Chapter 7

Facilities
Operations Management - 5th Edition
Roberta Russell & Bernard W. Taylor, III

Copyright 2006 John Wiley & Sons, Inc.

Beni Asllani University of Tennessee at Chattanooga

Lecture Outline
Basic Layouts Designing Process Layouts Designing Service Layouts Designing Product Layouts Hybrid Layouts

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Facility Layout
Arrangement of areas within a facility to:
Minimize material-handling costs Utilize space efficiently Utilize labor efficiently Eliminate bottlenecks Facilitate communication and interaction Reduce manufacturing cycle time Reduce customer service time Eliminate wasted or redundant movement Increase capacity
Copyright 2006 John Wiley & Sons, Inc.

Facilitate entry, exit, and placement of material, products, and people Incorporate safety and security measures Promote product and service quality Encourage proper maintenance activities Provide a visual control of activities Provide flexibility to adapt to changing conditions
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BASIC LAYOUTS
Process layouts

group similar activities together according to process or function they perform arrange activities in line according to sequence of operations for a particular product or service are used for projects in which product cannot be moved
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Product layouts

Fixed-position layouts

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Process Layout in Services

Womens lingerie Shoes Housewares

Womens dresses

Cosmetics and jewelry

Childrens department

Womens sportswear

Entry and display area

Mens department

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Manufacturing Process Layout

Lathe Department Milling Department Drilling Department

L L L L L

L L L L L

G G

G G
Grinding Department Receiving and Shipping

G G

P P
Painting Department

A
Assembly

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A Product Layout
In

Out

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Comparison of Product and Process Layouts

Product
Description Sequential arrangement of activities Continuous, mass production, mainly assembly

Process

Type of process

Product Demand Volume Equipment

Functional grouping of activities Intermittent, job shop, batch production, mainly fabrication Standardized, made Varied, made to to stock order Stable Fluctuating High Low Special purpose General purpose
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Comparison of Product and Process Layouts

Product
Workers Inventory Limited skills Low in-process, high finished goods Storage space Small Material handling Fixed path (conveyor) Aisles Narrow Scheduling Part of balancing Layout decision Line balancing Goal Equalize work at each station Advantage Efficiency

Process
Varied skills High in-process, low finished goods Large Variable path (forklift) Wide Dynamic Machine location Minimize material handling cost Flexibility

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Fixed-Position Layouts
Typical of projects Equipment, workers, materials, other resources brought to the site Highly skilled labor Often low fixed Typically high variable costs

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Designing Process Layouts

Goal: 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

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Computerized layout Solutions

CRAFT

Computerized Relative Allocation of Facilities Technique Computerized Relationship Layout Planning visual feedback allow user to quickly test a variety of scenarios

CORELAP

PROMODEL and EXTEND

Three-D modeling and CAD

integrated layout analysis available in VisFactory and similar software

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Designing Service Layouts

Must be both attractive and functional Types Free flow layouts

encourage browsing, increase impulse purchasing, are flexible and visually appealing encourage customer familiarity, are low cost, easy to clean and secure, and good for repeat customers both increase customer sightlines and exposure to products, while encouraging customer to circulate through the entire store

Grid layouts

Loop and Spine layouts

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Types of Store Layouts

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Designing Product Layouts

Objective

Balance the assembly line

tries to equalize the amount of work at each workstation physical restrictions on the order in which operations are performed maximum amount of time a product is allowed to spend at each workstation

Line balancing

Precedence requirements

Cycle time

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Designing Product Layout

Line balancing

Eliminating the bottleneck Dividing the work equally among stations Cycle time Idle time Line efficiency Balance delay
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Hybrids Layouts
Cellular layouts

group dissimilar machines into work centers (called cells) that process families of parts with similar shapes or processing requirements
automated machining and material handling systems which can produce an enormous variety of items processes more than one product model in one line

Flexible manufacturing system

Mixed-model assembly line

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Cellular Layouts
1. Identify families of parts with similar flow paths 2. Group machines into cells based on part families 3. Arrange cells so material movement is minimized 4. Locate large shared machines at point of use
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Parts Families

A family of similar parts

A family of related grocery items

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Original Process Layout

Assembly

5 2 1 3 10

8
12 11

Raw materials

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Part Routing Matrix

Parts A B C D E F G H 1 x 2 x x x x x x x x x 3 Machines 4 5 6 7 x x x x x x x x x 8 9 10 11 12 x x x x

x
x

x
x

x x
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Figure 5.8 Copyright 2006 John Wiley & Sons, Inc.

Revised Cellular Layout

Assembly

10

12

11
4 Cell 1 Cell 2 6 Cell 3 7 2 1 3 5

A B C Raw materials
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Reordered Routing Matrix

Parts 1 2 4 Machines 8 10 3 6 9 5 7 11 12

A D F C G B H E

x x x

x x

x x x

x x x x x
x x x x x x x x x x x x x x x
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A Manufacturing Cell with Worker Paths

Source: J.T. Black, Cellular Manufacturing Systems Reduce Setup Time, Make Small Lot Production Economical. Industrial Engineering (November 1983).

Direction of part movement within cell HM VM

Worker 3

VM

L
Paths of three workers moving within cell
Worker 2

Material movement Key: S L HM VM G = Saw = Lathe = Horizontal milling machine = Vertical milling machine = Grinder

L
Final inspection

Worker 1

Finished part

In

Out
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Automated Manufacturing Cell

Source: J. T. Black, Cellular Manufacturing Systems Reduce Setup Time, Make Small Lot Production Economical. Industrial Engineering (November 1983)

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Advantages and Disadvantages of Cellular Layouts

Advantages

Disadvantages

Reduced material handling and transit time Reduced setup time Reduced work-inprocess inventory Better use of human resources Easier to control Easier to automate

Inadequate part families Poorly balanced cells Expanded training and scheduling of workers Increased capital investment

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Flexible Manufacturing Systems (FMS)

FMS consists of numerous programmable machine tools connected by an automated material handling system and controlled by a common computer network FMS combines flexibility with efficiency FMS layouts differ based on

variety of parts that the system can process size of parts processed average processing time required for part completion

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Full-Blown FMS

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Mixed Model Assembly Lines

Produce multiple models in any order on one assembly line Issues in mixed model lines
Line balancing U-shaped line Flexible workforce Model sequencing
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Balancing U-Shaped Lines

Precedence diagram:

Cycle time = 12 min

(a) Balanced for a straight line

A,B C,D E

(b) Balanced for a U-shaped line

A,B

9 min Efficiency =

12 min

3 min
C,D

24 24 = = .6666 = 66.7 % 3(12) 36

24 24 = = 100 % 12 min 2(12) 24 Copyright 2006 John Wiley & Sons, Inc. Efficiency =

12 min 7-30