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Copyright 2006 John Wiley & Sons, Inc.Copyright 2006 John Wiley & Sons, Inc.Beni AsllaniBeni Asllani

University of Tennessee at ChattanoogaUniversity of Tennessee at Chattanooga

FacilitiesFacilitiesOperations Management - 5 th Edition

Operations Management - 5 th Edition

Chapter 7 Chapter 7

Roberta Russell & Bernard W. Taylor, IIIRoberta Russell & Bernard W. Taylor, III

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Copyright 2006 John Wiley & Sons, Inc.Copyright 2006 John Wiley & Sons, Inc. 7-7-22

Lecture OutlineLecture Outline

Basic Layouts

Designing Process LayoutsDesigning Service LayoutsDesigning Product Layouts

Hybrid Layouts

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Facility LayoutFacility Layout

Minimize material-handlingcostsUtilize space efficientlyUtilize labor efficientlyEliminate bottlenecksFacilitate communication andinteraction

Reduce manufacturing cycletimeReduce customer service timeEliminate wasted or redundantmovementIncrease capacity

Facilitate entry, exit, and placementof material, products, and peopleIncorporate safety and securitymeasuresPromote product and service qualityEncourage proper maintenanceactivitiesProvide a visual control of activities

Provide flexibility to adapt to changingconditions

Arrangement of areas within a facility to:

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BASIC LAYOUTS

Process layoutsgroup similar activities together according

to process or function they performProduct layoutsarrange activities in line according tosequence of operations for a particularproduct or service

Fixed-position layoutsare used for projects in which productcannot be moved

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Process Layout in ServicesProcess Layout in Services

Womenslingerie

Womensdresses

Womenssportswear

Shoes

Cosmeticsand jewelry

Entry anddisplay area

Housewares

Childrensdepartment

Mensdepartment

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Manufacturing Process LayoutManufacturing Process Layout

L

L

L

L

L

L

L

L

L

LM

M

M

M

D

D

D

D

D

D

D

D

G

G

G

G

G

G

A A AReceiving andShipping Assembly

Painting Department

Lathe Department MillingDepartment Drilling Department

GrindingDepartment

P

P

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7/47Copyright 2006 John Wiley & Sons, Inc.Copyright 2006 John Wiley & Sons, Inc. 7-7-77

A Product LayoutA Product Layout

InIn

OutOut

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Description

Type of process

Product

DemandVolumeEquipment

Description

Type of process

Product

DemandVolumeEquipment

Sequentialarrangement ofactivitiesContinuous, massproduction, mainlyassembly

Standardized, madeto stockStableHighSpecial purpose

Process

Comparison of ProductComparison of Product

and Process Layoutsand Process Layouts

Functionalgrouping ofactivitiesIntermittent, jobshop, batchproduction, mainlyfabricationVaried, made toorderFluctuatingLowGeneral purpose

Product

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WorkersInventory

Storage spaceMaterial handlingAislesScheduling

Layout decisionGoal

Advantage

WorkersInventory

Storage spaceMaterial handlingAislesScheduling

Layout decisionGoal

Advantage

Limited skillsLow in-process, high

finished goodsSmallFixed path (conveyor)NarrowPart of balancing

Line balancingEqualize work at eachstationEfficiency

Process

Comparison of ProductComparison of Product

and Process Layoutsand Process LayoutsVaried skillsHigh in-process, low

finished goodsLargeVariable path (forklift)WideDynamic

Machine locationMinimize materialhandling costFlexibility

Product

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Fixed-Position LayoutsFixed-Position Layouts

Typical of projectsTypical of projectsEquipment, workers,Equipment, workers,materials, othermaterials, otherresources brought to theresources brought to thesitesiteHighly skilled laborHighly skilled labor

Often low fixedOften low fixedTypically high variableTypically high variablecostscosts

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Designing Process LayoutsDesigning Process Layouts

Goal: minimize material handling costsGoal: minimize material handling costsBlock DiagrammingBlock Diagramming

minimize nonadjacent loadsminimize nonadjacent loadsuse when quantitative data is availableuse when quantitative data is available

Relationship DiagrammingRelationship Diagrammingbased on location preference between areasbased on location preference between areasuse when quantitative data is not availableuse when quantitative data is not available

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Block DiagrammingBlock Diagramming

Unit loadUnit loadquantity in whichquantity in which

material is normallymaterial is normallymovedmoved

Nonadjacent loadNonadjacent loaddistance fartherdistance fartherthan the next blockthan the next block

STEPSSTEPScreate load summary chartcreate load summary chartcalculate composite (twocalculate composite (twoway) movementsway) movementsdevelop trial layoutsdevelop trial layoutsminimizing number ofminimizing number ofnonadjacent loadsnonadjacent loads

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Block Diagramming: ExampleBlock Diagramming: Example

