FACILITY LAYOUT

16.11.2009
 What Is Layout Planning
• Layout planning is determining the
best physical arrangement of
resources within a facility
• Two broad categories of operations:
– Intermittent processing systems
– Continuous processing systems

 7 A -3

Facility Layout
Facility layoutcan be defined as the process by which the
placement of departments, workgroups within departments,
workstations, machines, and stock-holding points within a
facility are determined
This process requires the following inputs:

– Specification of objectives of the system in terms of output

and flexibility
– Estimation of product or service demand on the system
– Processing requirements in terms of number of operations
and amount of flow between departments and work centers
– Space requirements for the elements in the layout
– Space availability within the facility itself
Each process type (project, job shop, cell, assembly line,
continuous) has it corresponding basic layout
Determine the best layout (one that minimizes

flow*distance, or flow*unit flow cost, …, maximizes

throughput, …)
Objectives of facility layout
§ Minimize material handling costs
§ Utilize space efficiently
§ Utilize labor efficiently
§ Eliminate bottlenecks
§ Facilitate communication and interaction
between workers, between workers and
their supervisors, or between workers
and customers
§ Reduce manufacturing cycle time or
customer service time
§
ü
Objectives of facility layout
§ Eliminate waste or redundant movement
§ Facilitate the entry, exit, and placement of
material, products, or people
§ Incorporate safety and security measures
§ Promote product and service quality
§ Encourage proper maintenance activities
§ Provide a visual control of operations or
activities
§ Provide flexibility to adapt to changing
conditions
ü
Basic Layout Types

TY
 Basic Layout Types
n Product Layout
— Layout that uses standardized processing
operations to achieve smooth, rapid, high-
volume flow
— Linear arrangement of workstations to produce a
specific product
n Process Layout
— Layout that can handle varied processing
requirements
— Centers/machines grouped by process they
perform
n Fixed Position Layout
— Layout in which the product or project remains
stationary; workers, materials, and equipment
are moved as needed
— Used in projects where the product cannot be
 Hybrid Layouts

n Cellular layouts
– group machines into machining
cells
n Flexible manufacturing systems
– automated machining & material
handling systems
n Mixed-model assembly lines
– produce variety of models on one
line
 Layout Types
Grinding Forging Lathes

(a) Layout of a job shop

Painting Welding Drills

Milling
Office machines Foundry

(b) Layout of a
Station 1 Station 2 Station 3 Station 4 production line

9
Manufacturing Process Layout
Lathe Department Milling
Department Drilling Department

L L M M D D D D

L L M M D D D D

L L G G G P

L L G G G P

Grinding Painting Department

Department
L L

Receiving and A A A
Shipping
Assembly
 Hybrid Layout
§ Cellular layouts
§ Group machines into machining cells
§ Flexible manufacturing systems
§ Automated machining & material
handling systems
§ Mixed-model assembly lines
§ Produce variety of models on one line
§
11
 Hybrid Layout: Group Technology
Machine
One Worker, Multiple Machines 2
Machine
3
Machine
1

Materials in

Finished
goods out

Machine
Machine 4
5 12
Group Technology
Lathing Milling Drilling

L L M M D D

D D
L L M M

Grinding

L L M M
G G

L L Assembly
G G
A A

Receiving A A G G
and
shipping
Group Technology
Lathing Milling Drilling

L L M M D D

D D
L L M M

Grinding

L L M M
G G

L L Assembly
G G
A A

Receiving A A G G
and
shipping

( a ) Jumbled flows in a job shop without GT cells

Group Technology
Lathing Milling Drilling

L L M M D D

D D
L L M M

Grinding

L L M M
G G

L L Assembly
G G
A A

Receiving A A G G
and
shipping

( a ) Jumbled flows in a job shop without GT cells

Group Technology
Lathing Milling Drilling

L L M M D D

D D
L L M M

Grinding

L L M M
G G

L L Assembly
G G
A A

Receiving and A A G G
shipping

( a ) Jumbled flows in a job shop without GT cells

 Group Technology

L L M D G Assembly
area

Cell 1 Cell 2 A A

Receiving L M G G

Cell 3

L M D
Shipping

( b ) Line flows in a job shop with three GT cells

 Group Technology

L L M D G Assembly
area

Cell 1 Cell 2 A A

Receiving L M G G

Cell 3

L M D
Shipping

( b ) Line flows in a job shop with three GT cells

 Group Technology

L L M D G Assembly
area

Cell 1 Cell 2 A A

Receiving L M G G

Cell 3

L M D
Shipping

( b ) Line flows in a job shop with three GT cells

 Group Technology

L L M D G Assembly
area

Cell 1 Cell 2 A A

Receiving L M G G

Cell 3

L M D
Shipping

( b ) Line flows in a job shop with three GT cells

Cellular Layout HM

VM

1. Identify families of Worker 3

parts with similar VM
flow paths
L
2. Group machines into
cells based on
part families
3. Arrange cells so
Worker 2
material G
movement is
minimized L
4. Locate large shared
machines at point Final
of use inspection

•
Finished
S Worker 1 part

In Out
21
 Designing Flexible-Flow
Layout
1.Gather Information
– Space requirement
– Available space
– Closeness factors
– Other considerations


2.Develop block plan

– distance measure
– Calculating a weighted-distance score


3.Design a detailed layout

22
 Cell characteristics
e of values for the number of people (1-6) and workstations (1-10) and its own entran

aid out in a U-layout to simplify and minimize material movement.

wn inspection and work scheduling.

a family of similar parts that requires similar machines, or workstations, in the cell.(1)
 Examples of cells

1.Machining center
2.
3.Single operator, multiple machines
4.
5.Single- robot automated cell
6.
7.Multiple machines, multiple operators
8.
9.Multiple robots, automated cell
10.
11.Assembly cell
 Advantages of cells
• The tangible advantages of manufacturing cells
are due to the proximity of all machines
required to make a family of parts.(1)


• This reduces the total distance required to be

traveled by the batches of parts in the family.
•
• Manufacturing cells are the first step in the
implementation of Computer-Aided Design,
Computer-Aided Manufacturing, Flexible
Manufacturing Systems
 Disadvantages of cells


• Need for high investment in machine installation

and re-layout
•
• Lack of flexibility in handling demand changes,
product mix changes, infrequent ordering of
parts, variable lo sizes
•
• Imbalance of utilization of machines and labor


• Lack of a comprehensive cell formation method



• Data collection and analysis is time-consuming

•
 Examinations Of Layouts
Could Result From:

n Bottlenecks
n Quality Problems
n High Scrap Rates
n Accidents & Safety Hazards
n Absenteeism
n Turnover
n Complaints & Morale Problems
 Production Methods
Which is more efficient?

Operation 1 2 3 4 5

This? 6

Finished
Product 11 10 9 8
 Production Methods

Or this?

1a 1b 1c 1d

Operation Finished
1 2a 2b 2c
product

3a 3b 3c 3d
 Production Methods
Or this?

Finished Product Finished Finished Product

Product
 Production Methods
• Answer – it could be any of them!
• The design of the production space
can influence:
– Output levels
– Factor use
– Efficiency
– Cost levels
– Quality assurance procedures
•
 Common Reasons For
Redesign Of Layouts
n Changes In Design Of Products/services
n Introduction Of New Products/services
n Changes In Technology/equipment
n Changes In Volume Or Mix Of Outputs
n Improvements In Work Methods
n Compensation For Learning Curve Effect
n Compliance With Environmental Or Legal
Regulations
THANK YOU FOR YOUR
ATTENTION