CHAPTER 8: FACILITY LAYOUT LO8-1: Analyze the common types of manufacturing layouts. LO8-2: Illustrate layouts used in nonmanufacturing settings. CGapyrione 62017 MoGrawti Educaton. At igh vesseved.Layout Decisions : Facility layout: the process of determining placement of departments, workgroups within departments, workstations, machines, and stock-holding points within a facility » This process requires the following inputs: 1. Specification of the objectives used to evaluate the design Estimates of product or service demand Processing requirements Space requirements for the elements Space availability within the facility a bw Pp 82Basic Production Layout Formats — ses + Also called a jab-shop or functional layout » Similar equipment are grouped together = Assembly line * Also called a flow-shop layout + Work processes are arranged according to the steps by which the product is made [ee Manufacturing cell + Dissimilar machines are grouped to work on similar products mee | Project layout + Product remains at one locationee Workcenter Layout - Given + The flow (number of moves) to and from all departments. - The cost of moving from one department to another + The existing or planned physical layout of the plant - Determine + The “best” locations for each department, where best means maximizing flow, which minimizes costsee Example 8.1: Toy Factory : Goal is to arrange eight workcenters to minimize interdepartmental handling cost » Assume all workcenters have same space and fit in building : All material is transported in standard crates by forklift » Transportation costs are $1 to move between adjacent workcenters « Extra $1 for each workcenter in between———— Steps 4. Illustrate the interworkcenter flow by a model 2. Determine the cost of this layout 3. Search for workcenter location changes that will reduce costs BGExample 8.1: Interworkcenter Flow, and Building Dimensions and Workcenters Flow between WorkceatersiNumber of Moves} Warkcenter Activity Shippang and receiving Exhibits 8.1 and 8.2Example 8.1: Interworkcenter Flow Graph with Number of Annual Movements Exhibit 8.3Example 8.1: Cost Matrix—First Solution Total cost: $3,474 Exhibit 8.4Example 8.1: Revised Interworkcenter Flowchart and Cost Matrix—Second Solution Exhibits 85 and 8.6ee Systematic Layout Planning - Numerical flow of items between workcenters « Can be impractical to obtain - Does not account for the qualitative factors that may be crucial to the placement decision » Systematic layout planning - Accounts for the importance of having each department located next to every other department - Is also guided by trial and error » Switching workcenters then checking the results of the “closeness” score anSystematic Layout Planning for a Floor of a Department Store Exhibit 8.8 "Wat Chat ttn Tats aa —_ 23 Be 3S | Amati LC 0 2 pdt = 2 eee 0 RD ern ce 1 Cement va Cen dee 1 © iat og sas 2 [Ba 8 Sv a i se 2 ree tigate ns acted Seaeeert, a ieee om Seaman B42ee Assembly Line - Assembly line: progressive assembly linked by some material handling device - Some form of pacing is present and the allowable processing time is equivalent for all workstations - Important differences: ~ Material handling devices + Line configuration + Pacing + Product mix - Workstation characteristics » Length B13sy Takt Time Net Production Tune Waster oF Ua Proaaees Assembly-Line Design Cycle Time = + Cycle time: a uniform time interval in which a movi series of workstations Lead Time = Onder Gelwored - Onder Received + Also the time between successive units coming off the | @ «—-« - Assembly-line balancing: assigning all tasks to a series of workstations so that each workstation has no more than can be done in the cycle time + Precedence relationship: the order in which tasks must be performed in the assembly process Eee the time it takes for a team to make a product, while jeasures the time between the customer order and order fulfillment. Lead time is always longer than cycle time because cycle time fits into the timeline of lead time. C¥ele Time is the amount of time a team spends actually working on producing an item, up until the product is ready for shipment, It is the time it takes to complete one task. RRB: Lead time is the time measured from the moment a client puts in an order to when the final product gets delivered. is the rate at which you need to complete a product in order to meet customer demand. B44Assembly-Line Balancing 4 2. 