Department Department 11 2 2 33 44 5 5

Load Summary ChartLoad Summary Chart

FROM/TOFROM/TO DEPARTMENTDEPARTMENT

11 100100 505022 200200 505033 6060 4040 5050

44 100100 606055 5050

1 2 3

4 5

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Block Diagramming:Block Diagramming:

Example (cont.)Example (cont.)2 3 200 loads2 4 150 loads

1 3 110 loads1 2 100 loads4 5 60 loads3 5 50 loads2 5 50 loads3 4 40 loads1 4 0 loads1 5 0 loads

1 2 3

4 5

100 200

150 50 50

60

40

110

Grid 1

Nonadjacent Loads:110+40=150

1 2

3

4

5

100

200

150

50

50 6040110

Grid 2

Nonadjacent Loads:0

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Block Diagramming:Block Diagramming:

Example (cont.)Example (cont.)

12

3

4

53

2

5

1 4

(a) Initial block diagram(a) Initial block diagram (b) Final block diagram(b) Final block diagram

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Relationship DiagrammingRelationship Diagramming

Schematic diagram thatSchematic diagram that

uses weighted lines touses weighted lines todenote location preferencedenote location preferenceMuthers gridMuthers grid

format for displayingmanager preferences fordepartment locations

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RelationshipRelationship

Diagramming: ExampleDiagramming: ExampleProductionProduction

OfficesOffices

StockroomStockroom

Shipping andShipping andreceivingreceiving

Locker roomLocker room

ToolroomToolroom

AA AA

AA

OO

OO

OOOO

OO

UU

UUUU

UU

EEXX

II

A Absolutely necessaryE Especially importantI ImportantO OkayU UnimportantX Undesirable

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Relationship Diagrams: Example (cont.)Relationship Diagrams: Example (cont.)

(a) Relationship diagram of original layout(a) Relationship diagram of original layout

Key:Key: AAEEII

OOUUXX

OfficesOffices

StockroomStockroom

Locker Locker roomroom

ToolroomToolroom

ShippingShippingandand

receivingreceiving

ProductionProduction

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(b) Relationship diagram of revised layout(b) Relationship diagram of revised layout

OfficesOffices

StockroomStockroom

Locker Locker roomroom

ToolroomToolroom

ShippingShippingandand

receivingreceiving

ProductionProduction Key:Key: AAEEII

OOUUXX

Relationship Diagrams: Example (cont.)Relationship Diagrams: Example (cont.)

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Computerized layoutComputerized layout

SolutionsSolutionsCRAFT

Computerized Relative Allocation of FacilitiesTechnique

CORELAPComputerized Relationship Layout PlanningPROMODEL and EXTEND

visual feedbackallow user to quickly test a variety of scenarios

Three-D modeling and CADintegrated layout analysisavailable in VisFactory and similar software

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Designing Service

LayoutsMust be both attractive and functionalTypes

Free flow layoutsencourage browsing, increase impulse purchasing, are flexibleand visually appealing

Grid layoutsencourage customer familiarity, are low cost, easy to clean andsecure, and good for repeat customers

Loop and Spine layoutsboth increase customer sightlines and exposure to products,while encouraging customer to circulate through the entirestore

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Types of Store LayoutsTypes of Store Layouts

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Designing Product

LayoutsObjective

Balance the assembly line

Line balancingtries to equalize the amount of work at each workstationPrecedence requirements

physical restrictions on the order in which operations areperformed

Cycle timemaximum amount of time a product is allowed to spend ateach workstation

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Cycle Time ExampleCycle Time Example

C d =production time available

desired units of output

C d =(8 hours x 60 minutes / hour)

(120 units)

C d = = 4 minutes480120

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Flow Time vs Cycle TimeFlow Time vs Cycle Time

Cycle time = max time spent at any stationCycle time = max time spent at any stationFlow time = time to complete all stationsFlow time = time to complete all stations

1 2 3

4 minutes4 minutes 4 minutes4 minutes 4 minutes4 minutes

Flow time = 4 + 4 + 4 = 12 minutesFlow time = 4 + 4 + 4 = 12 minutesCycle time = max (4, 4, 4) = 4 minutesCycle time = max (4, 4, 4) = 4 minutes

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Line Balancing ProcedureLine Balancing Procedure

1. Draw and label a precedence diagram2. Calculate desired cycle time required for the line

3. Calculate theoretical minimum number of workstations4. Group elements into workstations, recognizing cycle timeand precedence constraints

5. Calculate efficiency of the line6. Determine if the theoretical minimum number of

workstations or an acceptable efficiency level has beenreached. If not, go back to step 4.

