4.

Systematic Layout
Planning
References
1.Richard L. Francis, Facility Layout and
Location: An Analytical Approach
2.S.K. Sharma, Industrial engineering and
operations management.
3.Daniel Kitaw,Industrial Management and
Engineering Economy.
SYSTEMATIC LAYOUT PLANNING (SLP)
 The most popular approach used in designing
plant layout.

 The procedure has been applied to

production, transportation, storage,
supporting services, and office activities,
among others.
4-2
 CONT’D
 Information gathering
 Flow analysis + Activity analysis
 Relationship diagram
 Space consideration + Relationship diagram
 Space relationship diagram
 Modifying consideration + Practical limitation
 A number of alternative layouts are designed
and evaluated
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4-4
 INFORMATION GATHERING
 Information is required pertaining to
the
product , proces s, and schedule.
 Data regarding product design decisions
can
affect the layout significantly.
 The product design decisions can 4-5

directly or indirectly affect the layout.

 CONT’D
 Basic product design data can be obtained from
photographs of the product, exploded drawings,
engineering drawings of individual parts, parts lists,
bill of material and assembl chart .

4-6
CONT’D

4-7
CONT’D

4-8
 CONT’D
Company open close valve company Prepared by Jhon Mc Francies
Product gate valve Date October 31, 19xx
Part Part Drawing No. Unit Materials Size Make Buy
No. Name No.
0105 Nut 2005 1 Brass Buy
0204 Washer 2003 1 Aluminum 0.8”odx0.22”idx0.01” thick Buy
0303 Handle 1010 1 Zinc, die casting 2.0”x0.6” Make
0501 Cap 1008 1 Brass, hex bar stock 0.75”x0.40” Make
0601 Packing 2001 1 Rubber 0.58”odx0.25”idx0.25” Buy
0702 Ferrule 1007 1 Brass, tube 0.4”x0.2” Make
0802 Stem 1000 1 Brass, rod 3.0”x0.375” Make
0901 Bushing 1004 1 Bronze 1.1”x1.5” Make
1001 Gasket 2007 1 Rubber 1.4”odx1.17”idx0.025” Buy
1101 Gate 1006 1 Bronze 1.2”x0.96”x0.55” Make
1305 Body 1002 1 Bronze 1.4”x1.9”x2.125” Make
1402 Box 2011 1 Cardboard 2.125”x2.125”x4.25” Buy
1503 Staple 2012 4 Aluminum Buy

1603 Label 2013 1 Adhesive backed paper 2.0”x1.0” Buy 4-9

Company open-close valve company Prepared by Jhon Mc Francies
Product gate valve Date October 31, 19xx

Level Part No. Part Name Drawing No. No. Unit Make Buy Comments
0 0010 Pipe valve 0010 1 Make
1 0100 Bottom assembly 0020 1 Make
2 0200 Top assembly 0030 1 Make
4 0105 Nut 2005 1 Buy
3 0204 Washer 2003 1 Buy
2 0303 Handle 1010 1 Make
3 0403 Paint - 0.010 oz. Buy
4 0501 Cap 1008 1 Make
5 0601 Packing 2001 1 Buy
3 0702 Ferrule 1007 1 Make
1 0802 Stem 1000 1 Make
2 0901 Bushing 1004 1 Make
3 1001 Gasket 2007 1 Buy
2 1101 Gate 1006 1 Make
2 1201 Grease - 0.001 oz. Buy
3 1305 Body 1002 1 Make
6 1402 Box 2011 1 Buy
7 1503 Staple 2012 4 Buy

7 1603 Label 2013 1 Buy 4 - 10

CONT’D

4 - 11
 CONT’D
♦ The assembly chart is an analog model of the
operations and inspections required in assembling a
product.

♦ Assembly chart shows graphically which parts must

go into(or be assembled to) other parts.

♦ The assembly chart is the basis for the layout of the

assembly department or assembly lines.
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 CONT’D
♦ Process design decisions determine whether a part
will be purchased or produced, how the production of
parts will be achieved, what equipment will be used,
and how long it will take to perform the operation.

♦ Such information is typically summarized on

an
operation sheet or route sheet.
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 CONT’D
Company open close valve company Prepared by Jhon Mc Francies
Product gate valve Date October 31, 19xx _
Part name Bushing Part Number 0901
_ Material Bronze casting Production Quantity 1500
_Op. No. Op. Description Machine type Tooling an d supplies Setup time (hrs) Op. time
05 Cast: using green sand mold with 50 Bench mold T- shaped dry sand core 0.50 2.00
bushings per mold; pour, cool, cut off gates Band saw for each bushing
and risers
06 Clean: grind, as needed to remove flashing, Bench or pedestal A-24-M-8-V type 0.25 0.75
and tumble grinder; tabling barrel grinding wheel