7 em Specify the sequential relationships among tasks Determine the required cycle time Determine the theoretical minimum number of workstations Select a primary and secondary assignment rule Assign tasks Evaluate the efficiency of the balance Rebalance if needed B15ee Assembly-Line Balancing Formula . _ Production time per day Cycle time C = Required output per day (in units) ‘ reir, Sum of task times (T. - Theoretical minimum N, = Sut oF emebintes ia) Cycle time (C) (No of workstations= Ni) Sum of task times (T) A A f. f y Actual number of workstations (Nq) xCycle time (C) B16———— Example 8.2: Assembly Steps and Times Task Time Tasks That Tosk —(inseeonds) Description Must Precede A 45 Position rear axle support and hand fasten four - serous to nuts. 8 i Insert rear atte a c 9 Tighten rear axlo suppart screws to nuts: B D 50 Postion front ake assembly and hand faston with = four serews to nuts. E 1s. Tiahiten front axle assembly screws. D F 12 Postion rear Wheel #1 abd fasten hubcap. = 6 12 Postion rear wheel #2 and fasten hubtcap, ¢ 4 12 Position front wheel #1 and fasten hubeap, E ! 12 Position front wheel #2 and fasten hulcap. E J 8 Position wagon handle shaft on front axle. assembly FGHI ‘and hand fasten bolt ana nut x ay ‘Tighten bolt and rut J 155 Exhibit 8.94 BazExample: Precedence Graph Exhibit 8.98eee Example: C and N, C= Production time perday _ 60sec. x 420 min Output per day 500 wagons _T _ 195seconds = = oe =3 87 4 C 50.2 secondsee Example: Assignment Tal i { Exhibit 8.104 and & oe rvs) Tinw (hsasenty * 50 wi 16 * 2 2 2 2 ® i eaue ase Rewsihls Fuckin TE wi ge RewiningTadn —Falowers Option Toms None - Nore ce ce e cK < Foi FaKI Rani None HI n Ke 4 None “None ws3 Ree Wws1 Mee, Oe. } SB @ wss Sse Sse. tee. Be hee oe -8 ___s_-® ai 8-20Example: Efficiency 195 Efficiency = —— = ——, =0.77 =77% Miclency =~ a= 550.4) ° Exhibit 8.100 824———— Splitting Tasks That Are Too Long for the Gyde Tl Time Split the task » Can we split the task into two different tasks 2, Share the task » Can an adjacent workstation do part of the work 3. Use parallel workstations » Using parallel workstations doubles the cycle time available for the task 4, Use a more skilled worker - Cana more skilled worker complete the task faster 5, Work overtime + Use longer cycle time and make up needed production using overtime ~ Affects all workstations 6, Redesign - Can we redesign the product to save time 8-22ON Flexible Line Layouts cam trade elements of work. Cam aud and subtract ‘operators, Trained ones can nearly self-balance at different ¢Subassembly-Tine layout ‘nur pat rates. ince i common it American plants) each other, Might @ = ans Exhibit 8.11 Partialee Flexible Line Layouts Bad: Straight line difficult to balance. Better: One of several advantages of Uline is better operaior access. Here, five operators were reduced to four, Exhibit 8.11 Partial B24Mixed-Model Line Balancing : Most factories produce a number of different products + Inventory can be reduced by building some of each product during every period (e.g., day, week, etc.) - Mixed-model line balancing is one means of scheduling this varied production - Used by JIT manufacturers « Objective is to meet demand and avoid high inventories This approach often requires diligent efforts to reduce setup times and costs » Can significantly reduce overall inventory levels 8-25———— Example 8.3: Mixed-Model Line Balancing - Processing must be completed for both Model J and Model K wagons » Equal number of each model are required - Cycle time is 6 minutes for Model J and 4 minutes for Model K » In an 8-hour day, how should the models be processed? - We know 6K + 4J =480 and K = J » Solving gives us K = J =48 per day or 6 per hour 8-26———— Example 8.3: Mixed-Model Line Balancing Balanced Mixed-Model Sequence Model sequence Operation time Repeats 8 times: Minicycle time per day Total cycle time - Line balanced at six frames of each time per hour with a mini-cycle time of 12 minutes » Another balance is JKKJKJ + Times of 6, 4, 4,6, 4,6 » Produces 3J and 3K every 30 minutes with 10 minute mini-cycle timeee