Facility Layout
Part a
Definition (J. M. Apple)
• Arrangement of physical facilities to
optimize the interrelationships among
operating personnel, material flow,
information flow, and the methods
required in achieving enterprise
objectives efficiently, economically,
and safely.
The Overall Objective of
Facility Layout
• To get the inputs (materials,
supplies, etc.) into, through, and
out of each facility in the shortest
practicable time, at an acceptable
cost.
3
Objectives of Facility Layout
•
•
•
•
•
Minimize material handling costs
Utilize space efficiently
Utilize labor efficiently
Eliminate bottlenecks
Facilitate communication and interaction between
workers, between workers and their supervisors, or
between workers and customers
• Minimize investment in equipment
4
• Reduce manufacturing cycle time or customer service time
• Eliminate waste or redundant movement
• Facilitate the entry, exit, and placement of material, products,
or people
• Incorporate safety and security measures
• Promote product and service quality
• Encourage proper maintenance activities
• Provide a visual control of operations or activities
• Provide flexibility to adapt to changing conditions
• Provide for employee convenience, safety, and comfort
5
Basic Types of Layouts
• Process Layout (or Lot Production)
–machines grouped by process they perform
• Product Layout (or Continuous Production)
–linear arrangement of workstations to produce a
specific product
• Fixed Position Layout
–used in projects where the product cannot be
moved
6
Hybrid Layouts
• Cellular layouts
–group machines into machining cells
• Flexible manufacturing systems
–automated machining & material handling systems
• Mixed-model assembly lines
–produce variety of models on one line
7
Manufacturing Process Layout
Lathe Department
L
L
L
L
L
L
L
L
L
L
Milling
Department
Drilling Department
M
M
D
D
D
D
M
M
D
D
D
D
G
G
G
P
G
G
G
P
Grinding
Department
Receiving and
Shipping
Painting Department
A
A
A
Assembly
8
Service Process Layout
Women’s
lingerie
Shoes
Housewares
Women’s
dresses
Cosmetics
and jewelry
Children’s
department
Women’s
sportswear
Entry and
display area
Men’s
department
9
A Product Layout
In
Out
10
Comparison Of Product And
Process Layouts
1. Description
2. Type of Process
3. Product
4.
5.
6.
7.
Demand
Volume
Equipment
Workers
PRODUCT LAYOUT
Sequential arrangement
of machines
Continuous, mass
production, mainly
assembly
Standardized
made to stock
Stable
High
Special purpose
Limited skills
PROCESS LAYOUT
Functional grouping
of machines
Intermittent, job shop
batch production,
mainly fabrication
Varied,
made to order
Fluctuating
Low
General purpose
Varied skills
11
Comparison Of Product And
Process Layouts
8. Inventory
9. Storage space
10. Material
handling
11. Aisles
12. Scheduling
13. Layout decision
14. Goal
15. Advantage
PRODUCT LAYOUT
Low in-process,
high finished goods
Small
Fixed path
(conveyor)
Narrow
Part of balancing
Line balancing
Equalize work at
each station
Efficiency
PROCESS LAYOUT
High in-process,
low finished goods
Large
Variable path
(forklift)
Wide
Dynamic
Machine location
Minimize material
handling cost
Flexibility
12
Designing Process Layouts
• 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
13
Block Diagramming
• Create load summary chart
• Calculate composite (two way) movements
• An Approach: Develop trial layouts minimizing
number of nonadjacent loads
14
Block Diagramming
Example
LOAD SUMMARY CHART
DEPARTMENT
DEPT. 1
2
3
4
5
1
100 50
2
200 50
3
60
40
50
60
4
100
5
50
15
Initial & Final Designs
16
Block Diagrams
17
Example 1
A warehouse processes six different products monthly: a, b, c, d, e, and f.
Two alternative layouts for the warehouse are being considered, A and B:
Layout B
Layout A
1
3
5
Receiving
(R)
5
1
4
Shipping
(S)
2
4
6
Shipping
(S)
6
2
3
Receiving
(R)
18
Example 1 (cont.)
The products, their monthly production levels, their sequence of
processing, and distances between processing are shown in the following
table:
Product
A
B
C
D
E
F
Number of
Product
Sequence
Sequence
Products
Sequences Distance for Distance for
Processed/Month
Layout A
Layout B
1,000
R-1-S
70 feet
50 feet
3,000
R-2-S
70
50
2,000
R-3-S
50
30
3,000
R-4-S
50
30
2,000
R-5-S
30
70
2,000
R-6-S
30
70
Which layout alternative minimizes the monthly warehouse travel? 19(Use
load-distance analysis)
Example 1: Solution
Load-Distance Load-Distance For
For Layout A Layout B
70000
210000
100000
150000
60000
60000
650000
50000
150000
60000
90000
140000
140000
630000
SELECT LAYOUT B
20
Relationship Diagramming
• Used when quantitative data is not available
• Muther’s grid displays preferences
• Denote location preferences with weighted lines
21
Ranking System For
Departments
A
E
I
O
U
X
- absolutely necessary
- especially important
- important
- okay
- unimportant
- undesirable
22
Relationship Diagramming
Example
Production
O
Offices
A
U
I
O
Stockroom
A
Shipping and Receiving
E
X
U
U
A
U
O
O
Locker Room
O
Toolroom
23
Original Layout
24
Revised Layout
25