impact location of loading & unloading
Facility Layout
(Chapter 10)
Production & Operations Management
INFO 335-71
Week 3
2
Learning Objectives
Define layout planning and explain its importance
Identify and describe different types of layouts
Compare process layouts & product layouts
Describe the steps involved in designing a process layout
Describe the steps involved in designing a product
layout
Define the meaning of group technology (cell)
layouts
3
Types of Layouts
Four basic layout types:
• Process layouts – Group similar resources together based on similar processes/functions
• Product layouts – Designed to produce a specific product efficiently
• Hybrid layouts – Combine aspects of both process and product layouts
• Fixed-Position layouts – Product is too large to move; e.g. a building
4
Process vs. Product Layouts
Characteristic differences:
5
Designing Process Layouts
Step 1: Gather information: Space needed, space available, identify closeness
measures (From-to Matrix, REL, SLP)
Step 2: Develop alternative block plans: Using trial-and-error or decision support tools (load-
distance model, ALDEP, CRAFT)
Step 3: Develop a detailed layout: Consider exact sizes/shapes of departments and work
centers including aisles and stairways
Tools like drawings, 3-D models, and CAD software are available to facilitate this process
Load-Distance Model
6
Warehouse Layout
7
Warehouse Layout
8
Trips/block
9
Designing Product Layouts
Designing product layouts requires consideration of:
• Sequence of tasks to be performed by each workstation • Logical order • Speed considerations – line balancing
WS1 WS2 WS3 WS4
Work In-
process
Inventory
t t t t
Raw After
WS1
After
WS2
After
WS3
Finished
Product
10
Designing Product Layouts – cont’d
Step 1: Identify tasks & immediate predecessors
Step 2: Determine output rate
Step 3: Determine cycle time
Step 4: Compute the Theoretical Minimum number
of Stations
Step 5: Assign tasks to workstations
(balance the line)
Step 6: Compute efficiency, idle time &
balance delay
11
Step 1: Identify Tasks &
Immediate Predecessors
Example 10.4 Vicki’s Pizzeria and the Precedence Diagram
Immediate Task Time
Work Element Task Description Predecessor (seconds A Roll dough None 50
B Place on cardboard backing A 5
C Sprinkle cheese B 25
D Spread Sauce C 15
E Add pepperoni D 12
F Add sausage D 10
G Add mushrooms D 15
H Shrinkwrap pizza E,F,G 18
I Pack in box H 15
Total task time 165
Precedence Diagram
bottleneck
12
Step 2: Determine Output Rate
Output Rate is the number of units to be produced
over a specific period of time
• Vicki needs to produce 60 pizzas per hour
• Vicki will need to divide the work among a number of people simultaneously at workstations
The goal is to design a product layout that can
produce the desired number of units with the least
amount of work centers and a balance of workload
hourper pizzas 8.12 sec./unit 165
sec./hr. 3600 output Maximum ==
Minimum
13
Step 3: Determine Cycle Time
Determine cycle time calculations
• The amount of time each workstation is allowed to complete its tasks
• Limited by the bottleneck task (the longest task):
• Minimum cycle time = bottleneck (50 sec.) • Maximum cycle time = sum of the task times (165
sec.)
( ) ( )
sec./unit 60 units/hr 60
sec/min 60x min/hr 60
units/hroutput desired
sec./day time available )(sec./unit time Cycle ===
hourper pizzas 72 sec./unit 50
sec./hr. 3600 output Maximum ==
Seconds/hr
60 pizzas per hour
60 pizzas per 3600 seconds
1 pizza every 3600/60 = 60 seconds
14
Step 4: Theoretical Minimum
Number of Stations
Computing the theoretical minimum (TM) number of stations
• TM = number of stations needed to achieve 100% efficiency (every second is used)
• Always round up (no partial workstations) • Serves as a lower bound for our analysis
( ) stations 3or 2.75,
itseconds/un 60
itseconds/un 165
timecycle
task times TM ===
Round it up
15
Step 5: Assign Tasks to
Workstations Assigning tasks to workstations (Balance the Line)
• Start at the first station & choose the longest eligible task following precedence relationships
• Continue adding the longest eligible task that fits without going over the desired cycle time
• When no additional tasks can be added within the desired cycle time, begin assigning tasks to the next workstation until finished
Workstation Eligible task Task Selected Task time Idle time
A A 50 10
B B 5 5
C C 25 35
D D 15 20
E, F, G G 15 5
E, F E 12 48
F F 10 38
H H 18 20
I I 15 5
1
2
3
WS1
WS2
WS3
16
Step 6: Efficiency and Balance
Delay
Computing efficiency and balance delay
• Efficiency (%) is the ratio of total productive time divided by total time
• Balance delay (%) is the amount by which the line falls short of 100%
( ) 91.7%100 sec. 60x stations 3
sec. 165
NC
t (%) Efficiency ===
8.3%91.7%100%delay Balance =−= (15/180)*100
17
Other Product Layout
Considerations
Shape of the line (S, U, O, L): • Share resources, enhance communication & visibility,
impact location of loading & unloading
Paced versus Un-paced lines • Paced lines use an automatically enforced cycle time • Un-paced has more autonomy; product may be
removed off assembly line
Number of Product Models produced • Single-model lines – one version of a product • Mixed-model lines – many versions of a product
© Wiley 2013 18
Group Technology
(CELL) Layouts
One of the most popular hybrid layouts uses Group Technology (GT) and a cellular layout
GT has the advantage of bringing the efficiencies of a product layout to a process layout environment
19
Problem – Facility Layout
•The items listed below are stored in a one-dock warehouse. How should the item areas be allocated to the warehouse layout below (assume all blocks are equal in area)?
Item Trips Area Needed (blocks) A 300 2 B 220 1 C 72 1 D 50 1 E 24 1
Dock
XYZ Company is designing a new product layout. It plans to use this
production line eight hours a day in order to meet a schedule of 50 units
per hour. The task necessary to produce this product are detailed in the
table below,
(a) Draw the precedence Diagram 3pt
(b) What is the required cycle time (seconds) in order to meet the
schedule? 2pts
(c) What is the minimum number of work stations needed to meet the
Schedule? 2pts
(d) Balance the line by assigning tasks to workstations 3pts20
Problem – Product Layout
Task Predecessor Time (seconds)
A – 50
B A 36
C B 26
D – 52
E C,D 70
F C,E 30
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