CHAPTER SIX

FACILITIES LAYOUT

Chapter 6

Facilities
Layout
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 CHAPTER SIX
FACILITIES LAYOUT
Basic Layout Types

• Product Layouts
• Process Layouts
• Fixed-Position
• Combination Layouts

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 CHAPTER SIX
FACILITIES LAYOUT
Basic Layout Formats
• Group Technology Layout

• Just-in-Time Layouts
– May be assembly-line or Part Family W Part Family X

– Group Technology formats

• Fixed Position Layout

– e.g. Shipbuilding

Part Family Y Part Family Z

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 CHAPTER SIX
FACILITIES LAYOUT
The Need for Layout Decisions
Inefficient operations
For Example: Changes in the design
High Cost of products or services
Bottlenecks

Accidents
The introduction of new
products or services

Safety hazards
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 CHAPTER SIX
FACILITIES LAYOUT
The Need for Layout Designs (Cont’d)
Changes in
environmental Changes in volume of
or other legal output or mix of
requirements products

Morale problems
Changes in methods
and equipment

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 CHAPTER SIX
FACILITIES LAYOUT
Cellular Layouts

• Cellular Manufacturing

• Group Technology

• Flexible Manufacturing Systems

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 CHAPTER SIX
FACILITIES LAYOUT
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
• 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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 CHAPTER SIX
Figure 6-1 FACILITIES LAYOUT
A Flow Line for Production or Service
Flow Shop or Assembly Line Work Flow

Raw materials Station Station Station Station Finished

or customer 1 2 3 4 item

Material Material Material Material

and/or and/or and/or and/or
labor labor labor labor

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 CHAPTER SIX
Figure 6-3 FACILITIES LAYOUT
A U-Shaped Production Line

In 1 2 3 4

Workers

Out 10 9 8 7

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 CHAPTER SIX
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Process Layout
Milling

Assembly
Grinding
& Test

Drilling Plating

Process Layout - work travels to dedicated process centers

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 CHAPTER SIX
FACILITIES LAYOUT
Cellular Layouts
• Cellular Manufacturing
– Layout in which machines are grouped into a cell that can process items that
have similar processing requirements
• Group Technology
– The grouping into part families of items with similar design or manufacturing
characteristics

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 CHAPTER SIX
Figure 6-5 FACILITIES LAYOUT
Cellular Manufacturing Layout

Heat Gear
-1111 Lathe Mill Drill -1111
treat cut

Heat
222222222 Mill Drill Grind - 2222

Assembly
treat

Heat
3333333333 Lathe Mill Grind - 3333
treat

44444444444444 Mill Drill Gear - 4444

cut

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 CHAPTER SIX
FACILITIES LAYOUT
Design Product Layouts: Line Balancing

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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 CHAPTER SIX
FACILITIES LAYOUT
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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 CHAPTER SIX
FACILITIES LAYOUT
Determine Maximum Output

OT
O u tp u t c a p a c ity =
CT

O T  o p e ra tin g tim e p e r d a y

D = D e s ire d o u tp u t ra te

OT
C T = c yc le tim e =
D

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 CHAPTER SIX
Figure 6-8 FACILITIES LAYOUT
Precedence Diagram
Precedence diagram: Tool used in line balancing
to display elemental tasks and sequence
requirements
0.1 min. 1.0 min.
A Simple Precedence
a b Diagram

c d e
0.7 min. 0.5 min. 0.2 min.
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 CHAPTER SIX
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Example 1: Assembly Line Balancing

• Arrange tasks shown in the previous

slide into workstations.
– Use a cycle time of 1.0 minute
– Assign tasks in order of the most
number of followers

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 CHAPTER SIX
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Solution to Example 1

W o rk - T im e A s s ig n S ta tio n
S ta tio n R e m a in in g E lig ib le Task Id le T im e
1 1 .0 a a
.9 c c
.2 none - .2
2 1 .0 b b
0 none - 0
3 1 .0 d d
.5 e e
.3 - - .3
.5
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Line Balancing Rules
Some Heuristic (intuitive) Rules:
• Assign tasks in order of most
following tasks.
• Assign tasks in order of greatest
positional weight.
– Positional weight is the sum of
each task’s time and the times of
all following tasks.
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 CHAPTER SIX
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Calculate Percent Idle Time

I
dlet
imeperc
yc
le
P
er
cen
ti
d l
e t
ime=
(
N)(
CT)

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 CHAPTER SIX
FACILITIES LAYOUT
Determine the Minimum Number of Workstations
Required: Efficiency

(D)(t)
N=
OT

t = sum of task times

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 CHAPTER SIX
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Solution to Example 2

Station 1 Station 2 Station 3 Station 4

a b e
f g h
c d

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Parallel Workstations
30/hr. 30/hr. 30/hr. 30/hr.
1 min. 1 min. 2 min. 1 min.

Bottleneck

30/hr. 1 min. 30/hr.

60/hr. 60/hr.
1 min. 1 min. 1 min.
30/hr.
1 min. 30/hr.

Parallel Workstations
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 CHAPTER SIX
Figure 6-10 FACILITIES LAYOUT
Interdepartmental Work Flows
for Assigned Departments

30

170 100
1 3 2

A B C

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