Facilities Planning and Layout
Facilities Planning and Layout
Facilities Planning and Layout
Agenda
Definitions
Introduction
Facilities Planning
Types of facilities layout problems
The objectives of facility layout
Requirements of layout
y strategy
gy By: NEHAL ELSAYAR
Basic types of layout
9 Layout by product
9 Layout by process
9 Layout by fixed material location To: Dr. / Ashraf S. Youssuf
Which type of layout to use
Factors affecting facility layout
Layout design procedure
Comparative analysis of layout types
2 1
layout
From: The Oxford Pocket Dictionary of Current English / Date: Definitions
2008
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Yes
Facilities Facility Layout Handling Systems Develop & evaluate alternative plans
Systems Design Design Design
10
Select & implement plan 9
12 11
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Jobbing processes
Relative positioning of Allocation of tasks to Functional layout
transforming resources transforming resources
Service shops
Batch processes
Cell layout
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Volume
Lathe Press Grind High Product
W Planning
S a Department
t r
o Product
P d t
e
r
Production Layout Product
h
a o volume Family
g
Medium Fixed Location
Planning
Process
u Department
e s Layout Layout
e Group Technology
Fixed Materials Layout Process
Location
Planning
Weld Paint Assembly Planning
Department
Department
Low
Low Medium High Variety
26
Product variety 25
This is the layout for project type systems in which the major
component is kept at a fixed position and all other materials,
components, tools, machines, workers etc. are brought and
assembly or fabrication is carried out.
Thi ttype off layouts
This l t is
i now nott usedd very commonly l ads
d ththe
machines required for manufacturing work are big and
complicated.
The fixed position layout is used only when it is difficult to move
the major component and fabrication is to be carried out e.g.
production of ships.
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Limitations:
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sack
iii. Total production time is usually longer.
iv. Comparatively large amounts of in-process inventory
Enquiries
Current
journals result.
v. Space and capital are tied up by work in process.
vi. Because of the diversity of the jobs in specialized
Reference departments, higher grades of skill are required.
section
Reserve
collection
Store Counter staff
room Copying area
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Entrance Exit
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• Conversion of a process focused layout into a miniature version of a product The single row layout may assume different configuration such as semi-circular, linear
layout to increase productivity. or U-shaped. The machines in the single row layout are arranged as close as
possible to the sequence of operations of all the parts processed in the layout in
• Dissimilar machines are grouped together into work cells to perform work to order to minimize traveling time.
produce goods that can be grouped into families on the basis of common
processing requirements, materials, geometrical shape, size, weight, function. In this layout, the sequence of operations are normally similar from one part to another
andd the
h material
i lh
handling
dli equipment
i usedd are normallyll conveyors.
• These cells are temporary and can shrink or expand in size based upon product
demand.
• Flexible Manufacturing Systems represent a special case of group technology The multi-row layout is usually linear and the movements of parts can be between
by integrating computer aided manufacturing systems and automated material any machines in different rows as well as in the same row, which is suitable for
flow using computer controlled machines for a wide range of manufacturing FMS.
operations.
• Example: production of components for a medical device such as a pace maker. In the loop layout, machines are arranged in an oval path with unidirectional
A cell can be assigned to produce and be responsible for inspection of a movement.
complete component.
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5 8
2 10 12
1 3 11 Work Cell
Tool Room
A B C Raw materials
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Machines Machines
Parts 1 2 4 3 5 6 7 8 9 10 11 12 Parts 1 2 4 3 5 6 7 8 9 10 11 12
A x x x x x A x x x x x
D x x x x x B x x x x
B x x x x C x x x
C x x x D x x x x x
E x x x E x x x
F x x x F x x x
G x x x x G x x x x
H x x x 58
H x x x 57
Machines Machines
Parts 1 2 4 8 3 5 6 7 9 10 11 12 Parts 1 2 4 8 3 5 6 7 9 10 11 12
A x x x x x A x x x x x
D x x x x x D x x x x x
F x x x B x x x x
B x x x x C x x x
C x x x E x x x
E x x x F x x x
G x x x x G x x x x
H x x x 60
H x x x 59
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Machines Machines
Parts 1 2 4 8 10 3 6 9 5 7 11 12 Parts 1 2 4 8 10 3 5 6 7 9 11 12
A x x x x x A x x x x x
D x x x x x D x x x x x
F x x x F x x x
C x x x B x x x x
G x x x x C x x x
B x x x x E x x x
E x x x G x x x x
H x x x 62
H x x x 61
Assembly
Lathe Drill Grind Drill
S
A W 8 10 9 12
s a
t s r
Press Bend Drill
o e
r
e
m h 11
a b o 4 Cell1 6 Cell 3
g
Mill Drill l u Cell 2
e y s
e 7
Lathe Lathe Drill
2 1 3 5
Raw materials A C B
64 Each of A, B, C now visits only one area, minimizing jumping 63
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Advantages
Limitations i. Since the layout corresponds to the sequence of operations, smooth and logical
flow lines result.
i. A breakdown of one machine may lead to a complete stoppage of the line that ii. Since the work from one process is fed directly into the next, small in-process
follows that machine. inventories result.
ii
ii. Since the layout is determined by the product
product, a change in product design may iii.
iii Total
T t l production
d ti ti time per unitit is
i short.
h t
require major alternations in the layout.
iv. Since the machines are located so as to minimize distances between consecutive
iii. The “pace” of production is determined by the slowest machine. operations, material handling is reduced.
iv. Supervision is general, rather than specialized. v. Little skill is usually required by operators at the production line; hence, training is
v. Comparatively high investment is required, as identical machines (a few not fully simple, short, and inexpensive.
utilized) are sometimes distributed along the line. vi. Simple production planning control systems are possible.
vii. Less space is occupied by work in transit and for temporary storage.