07 Drill hole:3/16”x1/2” Turret lathe 3/16” drill 0.50 2.5o

08 Bore hole: 7/16”x1/4” Turret lathe 7/16” bore - 2.75
09 Turn: small end to 5/8” large end to 3/2” and Turret lathe Round-nose turning tool, - 10.50
then large end to 5/4” cut-off tool and right-hand
facing tool

10 Thread: small and large ends (5/8”-16 UNC- Turret lathe Stationary, self-opening - 9.25
2A and 5/4”-16 UNC-2A threads) die heads for 5/8” and
5/4”

Total 1.25 27.75

Comments: Operations 7 through 10 are performed on the same turret lathe, using one setup. The operating times given include rechecking the work
piece. The operations are performed as follows: chuck large end; drill, bore, turn, thread, and cutoff small end to length; chuck small end, grip hexagonal
surface; turn large end to 1.50” over 0.375” length, cutoff to length, turn large end to 1.25” over 0.25” length, retaining 1.50” diameter over 1.25” length.
4 - 14
 CONT’D
♦ The operation process chart is often used to
supplement the route sheet; in a sense, it is a pictorial
representation of the route sheet.

♦ Its an expansion of the assembly process chart in that

it includes all operations and inspections performed
on the product.

♦ The basis for the layout of a manufacturing plant.

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4 - 16
 CONT’D
♦ A precedence diagram establishes the prerequisite
assembly steps that must be completed before
performing a given assembly step.

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 CONT’D
♦ Schedule design decisions tell us how much to produce
and when to produce.

♦ Production schedules are given using an analog

model called Gantt chart.

4 - 18
CONT’D

4 - 19
 CONT’D
♦ Most information sources available portray yesterdays
and, possibly today’s data.

♦ We are interested in tomorrow's data, since we

are developing a solution to be used tomorrow.

♦ Data sources emphasizes the interrelationships among

product, process, schedule, and layout design.

♦ The layout must support the objectives of the facility.4 - 20

 CONT’D
♦ The effective arrangement of personnel and
equipments depends on accurate information regarding
product, process, and schedule requirements.

♦ When such requirements change rapidly, it is

important for the layout to accommodate changes in
requirements.

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FLOW ANALYSIS AND ACTIVITY ANALYSIS

 Flow analysis concentrates on some

quantitative measures of movement between
departments or activities.

 Activity analysis is concerned with the non-

quantitative factors that influence the
location of departments or activities.
4 - 22
 CONT’D

♦ Basic data have been obtained concerning the process,

product and schedule, the layout analyst is in position
to analyze the flow of materials, equipment, and
personnel.

4 - 23
 CONT’D
Factor that affect the flow pattern given by:
1. External transportation facilities
2. Number of parts in product
3. Number of operations on each part
4. Sequence of operations on each part
5. Number of subassemblies
6. Number of units to be produced
7. Necessary flow between work areas
8. Amount and shape of space available 4 - 24
 CONT’D
9. Influence of process
10. Types of flow pattern
11. Product versus process type of layout
12. Location of service areas
13. Production department location
14. Special requirement of departments
15. Material storage
16. Desired flexibility
17. The building
4 - 25
 CONT’D
Types of Flow Patterns

♦ Flow patterns can be classified either horizontal

or
vertical.

♦ There are at least five basic types of horizontal flow

patterns.

4 - 26
CONT’D

4 - 27
 CONT’D

♦ Vertical flow pattern exist both in single-story and

multi-story buildings. Utilization of overhead space
has focused great attention on the design of vertical
flow pattern.

4 - 28
CONT’D

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 CONT’D
Types of layout

♦ The choice of layout type is the factor affecting the

flow pattern.

♦ There are four general types of layout categories:

1. Product layout
2. Process layout
3. Fixed position and,
4. Combination layout 4 - 30
 CONT’D
Flow analysis approach

♦ Flow process chart

♦ Multiproduct
process chart

♦ Flow diagram

♦ From-to-chart

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 CONT’D

Flow process chart

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 CONT’D

Multiproduct process chart

4 - 33
 CONT’D

Flow diagram

4 - 34
 CONT’D

From-to-chart
4 - 35
 ACTIVITY RELATIONSHIP ANALYSIS

• Flow analysis tends to relate various activities on some

quantitative basis.

• Typically, the relationship is expressed as a

function of transport cost or material handling cost.

• There might be other qualitative aspects of

layout design that might be important.

4 - 36
 CONT’D
Relationship chart

• A relationship hart is a triangular matrix

c A: Absolutely
necessary E: Especially important whose
elements sent the relation
repre I: Important
ships among plant
nts
O: Ordinary closeness OK
layout departme.
e U:also used to
Unimportant resent desirable or
• Letter codes rep
X: Undesirable
undesirable leve ween departments.
ar
ls of closeness bet
4 - 37
 CONT’D
• The activity relationship chart (REL chart) was
developed to facilitate the consideration of qualitative
factors – analytically!

