Facilities Layout

Example 2
Using the information contained in the table shown do each
of the following
Task Immediate Task Time
Predecessor (Minutes)
a - .2

b a .2

c - .8

d c .6

e b .3

f d,e 1.0
g f .4

h g .3
1. Draw a precedence diagram
2. Assuming an 8 hour workday, compute the cycle
time required to obtain an output of 400 units per
day
3. Determine the minimum number of workstations
required
4. Assign the tasks to workstations using this rule:
Assign tasks according to greatest number of
following tasks.
Step 1: Begin with activities with no Predecessor

c
Step 2: Task b follows a and d follows c

a b

c d
 Step 3: Task e follows b

a b e

c d
 Step 4: Task f follows e and d

a b e

c d f
 Step 5: Task g follows f, and h follows g

a b e

c d f g h
 Step 5: Task g follows f, and h follows g

0.2 0.2 0.3

a b e

0.8 0.6 0.4 0.3

c d f g h
1.0
2 and 3
Cycle time = operating time / desired output rate
= 480 minutes per day / 400 units per day = 1.2
minutes per unit
N (min) = summation of t / Cycle time =
3.8 minutes per unit / 1.2 minutes per cycle per station
= 3.17 stations (rounded to 4)
4 Station Time
remaining
Will fit Assign
task time
Revised
time
Idle

remaining

1 1.2 a,c a (.2) 1.0 0

1.0 c,b c (.8) .2
.2 b b (.2) 0
0 none -
2 1.2 e,d d (.6) .6 .3
.6 e e (.3) .3
.3 none -

3 1.2 f f (1.0) .2 .2
.2 none -
4 1.2 G G(.4) .8 .5
.8 H H(.3) .5
.5 - -
1.0 min
Station 1 Station 2 Station 3 Station 4

a b e
f g h
c d
Percent Idle Time = 1.0 min / (4 *1.2 min) =
20.83%
 Exercise
The tasks shown in the following diagram are to be assigned to
workstations with the intent of minimizing idle time. Management
has designed an output rate of 275 units per day. Assume 440
minutes are available per day.
.3 min
.3 min .4 min .2 min .1 min .5 min

a c e h i
g

b d f

.6 min 1.2 .6 min

min
A. Determine the appropriate cycle time
B. What is the minimum number of
workstations possible
C. Assign tasks to each workstation
D. Compute the efficiency
Example 2
Using Task
the information contained
Immediatein the table shown
Task Time do each
of the following Predecessor (Minutes)
a - .9

b a .4

c b .6

d c .2

e c .3
f d,e .4

g f .7
h g 1.1
1. Draw a precedence diagram
2. Assuming that 55 minutes per hour are productive,
compute the cycle time required to obtain 50 units
per hour
3. Determine the minimum number of workstations
required
4. Assign the tasks to workstations using this rule:
Assign tasks according to greatest number of
following tasks.
5. Calculate utilization of the system
 Example
A company is setting up an assembly line to produce 192
units per 8-hour shift. The following table identifies the work
elements, times, and immediate predecessors:
Work Element Time (sec) Immediate Predecessor(s)
A 40 None
B 80 A
C 30 D, E, F
D 25 B
E 20 B
F 15 B
G 120 A
H 145 G
I 130 H
J 115 C, I
a. What is the desired cycle time (in seconds)?
b. What is the theoretical minimum number of stations?
c. Assign tasks to each workstation
d. Compute the efficiency
 D
25

Work Immediate
B E C Element Predecessor(s)
A None
80 20 30
B A

F J C D, E, F
A D B
15 115
40 E B
G
F B
120 G A
H I H G
130 I H
145
J C, I
 D
25

B E C

80 20 30
J

A F 115

40 G 15 I
H
120 130
145

D
25

Work Immediate
B E C Element Predecessor(s)
A None
80 20 30
B A

F J C D, E, F
A D B
15 115
40 E B
G
F B
120 G A
H I H G
130 I H
145
J C, I
SOLUTION
a. Substituting in the cycle-time formula, we get:
Cycle time = Operating time / desired output rate = 8*60*60 / 192 =
150 sec/unit

b. The sum of the work-element times is 720 seconds, so

t 720 sec/unit
N= c = = 4.8 or 5 stations
150 sec/unit-station
d. Calculating the inefficiency, we get

30 30 sec/unit
InEfficiency (%) = nc (100) =
5(150 sec/unit)

= .04 or 4%

Efficiency (%) = 96%

 Example
A plant manager needs a design for an assembly line to assembly a new
product that is being introduced. The time requirements and
immediate
predecessors for the
work elements are Work Element Time (sec)
Immediate
Predecessor
as follows:
A 12 ―
B 60 A
C 36 ―
D 24 ―

Draw a precedence diagram E 38 C, D

F 72 B, E
G 14 ―
H 72 ―
I 35 G, H
J 60 I
K 12 F, J
In class - Example
Draw a precedence diagram, complete I, F, J, and K

Work Time (sec) Immediate

Element Predecessor A
A 12 ―
B 60 A
C 36 ― B
D 24 ― C
E 38 C, D F
F 72 B, E
D E K
G 14 ―

H 72 ―
J
I 35 G, H

J 60 I
G I
K 12 F, J

H
Designing Process Layouts

Information Requirements:
– List of departments
• Shape requirements
– Projection of work flows
– Distance between locations
– Amount of money to be invested
– List of special considerations
• Technical, Environmental requirements
Disadvantages of Process Layouts

• In process inventory costs can be high

• Challenging routing and scheduling
• Equipment utilization rates are low
• Material handling is slow