Facility layout

Prof. Dr. Md. Abdus Shahid

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 Question
• Define plant layout and explain its importance.
• Objectives of layout
• Principles of Plant Layout
• Basic layout types and their characteristics
• Difference between process layout and product layout
• Assembly-line balancing; Workstation cycle time
• How do you determine the idle-time percentage from given assembly line balance?
• Determine the idle time percentage from a given assembly line balance.
• The steps in balancing an assembly line
• Criteria for a good layout
• Advantages of a good layout
• Principal factors which influence the choice of location.
• Procedures for evaluation location alternatives

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 Layout
• The configuration of departments, work
centers, and equipment with particular
emphasis on movement of work (customers or
materials) through the system.

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 Meaning of plant layout

• According to Apple, “Plant layout is planning the

path each component/ part of the product is to follow
through the plant, coordinating the various parts so
that the manufacturing processes may be carried out
in the most economical manner, then preparing
drawing or other representation of the arrangement
and finally seeing that the plan is properly put into
effect.”

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 Principles of Plant Layout
1. Principle of integration
2. Principle of minimum distance
3. Principle of cubic space utilization
4. Principle of flow
5. Principle of maximum flexibility
6. Principle of safety, security and satisfaction
7. Principle of minimum handling

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 Types of layout
• Manufacturing layout
– Process layout (Job shop/Batch)
– Product layout (Assembly line/Continuous and
repetitive)
– Cellular layout
• Office layout
• Retail store layout
• Fixed position layout

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1. Process Layout

Model of process Layout

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2. Product Layout
Model of product Lay-out

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Product layout
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 3. Combination Layout
combination
type of layout for manufacturing different sized gears

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 4. Fixed Position Layout
Fixed type of position Layout

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 Basic Layout Types
• Product layout –Layout that uses standardized processing
operations to achieve smooth, rapid, high-volume flow
• Process layout– Layout that can handle varied processing
requirements
• Group technology layout- Groups dissimilar machines
into work centers (or cells) to work on products that have
similar shapes and processing requirements.
• Fixed Position layout–Layout in which the product or
project remains stationary, and workers, materials, and
equipment are moved as needed.

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Steps in balancing an assembly line
1. Specify the sequential relationships among tasks using a precedence
diagram. The diagram consists of circles and arrows. Circles represent
individual tasks; arrows indicate the order of task performance.

2. Determine the required workstation cycle time (C), using the formula

3. Determine the theoretical minimum number of workstations (Nt )

required to satisfy the workstation cycle time constraint using the
formula (note that this must be rounded up to the next highest integer).

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4. Select a primary rule by which tasks are to be assigned to
workstations, and a secondary rule to break ties.

5. Assign tasks, one at a time, to the first workstation until the sum of
the task times is equal to the workstation cycle time, or no other
tasks are feasible because of time or sequence restrictions.

6. Repeat the process for Workstation 2, Workstation 3, and so on until

all tasks are assigned. 6 Evaluate the efficiency of the balance derived
using the formula

7. If efficiency is unsatisfactory, rebalance using a different decision rule.

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 Objective of Layout Design
1. Facilitate attainment of product or service quality.
2. Use workers and space efficiently.
3. Avoid bottlenecks.
4. Minimize unnecessary material handling costs.
5. Eliminate unnecessary movement of workers or
materials.
6. Minimize production time or customer service time.
7. Design for safety.

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 Criteria for a good layout
1. Maximum flexibility: A good layout will be one which can be rapidly
modified to meet changing circumstances.
2. Maximum co-ordination: Entry into, and disposal from, any department or
functional area should be in such a manner that it is must convenient to the
issuing or receiving departments. Layout requires to be considered as a
whole and not partially.
3. Maximum use of volume: Facilities should be considered as cubic devices
and maximum use made of the volume available. This principle is
particularly useful in stores, where goods can be stacked at considerable
heights without inconvenience, especially if modern lifting devices are
used. In offices, racking can be installed to minimize use of floor space.
4. Maximum visibility: All the people and materials should be readily
observable at all the time; there should be no ‘hidden places’ into which
goods or information can get mislaid.

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 Criteria for a good layout (Cont….)

1. Maximum accessibility: All servicing and maintenance points should be readily

accessible. For example, equipment should not be placed against a wall in such
a manner that necessary maintenance cannot easily be carried out.
2. Minimum distance: All movements should be both necessary and direct.
Handling work adds to cost but does not increase value; consequently any
unnecessary or indirect movements should be avoided.
3. Minimum handling: The best handling of material and information is no
handling, but where it is unavoidable it should be reduced to a minimum by the
use of whatever devices are most appropriate.
4. Minimum discomfort: poor lighting, excessive sunlight, heat, noise, vibration
and smells should be minimized and if possible counteracted.
5. Inherent safety
6. Maximum security
7. Efficient process flow

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 Cycle time
• Cycle time is the maximum time allowed at
each workstation to complete its set of tasks
on a unit.

