Chapter 10 – Facility Layout
Operations Management
by
R. Dan Reid & Nada R. Sanders
2nd Edition © Wiley 2005
PowerPoint Presentation by R.B. Clough - UNH
Learning Objectives
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Define layout planning and its importance
Identify and describe different types of layouts
Compare process layouts & product layouts
Describe the steps involved in designing process layouts
Explain the objectives of product layout design
Explain the advantages of hybrid layouts
Define the meaning of group technology & its importance
to cellular layouts
What Is Layout Planning
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Layout planning is determining the best
physical arrangement of resources
within a facility
Two broad categories of operations:
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Intermittent processing systems
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Continuous processing systems
Types of Layouts
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Process layouts:
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Product layouts:
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Designed to produce a specific product efficiently
Hybrid layouts:
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Group similar resources together
Combine aspects of both process and product layouts
Fixed-Position layouts:
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Product is two large to move; e.g. a building
Process Layouts
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General purpose & flexible resources
Lower capital intensity & automation
Higher labor intensity
Resources have greater flexibility
Processing rates are slower
Material handling costs are higher
Scheduling resources & work flow is more
complex
Space requirements are higher
Product Layouts
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Specialized equipment
High capital intensity & wide use of
automation
Processing rates are faster
Material handling costs are lower
Less space required for inventories
Less volume or design flexibility
Designing Process Layouts
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Step 1: Gather information:
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Space needed, space available, importance of proximity
between various units
Step 2: Develop alternative block plans:
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Using trial-and-error or decision support tools
2 approaches
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Relationship (REL) chart
From-to matrix
Can use both
Decision support systems are heuristic methods
 Usually give a "good" solution
 Solution may not be optimal (best solution)
Designing Process Layouts (2)
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Step 3: Develop a detailed layout
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Consider exact sizes and shapes of departments
and work centers including aisles and stairways
Tools like drawings, 3-D models, and CAD
software are often used
Process Layout Example
Block layout for a sports medicine clinic
A
Radiology
B
Laboratory
C
Lobby &
Waiting
D
Examining
Rooms
E
Surgery &
Recovery
F
Physical
Therapy
Process Layout Example (2)
Process Layout Example (3)
Process Layout Example (4)
Proposed Layout
Process Layout Example (5)
Office Layouts
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Office Layout Considerations:
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Almost half of US workforce works in an office environment
Human interaction and communication are the primary factors in
designing office layouts
People who need to talk frequently should be close to each other
One key layout trade-off is between proximity and privacy
Open concept offices promote understanding & trust
Flexible layouts with “office landscaping” help to solve the privacy
issue in open office environments
A few closed rooms may be needed for private discussions, such as
personnel matters.
Designing Product Layouts
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Objectives
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Produce the required number of units to
meet demand
Use workers and equipment efficiently
Balance workload among employees
Designing Product Layouts (2)
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Based on a precedence diagram
Assign tasks to work stations
Assign work stations to locations
Other Product Layout Considerations
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Shape of the line (S, U, O, L):
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Paced versus un-paced lines
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Share resources, enhance communication &
visibility, impact location of loading &
unloading
Paced lines use an automatically enforced
cycle time
Single or mixed-model lines
Hybrid Layouts
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Combine elements of both product & process
layouts
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Maintain some of the efficiencies of product layouts
Maintain some of the flexibility of process layouts
Examples:
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Group technology & manufacturing cells – used in Justin-Time manufacturing
Grocery stores
Designing Hybrid Layouts
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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
Process Flows before the Use of GT Cells
Process Flows after the Use of GT Cells
Chapter 10 Highlights
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Layout planning is deciding on the best physical
arrangement of resources.
There are four basic types of layouts: process,
product, hybrid, and fixed position.
Process layouts provide flexibility to make a
variety of different products. Product layouts
provide greater efficiency for one product.
The steps for designing process layouts are:
gather space and closeness information, develop a
block plan, and develop a detailed layout.
Chapter 10 Highlights
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(continued)
The steps for designing an product layout are:
identify tasks and predecessors, determine output
rate, determine cycle time, computing the
theoretical minimum number of work stations,
assigning tasks to workstations, and computing
efficiency and balance delay.
Hybrids layouts combine elements from both types
of layouts to increase efficiency.
Hybrid layouts combine GT analysis with cellular
layout concepts .