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Line Balancing: ExampleLine Balancing: ExampleWORK ELEMENTWORK ELEMENT PRECEDENCEPRECEDENCE TIME (MIN)TIME (MIN)

AA Press out sheet of fruitPress out sheet of fruit 0.10.1BB Cut into stripsCut into strips AA 0.20.2CC Outline fun shapesOutline fun shapes AA 0.40.4DD Roll up and packageRoll up and package B, CB, C 0.30.3

0.10.1

0.20.2

0.40.4

0.30.3D

B

C

A

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Line Balancing: Example (cont.)Line Balancing: Example (cont.)WORK ELEMENTWORK ELEMENT PRECEDENCEPRECEDENCE TIME (MIN)TIME (MIN)

AA Press out sheet of fruitPress out sheet of fruit 0.10.1BB Cut into stripsCut into strips AA 0.20.2CC Outline fun shapesOutline fun shapes AA 0.40.4DD Roll up and packageRoll up and package B, CB, C 0.30.3

C d

= = = 0.4 minute40 hours x 60 minutes / hour

6,000 units

2400

6000

N = = = 2.5 3 workstations1.00.4

0.1 + 0.2 + 0.3 + 0.40.4

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A, B C D

Workstation 1

Workstation 2

Workstation 3

0.3minute

0.4minute

0.3minute

C C d d = 0.4= 0.4 N N = 2.5= 2.5

E = = = 0.833 = 83.3%0.1 + 0.2 + 0.3 + 0.4

3(0.4)1.01.2

Line Balancing: Example (cont.)Line Balancing: Example (cont.)

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Hybrids LayoutsHybrids Layouts

Cellular layoutsgroup dissimilar machines into work centers(called cells) that process families of parts withsimilar shapes or processing requirements

Flexible manufacturing systemautomated machining and material handlingautomated machining and material handlingsystemssystems which can produce an enormous varietyof items

Mixed-model assembly lineprocesses more than one product model in oneline

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Cellular Layouts

1.1. Identify families of parts with similarIdentify families of parts with similarflow pathsflow paths

2.2. Group machines into cells based onGroup machines into cells based onpart familiespart families

3.3. Arrange cells so material movementArrange cells so material movement

is minimizedis minimized4.4. Locate large shared machines atLocate large shared machines at

point of usepoint of use

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Parts FamiliesParts Families

A family of A family of similar partssimilar parts

A family of relatedA family of relatedgrocery itemsgrocery items

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Original Process LayoutOriginal Process Layout

CA B Raw materials

Assembly

1

2

3

4

5

6 7

8

9

10

11

12

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Part Routing MatrixPart Routing Matrix

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

A x x x x x

B x x x xC x x xD x x x x xE x x x

F x x xG x x x xH x x x

Figure 5.8Figure 5.8

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Revised Cellular LayoutRevised Cellular Layout

3

6

9

Assembly

12

4

8 10

5

7

11

12

A B CRaw materials

Cell 1 Cell 2 Cell 3

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Reordered Routing MatrixReordered Routing Matrix

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

A x x x x x

D x x x x xF x x xC x x xG x x x x

B x x x xH x x xE x x x

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Automated Manufacturing CellAutomated Manufacturing Cell

Source: J. T. Black, Cellular Manufacturing Systems Reduce SetupTime, Make Small LotProduction Economical. Industrial

Engineering (November 1983)

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Advantages and DisadvantagesAdvantages and Disadvantages

of Cellular Layoutsof Cellular LayoutsAdvantages Advantages

Reduced material Reduced material

handling and transit time handling and transit time Reduced setup time Reduced setup time Reduced work-in- Reduced work-in- process inventory process inventory Better use of human Better use of human

resources resources Easier to control Easier to control Easier to automate Easier to automate

Disadvantages Disadvantages Inadequate part families Inadequate part families

Poorly balanced cells Poorly balanced cells Expanded training and Expanded training and scheduling scheduling of workers of workers Increased capital Increased capital

investment investment

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Flexible ManufacturingFlexible Manufacturing

Systems (FMS)Systems (FMS)FMS consists of numerous programmablemachine tools connected by an automatedmaterial handling system and controlled bya common computer networkFMS combines flexibility with efficiencyFMS layouts differ based on

variety of parts that the system can process

size of parts processedaverage processing time required for partcompletion

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Full-Blown FMS

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Mixed ModelMixed Model

Assembly LinesAssembly LinesProduce multiple models in any orderProduce multiple models in any order

on one assembly lineon one assembly lineIssues in mixed model linesIssues in mixed model lines

Line balancingLine balancing

U-shaped lineU-shaped lineFlexible workforceFlexible workforceModel sequencingModel sequencing

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Balancing U-Shaped LinesBalancing U-Shaped Lines

A B C

D E

Precedence diagram:Precedence diagram:

Cycle time = 12 minCycle time = 12 min

A,B C,D E

(a) Balanced for a straight line(a) Balanced for a straight line

9 min9 min 12 min12 min 3 min3 min

Efficiency = = = .6666 = 66.7 %Efficiency = = = .6666 = 66.7 %24243636

24243(12)3(12)

12 min12 min 12 min12 min

C,D

A,B

E

(b) Balanced for a U-shaped line(b) Balanced for a U-shaped line

Efficiency = = = 100 %Efficiency = = = 100 %2424

2424

2424

2(12)2(12)

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