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 Determine the Theoretical Minimum Number
of Workstations Required

or
Efficiency of the balance

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 Example-1
Task Task Time (in Tasks must
minute) precede

a 0.1 -
b 1.0 a
c 0.7 -
d 0.5 b, c
e 0.2 d

Desired output=420 units, Operating time per day= 7 hours

1. Draw a precedence diagram.
2. Determine workstation cycle time.
3. Determine the theoretical min. no. of workstation.
4. Balance the line in the minim. No. of station.
5. Evaluate the efficiency.
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1. Draw a precedence diagram.

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2. Work station cycle time=420/420=1.0 min.

3. Theoretical min. no. of workstation= Sum of task

time/ Cycle time=2.5/1.14285=2.18=3

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4. Balance the line in the minim. No. of station.

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 Example-2
Task Task Time (in Tasks must
minute) precede

a 0.2 -
b 0.2 a
c 0.8 -
d 0.6 c
e 0.3 b
f 1.0 e, d
g 0.4 f
h 0.3 g

1. Draw a precedence diagram.

2. Determine workstation cycle time.
3. Determine the theoretical min. no. of workstation.
4. Balance the line in the minim. No. of station.
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5. Evaluate the efficiency.
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 Example-3

1. Draw a precedence diagram.

2. Determine workstation cycle time.
3. Determine the theoretical min. no. of workstation.
4. Evaluate the efficiency.
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Example-4

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The desired daily output for an assembly line is 360 units. This assembly line will operate
450 minutes per day. The following table contains information on this product’s task times
and precedence relationships:

Task Task Time (seconds) Immediate predecessor

A 30 -
B 35 A
C 30 A
D 35 B
E 15 C
F 65 C
G 40 E,F
H 25 D,G

a) Draw the precedence diagram.

b) What is the workstation cycle time?
c) Balance this line using the largest number of following tasks. Use the
longest task time as a secondary criterion.
d) What is the efficiency of your line balance?

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 Key Terms
• Process layout Also called a job-shop or functional
layout; a format in which similar equipment or
functions are grouped together.
• Product layout Also called a flow-shop layout;
equipment or work processes are arranged according
to the progressive steps by which the product is made.
• Group technology (cellular) layout Groups dissimilar
machines into work centers (or cells) to work on
products that have similar shapes and processing
requirements.
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 Key Terms (Cont….)
• Fixed-position layout The product remains at one
location and equipment is moved to the product.
• CRAFT (Computerized Relative Allocation of
Facilities Technique) A method to help devise
good process layouts. The technique is designed
to minimize material handling costs in the facility
and works by iteratively exchanging pairs of
departments until no further cost reductions are
possible.

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 Key Terms (Cont….)
• Systematic layout planning (SLP) A technique for
solving process layout problems when the use of
numerical flow data between departments is not
practical. The technique uses an activity relationship
diagram that is adjusted by trial and error until a
satisfactory adjacency pattern is obtained.
• Workstation cycle time The time between successive
units coming off the end of an assembly line.

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 Key Terms (Cont….)
• Assembly-line balancing The problem of
assigning all the tasks to a series of
workstations so that each workstation has no
more than can be done in the workstation
cycle time, and so that idle time across all
workstations is minimized.
• Precedence relationship The order in which
tasks must be performed in the assembly
process.
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 Key Terms (Cont….)
• Line Balancing is the process of assigning tasks
to workstations in such a way that the
workstations have approximately equal time
requirements.

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Problem: A university advising office has four rooms, each
dedicated to specific problems: petitions (Room A), schedule
advising (Room B), grade complaints (Room C), and student
counseling (Room D). The office is 80 feet long and 20 feet wide.
Each room is 20 feet by 20 feet. The present location of rooms is
A, B, C, D—that is, a straight line. The load summary shows the
number of contacts that each adviser in a room has with other
advisers in the other rooms. Assume that all advisers are equal in
this value. Load summary:
AB = 10, AC = 20, AD = 30, BC = 15, BD = 10, CD = 20.
a. Evaluate this layout according to the material handling cost
method.
b. Improve the layout by exchanging functions within rooms.
Show your amount of improvement

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Solution:

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Problem -1: An office security system at Delco,
Inc. has two component parts, both of which
must work for the system to function. Part 1
has a reliability of 80%, part 2 has a reliability
of 98%, and part 3 a reliability of 80%.
Compute the reliability of the system.
• Problem 2: Delco, Inc., from Problem 1, is not
happy with the reliability of its security system
and has decided to improve it. The company
will add a backup component to part 1 of its
security system. The backup component will
also have a reliability of .80. What is the
reliability of the improved security system?
Solution 2
The system for Delco, Inc. now looks like this: