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Facility Design - An IntroductionsSet12
Facility Design - An IntroductionsSet12
R. Lindeke, Ph. D.
IE 3265
Sp. 2006
Facility Layouts:
IMPROVED
Standard Layouts
LAYOUTS:
End to End
Front to Front
I/O
Back to Back
(poor) Circular or U Flow
Considering Circular or U-Flow:
Advantages:
One operator can tend several machines
Common I/O station simplifies material
transfer to/from cell to the rest of the
facility
Automation can be tried for several
machines
Disadvantages:
Limited Queuing space or WIP storage
within cell
Requires excellent balance and high
quality to keep flow active between
workstations in the cell
Flow Patterns within Process
Departments (Job Shops)
Aisle
Aisle
Aisle
A. Parallel Flow
B. Perpendicular Flow
Aisle
C. Diagonal Flow
Aisle
Some Job Shop Ideas:
*No Backtracks!
An Example:
50
A
D
50
25
50 75
B C
Place F in Center.
F
Then follow in order
keeping Ideas
E
By This (AEIOUX) of
Order: arrangements:
G
B A
C
D B
D E F
G
A
C
A Final Step: now we consider actual
departmental areas:
# Units
Code Function Area Ft2
(2000 per)
A Receiving 12,000 6
B Milling 8,000 4
C Press 6,000 3
Sc.
D 12,000 6
Machines
E Assembly 8,000 4
F Plating 12,000 6
G Shipping 12,000 6
Leads to the following Proposed
Layout:
A B C D E
BackTracks:
From-To Charts
A B C D E
A B C D E
Pr 1 30 +
A XXX Pr2 12 Pr 3 2*7 = 0 0
30 +14 = 44
Pr 1 30 + Pr 3 2*7 =
B 0 XXX 0
Pr2 12 = 42 14
Pr 3 2*7 =
C 0 Pr 1 30 XXX
14
0
Pr 3 2*7 = Pr 1 30 +
D 0
14
0 XXX
Pr2 12 = 42
E 0 0 0 0 XXX
For comparison:
all forward moves cost $1/unit vol/unit distance
All Backtrack move cost $1.25/unit vol/unit distance
Costs A B C D E
A xxx 1 1 1 1
B 1.25 xxx 1 1 1
C 1.25 1.25 xxx 1 1
D 1.25 1.25 1.25 xxx 1
E 1.25 1.25 1.25 1.25 xxx
Layout Total Transport Cost
A C B D E
A C B D E
A C B D E
Pr 1 30 +
A XXX Pr 3 2*7 = Pr2 12 0 0
30 +14 = 44
Pr 3 2*7 =
C 0 XXX Pr 1 30
14
0
Pr 1 30 + Pr 3 2*7 =
B 0 0 XXX
Pr2 12 = 42 14
Pr 3 2*7 = Pr 1 30 +
D 0 0
14
XXX
Pr2 12 = 42
E 0 0 0 0 XXX
New Cost Matrix:
Costs A C B D E
A xxx 1 1 1 1
C 1.25 xxx 1 1 1
A C D
B E
Distance from A to B is: (1002+1002).5 = 142 units
Distance A to E is: (2002+1002).5 = 224 units
Typically, with Euclidean distances, were would not consider
transport cost differences in either direction this facility shape
doesnt favor general directions of flow!
Mileage Chart (now)
A C B D E