Cells - Cellular layouts allocate dissimilar machines into cells » Widely used in metal fabricating, computer chips manufacture, and assembly work » Objective is to gain the benefits of assembly lines with workcenter kinds of production 1. Better human relations 2. Improved operator expertise 3. Less in-process inventory and material handling 4. Faster production setup 828ee Developing a Manufacturing Cell 1. Grouping parts into families that fallow a common sequence of steps Identifying dominant flow patterns of parts families as a bases for location of processes Physically grouping machines and processes into cells 829Example: Original Workcenter Layout———— Example: Routing Matrix Based upon Flow of Parts Exhibit 8.128 8-31Example: Reallocating Machines to Form Cells — |) Cell One — (oJ HT) Cell Two +e Cell Three ‘Call Four Exhibit 8.12¢Project Layout : Is characterized by a relatively low number of production units + Visualize the product as the hub of a wheel with materials and equipment arranged concentrically around the production point : Ahigh degree of task ordering is common + To the extent that this precedence determines production stages, a project layout might be developed by arranging materials according to their technological priority 8-43ee Retail Service Layout : Goal is to maximize net profit per square foot of floor space « Servicescapes + Ambient conditions » Background characteristics, such as noise + Spatial layout and functionality + Planning the circulation path of customers and grouping merchandise + Signs, symbols, and artifacts + Parts of the service that have social significance 8-34ee Alternative Store Layouts aay ee | =. eas wes .——_ 1 a “Rectansiat Layemt | “Ami Laat Exhibit 8.14 835ee Marketing Research and Retail Layout 4. People in supermarkets tend to follow a perimeter pattern in their shopping behavior 2. Sale merchandise placed at the end of an aisle in supermarkets almost always sells 3. Non-selling departments should be placed either on upper floors or in “dead” areas 4. Locations nearest the store entrances and adjacent to front window displays are most valuable 8-36ee Office Layout - More open offices » Low divider walls - Fewer walls fosters greater communication and teamwork - Size and orientation of desks indicates importance of people behind them 8-47Summary : The focus is on understanding the quantitative techniques used to design manufacturing layouts - Workcenter, assembly line, manufacturing cell, and project layouts - Workcenter layouts involve arranging functional workcenters to optimize the flow between these areas » Assembly-line design is centered on defining the work content of workstations spaced along the line + Assembly-line balancing » Manufacturing cells are used for lower volume settings - Other types of layouts include those used in retail stores and offices a8Practice Exam 1. Three terms commonly used to refer to a layout where similar equipment or functions are grouped together 2. Alayout where the work ta make an item is arranged in progressive steps and work is moved between the steps at fixed intervals of time 3. Ameasure used to evaluate a workcenter layout 4. This is a way to shorten the cycle time for an assembly line that has a task time that is longer than the desired cycle time » Assume that it is not possible to speed up the task, split the task, use overtime, or redesign the task 5. This involves scheduling several different models of a product to be produced over a given day or week on the same line in a cyclical fashionPractice Exam continued 6. If you wanted to produce 20 percent of one product (A), 50 percent of another (B), and 30 percent of a third product (C) in a cyclic fashion, what schedule would you suggest 7. Aterm used to refer to the physical surroundings in which a service takes place and how these surroundings affect customers and employees 8. Afirm is using an assembly line and needs to produce 500 units during an eight-hour day ~ What is the required cycle time in seconds 9. Whatis the efficiency of an assembly line that has 25 workers and a cycle time of 45 seconds + Each unit produced on the line has 16 minutes of work that needs to be completed based on a time study completed by engineers at the factory 40