Operations Management

Dr. Rajesh Chouksey

Presentations of Division B

Facility Layout
Big Boy Bakery – An Indonesian Bakery
Roll Number Name of Student Topic Presented Slide Number
123 Madhavan Facility Layout – Types, Introduction of Bakery 3,4,5,6
124 Sujitha Yadavar Process of making bread, current Layout of bakery 7,8
100 Akshay More Problems faced due to current layout 9
89 Aparna Systematic Layout Planning – method to improve 10, 11
layout
105 Parvathidevi Gurubaran Activity relationship chart, New layout of bakery 12, 13
95 Keyur Conclusion, Other suggestions to improve layout 14, 15
FACILITY LAYOUT
~A case study on Big boy bakery

Aparna - 89
Keyur - 95
Akshay - 100
Parvathi - 105
Madhavan - 123
Sujitha - 124
 FACILITY LAYOUT
• Arrangement of equipment, supplies, and personnel within a
facility to allow for maximum efficiency and safety.

• Includes the plan for the layout of the facility, the placement of
machinery and equipment, and the flow of personnel, materials,
and information.

• An important part of the facility planning process that can help

increase productivity, reduce costs, and improve safety.
 TYPES OF FACILITY LAYOUTS

Process Cellular Layout Fixed Position Line Layout Combination

Layout Layout Layout
 Introduction of case study
• Big Boy Bakery is a small-scale food industry in Indonesia facing competition from both
small and large scale food industries.
• Industrial development in Indonesia is increasing every year and the government is
encouraging the manufacturing industry to become the main source of state revenue.
• Food industry is one of the main sectors contributing to GDP.
• Big Boy Bakery is a small-scale food industry that produces pastries and bread with an
output of around 150 loaves a day.
• Big Boy Bakery faces common problems in small-scale industries such as distance from
production shift, unsystematic production line and unstructured facility layout.
 Introduction of case study
• They planned to work on the layout of facilities to increase efficiency.
• In this Case Study, the method used in layout planning is Systematic Layout Planning
(SLP).
• SLP can help to obtain an optimal alternative layout for the development of the production.
 PROCESS OF MAKING BREAD
1
1st Floor 0
Material Handling
Warehouse for raw
30
material Dough Maked

60
Bread Fermented
2nd Floor
Production of product 30
Bread Form

300 Bread Filled

Bread Enlargement
3rd Floor
1
Packaging 5
Bread Baked
300
Bread Chilled

4th Floor 70 Bread Quality Inspection

Bread Packaged
Final product Warehouse
OLD LAYOUT
 PROBLEMS
1 Long production cycles

2 Delay in delivery schedule

3 Increase in maintenance time

4 Excessive number of work in progress

5 Accessing in new technology

6 Rising costs of production
7 Need for improved quality control
SYSTEMATIC LAYOUT PLANNING
• Organized way to conduct layout planning

• It consists of:
• Framework of phases
• A pattern of procedures
• A set of conventions for identifying , rating and visualizing the elements & areas
involved in a plan.

• Each layout rests on three fundamentals:

1. Relationships
2. Space
3. Adjustments
 ACTIVITY RELATIONSHIP
CHART
• Tabular means of displaying closeness among all activities/ departments.
• Six Closeness rating assigned to each pair of department.

• A: Absolutely necessary
• E: Especially important
• I: Important and core
• O: Ordinary
• U: Unimportant
• X: Undesirable
 NEW LAYOUT

FIRST FLOOR LAYOUT

SECOND FLOOR LAYOUT
 CONCLUSION

SYSTEMATIC LAYOUT PLANNING (SLP) METHOD –

• Placement of important elements such as proper production operations will
reduce travel costs and time wastage, so that the planned layout can provide
increased productivity efficiency.

• With the proposed spatial planning made, it is hoped that it can make a
significant contribution to the development of Big Boy Bakery.
OTHER SUGGESTIONS TO IMPROVE
FACILITY LAYOUT
1 Automation and Streamlining of Production Process.

2 Use of Lean Manufacturing Techniques (Just-in-time production).

3 Comprehensive Quality Control Systems

4 Use of Scheduling Software.

7
 References
• Research paper titled “Facility Layout Planning In Small Industry Big Boy Bakery To Increase Efficiency “
published in Journal Of Industrial Engineering Management, JIEM Volume 5. No.2 2020.
• Web links –
1. https://theintactone.com/2019/06/17/pom-u2-topic-10-problems-in-facility-layout/
2. https://www.youtube.com/watch?v=GyMyTjTGOeY&feature=youtu.be
3. https://www.managementstudyguide.com/facility-layout.htm