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layout
Starter
buffet
buffet
cafeteria
BM TM TM
Main course
buffet Service line
Preparation
Oven
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The fixed position layout is used ideally for a project situation i.e. Fixed
Functional Cell Product
for one product of a different type. position
layout layout layout layout
As the quantity increases the production operations can be broken
Very high product High product and Can give good
down into different work centers and material can be allowed to and mix flexibility. mix flexibility. compromise. Low unit costs for
move rather than the machines,, and a p process layout
y is Product/customer
P d t/ t Relatively
R l ti l robust
b t F t throughput.
Fast th h t
high volume.
74 73
Fixed-position
layout
Regular flow morre feasible
Process
layout
Variety
Cell layout
Product
layout
Low
Flow
becomes
continuous 76 75
Regular flow more important
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Cell layout
Use Use
Use product Mass services
Use fixed- functional cell Mass processes
position Product layout
Volume Continuous processes
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Fixed-position
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• Cells are a compromise between the flexibility of • Complex due to large number of options possible
process layout and the simplicity of product layout • Flow charts and relationship charts
• Design of cell layout requires decisions as to • Some of the information requirements
• Extent and nature of cells to adopt – examining • Area required by each work centre
amount and of resources located within the cell • Constraints on the shape of work area allocated
• Resources to allocate to cells – cluster analysis / • Degree and direction of flow between work areas
parts family coding
• Desirability of work centres proximity to each other
• Production flow analysis or to fixed points in the layout
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Product Layout
Cycle time of product layouts
• Time between completed products /
services emerging from the operation Decisions required are:
• Calculated using projected demand for • What cycle time is needed?
period and the amount of production time • How many stages are needed?
available in that period • How should the task-time variation be dealt
• Cycle time = time available / with?
number to be processed • How should the layout be balanced?
• How should the stages be arranged?
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SYSTEMATIC FACILITIES
PLANNING
Systematic:
Systematic:
Organized, disciplined rational approach to a
problem
Facilities::
Facilities Systematic
y Layout
y Planning
g ((SLP))
Building, production & material handling
equipment, land, access (supporting
equipment)
Planning::
Planning
Decide a course of action based on facts and
analysis
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SYSTEMATIC FACILITIES
Systematic Layout Planning
PLANNING
• Systematic layout planning accounts for the Systematic Facilities Planning fits in this
importance of having each department located next
to every other department category:
– guided by trial and error Common Sense
– switch departments then check the results of the “closeness”
closeness
score
Pi E
Prior Experience
i
• Why us SLP? Simple Numerical Methods
– numerical flow of items between departments can be Visual Representations
impractical to obtain, or
– interdepartmental flow method does not account for any of
the qualitative factors that may be crucial to the placement Practical Perceptiveness
decision
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Phase I LOCATION
IV
II OVERALL LAYOUT
Level off Detail
Time IV INSTALLATION
II
Phase I: Phase II: Phase III: Phase IV:
I
MFG
BLDG
NEW BLDG B
HIWAY
D D
A
MAIN
BLDG C
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Time
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O
X E
A
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Systematic Layout Planning (cont’d …2/7) Systematic Layout Planning (cont’d …1/7)
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Systematic Layout Planning (cont’d …4/7) Systematic Layout Planning (cont’d …3/7)
Therefore, its goal is to Minimize the Total The most widely known algorithm
Cost of Moving Items between Departments. requiring an Initial Layout developed by
It attempts to improve an Initial Layout by hand is the Computerized Relative
switching the locations of pairs of All
Allocation
ti off Facilities
F iliti Technique
T h i
departments. (CRAFT).
It begins with one department, AND one by
CRAFT was developed for situations in
one Analyzes the effect on total travel cost of
switching those departments. which Materials Handling Costs were a
major consideration.
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Systematic Layout Planning (cont’d …6/7) Systematic Layout Planning (cont’d …5/7)
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Code Reason
1 Type of customer
CORELAP on the other hand, can lay
out only single story buildings.
2 E
Ease off supervision
ii
Both programs use closeness codes
3 Common personnel
defined in the Activity Relationship
4 Contact necessary
Charts.
5 Share same price
6 Psychology
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Scaled activity
relationship 4
diagram
A
E
I relationships
relationships
1 5 10 8
3 2 9
6 7
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Alternative
A small accounting Firm, GUNTAŞ Accounting, layouts
has rented Space in a new one-floor building.
The firm has allocated 6000 square meter to
its seven departments as follows:
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Some examples of Practical Limitations in this In this stage, there are no restrictions on
case were as follows:
the length and width of each department
1- It is considered that offices for partners
(2) the
(2), th meeting
ti room (7) and d the
th reception
ti In the final step, we should develop and
area (1) should be close to each other. evaluate several alternative layouts,
2- It is important that the juniors (4) and the while keeping in mind the Practical
managers (3) be close together. Limitations.
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Determine space arrangement Space relationship diagram • Include non-flow factors & combine with flow factors
plan • Determine space requirements
Fit space arrangement in to Floor plan • Fit space arrangement into available space
available space Detailed layout plan
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