that each department must remain as a 1 X 1 square, is the layout obtained by exchanging departments C and D optimum? Why or why not? (Hint: examine the properties of the resulting layout and consider the objective function of CRAFT.)
6.25 The following layout is an illegal CRAFT layout. Nevertheless, given that the volume of flow from A to B is 4, A to C is 3, and B to C is 9, and that all move costs are 1, what is the layout cost?
6.26 (Revised) When CRAFT evaluates the exchange of departments, instead of actually exchanging the departments, it only exchanges the centroids of departments.
a. What is the impact of this method of exchanging if all departments are the same size? b. Given the following fromto-chart and scaled layout (each square is 1 X 1), what does the evaluation of the exchange of departments B and C A indicate should be saved over the existing layout A and what is actually saved once this exchange is A made?
To From A B C
A
B C
2 0
10
0
6
7
A A A
A A A
C C C
B B B
B B B
B B B
B B B
B B B
6.27 Explain the steps CRAFT would take with the following problem and determine the final layout. Only twoway exchanges are to be considered. (Use CRAFT DSS.)
To From
A B C D E A 3 C 1 2 1 3 0 0 0 B 0 1 AAA AAA AAA DDD DDD BBB CCC CCC EEE EEE
0 4
D 0 0 0 0 E 0 0 0 0 From-to chart
Initial Layout
(1)
MULTI-floor Plant Layout Evaluation Developed by Bozer, Meller, and Erlebacher Initially multi-floor facilities but can also be used for single floor facilities Similar to CRAFT Uses a From-To (or Flow-Between) Chart Departments are not restricted to rectangular shapes Like Craft, improvement-type layout algorithm Two-way exchanges are sought Exchange with the largest reduction is selected Steepest-descent procedure
Multiple
(2)
Can exchange any two departments Use spacefilling curves (SFCs) Reconstruct a new layout when any two departments are exchanged Also known as Hilbert curve
Connects each grid such that always an adjacent grid is visited. Each grid is visited only once.
Multiple:
(3)
Dept Area 1 2 3 4 5 16 8 4 16 8
12
(4)
Dept Area 5 2 3 4 1 6 8 8 4 16 16 12