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1
Lecture Outline
• Capacity Planning
• Basic Layouts
• Designing Process Layouts
• Designing Service Layouts
• Designing Product Layouts
• Hybrid Layouts
• Process layouts
• group similar activities together according to process
or function they perform
• Product layouts
• arrange activities in line according to sequence of
operations for a particular product or service
• Fixed-position layouts
• are used for projects in which product cannot be
moved
Women’s
Shoes Housewares
lingerie
In
Out
7-17
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
3 4 40 loads 60
4 5
1 4 0 loads
1 5 0 loads Grid 1
40
1 4
1 2 4 2
3 5 3 5
Department
From /
To B A C AA B" CC
A 75 - 45 60
C 30 - 85 200
AA 100 50 - 70
B" 25 70 30 40 - 65
CC 65 150 35 -
Key: A
E
I
Stockroom Toolroom Production
O
U
X
Stockroom
Offices Shipping
and
receiving
• CRAFT
• Computerized Relative Allocation of Facilities Technique
• CORELAP
• Computerized Relationship Layout Planning
• PROMODEL and EXTEND
• visual feedback
• allow user to quickly test a variety of scenarios
• Three-D modeling and CAD
• integrated layout analysis
• available in VisFactory and similar software
Racetrack
Layout
1 2 3
4 minutes 4 minutes 4 minutes
t i t i
E= i=1
nCa
N= i=1
Cd
where
ti = completion time for element i
j = number of work elements
n = actual number of workstations
Ca = actual cycle time
Cd = desired cycle time
Balance delay j
total idle time of line = nCa -
t i
i=1
Copyright 2011 John Wiley & Sons, Inc. 7-41
Line Balancing Procedure
1. Draw and label a precedence diagram
2. Calculate desired cycle time required for line
3. Calculate theoretical minimum number of workstations
4. Group elements into workstations, recognizing cycle
time and precedence constraints
5. Calculate efficiency of line
6. Determine if theoretical minimum number of
workstations or an acceptable efficiency level has been
reached. If not, go back to step 4.
0.2
B
0.1 A D 0.3
C
0.4
0.2
B Cd = 0.4
0.3 N = 2.5
0.1 A D
C
0.4
4 6 7 9
5 8
2 10 12
1 3 11
A B C Raw materials
Machines
Parts 1 2 3 4 5 6 7 8 9 10 11 12
A x x x x x
B x x x x
C x x x
D x x x x x
E x x x
F x x x
G x x x x
H x x x
Figure 5.8
Copyright 2011 John Wiley & Sons, Inc. 7-52
Revised Cellular Layout
Assembly
8 10 9 12
11
4 Cell 1 Cell 2 6 Cell 3
7
2 1 3 5
A B C
Raw materials
Part 1 7 3 5 2 4 6
A 1 1 1 1
B 1 1 1 1
C 1 1 1 1
D 1 1 1
E 1 1 1
F 1 1 1
G 1 1 1
H 1 1 1
I 1 1 1
• Consists of
• programmable machine tools
• automated tool changing
• automated material handling system
• controlled by computer network
• Combines flexibility with efficiency
• Layouts differ based on
• variety of parts the system can process
• size of parts processed
• average processing time required for part completion
D E
(a) Balanced for a straight line (b) Balanced for a U-shaped line
A,B C,D E
A,B
9 min 12 min 3 min
24 24
Efficiency = = = .6666 = 66.7 % C,D
3(12) 36
24 24 12 min 12 min
Efficiency = = = 100 %
2(12) 24