Layouts

BITS Pilani
Pilani Campus

06/10/2020 1
 Outline
• Basic Layouts
• Designing Process Layouts
• Designing Service Layouts
• Designing Product Layouts
• Hybrid Layouts

06/10/2020 Manufacturing Management 2

 Objectives of Facility Layout

• Minimize material-handling costs

• Utilize space efficiently
• Utilize labor efficiently
• Eliminate bottlenecks
• Facilitate communication and interaction
• Reduce manufacturing cycle time
• Reduce customer service time
• Eliminate wasted or redundant movement
06/10/2020 Manufacturing Management 3
 Objectives of Facility Layout
• Facilitate entry, exit, and placement of material,
products, and people.
• Incorporate safety and security measures.
• Promote product and service quality.
• Encourage proper maintenance activities.
• Provide a visual control of activities.
• Provide flexibility to adapt to changing conditions.
• Increase capacity.
06/10/2020 Manufacturing Management 4
 Objectives of Facility Layout
• Facilitate entry, exit, and placement of material,
products, and people.
• Incorporate safety and security measures.
• Promote product and service quality.
• Encourage proper maintenance activities.
• Provide a visual control of activities.
• Provide flexibility to adapt to changing conditions.
• Increase capacity.
06/10/2020 Manufacturing Management 5
 Manufacturing Process Layout

Manufacturing Management 6
 A Product Layout

In

Out

Manuacturing Management 7-7

 Comparison of Product
and Process Layouts
Product Process
•• Description
Description  Sequential  Functional grouping
arrangement of of activities
activities  Intermittent, job
 Continuous, mass shop, batch
•• Type of process
production, mainly production, mainly
assembly fabrication

•• Product  Standardized, made  Varied, made to

to stock order
•• Demand  Stable  Fluctuating
•• Volume  High  Low
•• Equipment  Special purpose  General purpose

Manufacturing Management
8
 Comparison of Product
and Process Layouts
Product Process
• Workers
Workers  Limited skills  Varied skills
• Inventory
Inventory  Low in-process, high  High in-process, low
finished goods finished goods
• Storage
Storage space
space  Small  Large
• Material
Material handling
handling  Fixed path (conveyor)  Variable path (forklift)
• Aisles
Aisles  Narrow  Wide
• Scheduling
Scheduling  Part of balancing  Dynamic
• Layout
Layout decision
decision  Line balancing  Machine location
• Goal
Goal  Equalize work at each  Minimize material
station handling cost
• Advantage
Advantage  Efficiency  Flexibility

Manufacturing Management
9
 Fixed-Position Layouts
• Typical of projects
• Fragile, bulky, heavy items
• Equipment, workers & materials brought to
site
• Low equipment utilization
• Highly skilled labor
• Typically low fixed cost
• Often high variable costs

Manufacturing Management
10
 Designing Process Layouts
• Goal: minimize material handling costs

• Block Diagramming
– minimize nonadjacent loads
– use when quantitative data is available

• Relationship Diagramming
– based on location preference between areas
– use when quantitative data is not available

Manufacturing Management 11
 Block Diagramming

• Unit load • Steps

• Quantity in which • Create load summary
material is chart.
normally moved • Calculate composite
• Nonadjacent load (two way)
movements.
• Distance farther
than the next block • Develop trial layouts
minimizing number
of nonadjacent loads.
Manufacturing Management
12
 Block Diagramming: Example
Load Summary Chart
FROM/TO DEPARTMENT
1 2 3
Department 1 2 3 4 5
1 — 100 50
2 — 200 50
4 5 3 60 — 40 50
4 100 — 60
5 50 —

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13
 Block Diagramming: Example

Nonadjacent Loads
2 3 200 loads
110+40=150
2 4 150 loads
1 3 110 loads
1 2 100 loads 110
4 5 60 loads
3 5 50 loads 100 200
2 5 50 loads 1 2 3
3 4 40 loads 150 50 50
1 4 0 loads
1 5 0 loads 60
4 5
40
Grid 1

Manufacturing Management 14
 Block Diagramming: Example

Nonadjacent Loads: 0
2 3 200 loads
2 4 150 loads
1 3 110 loads
1 2 100 loads
100 150
4 5 60 loads 1 2 4
3 5 50 loads 200 50 40
2 5 50 loads 110 60
50
3 4 40 loads
3 5
1 4 0 loads
1 5 0 loads Grid 2

Manufacturing Management 15
 Block Diagramming: Example
• Block Diagram
– type of schematic layout diagram; includes space requirements
(a) Initial block diagram (b) Final block diagram

1 4
1 2 4 2

3 5 3 5

Manufacturing Management 16
 Relationship Diagramming

• Schematic diagram that uses

weighted lines to denote
location preference

• Muther’s grid
format for displaying manager
preferences for department
locations

Manufacturing Management 17
 Relationship Diagramming

A Absolutely necessary
E Especially important
I Important
Production
O O Okay
A U Unimportant
Offices
U I X Undesirable
Stockroom O E
A X A
Shipping and U U
receiving
U O
Locker room O
O
Toolroom

Manufacturing Management 7-18

 Relationship Diagramming
(a) Relationship diagram of original layout

Offices Locker Shipping

room and
receiving

Key: A
E
I
Stockroom Toolroom Production
O
U
X

Manufacturing Management 7-19

 Relationship Diagramming
(b) Relationship diagram of revised layout

Stockroom

Offices Shipping
and
receiving

Toolroom Production Locker Key: A

room E
I
O
U
X

Manufacturing Management 7-20