• The REL chart replaces the numbers in the Travel

chart by a qualitative closeness rating.

• All pairs of relationships are evaluated, and a closeness

rating (A, E, I, O, U, and X) is assigned to each pair.
4 - 38
 CONT’D

• With the exception of U rating, the reason for

the

assigned rating is indicated using a numeric code.

• Closeness ratings represent an ordered

preference for “closeness”.

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 CONT’D

• Specifically, A and X ratings are considered to

be most important ratings.

• Hence, any layout must satisfy A and X

ratings.
• Thus, A and X > E > I > O > U , where > means “more
important or higher ranking than.”

4 - 40
 CONT’D
Rule of thumb
• Very few A and X relationships should be
assigned. (no more than 5% of the closeness ratings
to be an A and X).
• No more than 10% should be an E.
• No more than 15% to be an I.
• No more than 20% to be an O.
• Which means that about 50% of the
relationships should be U.
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 CONT’D
• Block plans, or block layouts are developed first by
determining the sizes, shapes and relative locations of
departments or other designated activities.

• Next, detailed layouts are designed for each

department.

• Thus different REL charts are needed for designing

block plans and detailed layouts.
4 - 42
 CONT’D

• The process of constructing an activity relationship

chart can be complicated by the presence of multiple

relationships that will influence the design of the

layout.

4 - 43
CONT’D

4 - 44
 CONT’D
• The relationship chart and the numerically weighted

ratings, assigned to the closeness values, are the basis

for the order and placement in which departments
enter the layout.

• The ratings assigned for A,E,I,O,U and X are used to

calculate the Total Closeness Rating (TCR) for each
department.
4 - 45
 CONT’D
n

TCR i =  V( ); i = 1 ... m

Where
r ij
j= 1

TCRj = Total Closeness Rating for department;

V(rij) = Numerical value assigned to the closeness value for

department i and j.

n = Total number of departments.

4 - 46
 CONT’D
• The first department to be placed in the layout
is assigned by taking the department with the
greatest TCR.
• Next, the relationship chart is scanned to see if there
is any department that has an A value with the
department already placed.

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 CONT’D
• If no A value exists, a check is made for E value, and
if no E value appears, a check is made for I value,
followed by O value.

• If ties develop, the department having the greatest

TCR is chosen. This process is continually used until
finally all departments are placed in the layout.

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Example
Numerical values
A = 10,000; E = 1,000;
I = 100; O = 10; U = 0; and
X = -10,000

4 - 49
 CONT’D

a b c d

e f g 4 - 50
 CONT’D

i 4 - 51
 CONT’D
REL Diagram

• From REL chart, we construct activity

relationship diagram (REL diagram).

• The purpose is to depict spatially the relationships of

the activities.

• The basic premise is that geographic proximity can be

used to satisfy particular relationships.
4 - 52
 CONT’D
• For example, when the activity relationships reflect
the magnitudes of material flows, pairs of activities
having the greatest pair wise flow are located next to
each other.

• Similarly, pairs of activities having A rating are

an located adjacently.

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CONT’D

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 SPACE REQUIREMENT AND AVAILABILITY

The bases for determining the space requirement:

i. Production rate

ii. Equipment requirement

iii.Employee requirement

4 - 55
 CONT’D
Commonly used methods of determining space requirement:

i. Production center method

• Consists of a single machine plus all the

associated equipment and space required for its
operations.

• Work space, maintenance space, and storage

4 - 56

space are added to space requirement for the

machine.
CONT’D

4 - 57
 CONT’D
ii. Roughed-out layout method

• Templates or models are placed on the layout to

obtain an estimate of the general configuration and
space requirements.

iii. Space standards method

• Industry standards can be used to determine the

space requirement.
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CONT’D

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 DESIGNING THE LAYOUT
Designing the space relationship diagram

• The over all layout is designed by first combining the

space consideration with the REL diagram.

• For each activity, a space template is constructed, to

scale, to represent the size and shape of the activity.

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Example

4 - 61
CONT’D

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 CONT’D
• After construction the space relationship diagram, the
space templates are modified and adjusted and the
relative locations of the activities are shifted as
necessary to accommodate practical limitation and
other considerations.
• The block plan is a scaled diagrammatic representation
of the building normally shows the locations of
internal and columns.
partitions 4 - 63
4 - 64
 CONT’D
Presenting the layout

• A number of alternative component designs, a number

of alternative overall designs, or a number of
alternative detailed designs should have been
generated.

4 - 65
 CONT’D

There are three methods of visually representing layouts

• Drawing or sketches

• Two-dimensional iconic models

• Three-dimensional iconic models

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CONT’D

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 CONT’D
Selection, implementation and follow-up

• Select the design from alternatives which best meets

your objective.

• The design selected must be specified, all concerned

must be sold, and the layout must be installed,
observed, and periodically evaluated in an operating
environment.
4 - 68