Learning Objectives. Facility Layout. Layout. Strategic Importance of Layout. Layout Strategy Concerns. Importance of Layout Decisions
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1 Learning Objectives Facility Layout Dr. Richard Jerz List some reasons for redesign of layouts. Describe the basic layout types. List the main advantages and disadvantages of product layouts and process layouts. Understand line-balancing problems. 1 2 Layout Layout: the configuration of departments, work centers, and equipment, with particular emphasis on movement of work (customers or materials) through the system Strategic Importance of Layout Proper layout enables: Higher utilization of space, equipment, and people Improved flow of information, materials, or people Improved employee morale and safer working conditions Improved customer/client interaction Flexibility Cost, time, utilization 3 Layout Strategy Concerns Importance of Layout Decisions Requires substantial investments of money and effort Involves long-term commitments Has significant impact on cost and efficiency of short-term operations 6 7 1
2 Basic Layout Types Process, or Functional Layout Process Layout Layout that can handle varied processing requirements Product Layout Layout that uses standardized processing operations to achieve smooth, rapid, highvolume flow Fixed Position Layout Layout in which the product or project remains stationary, and workers, materials, and equipment are moved as needed 8 9 Designing Process Layouts Developing a Process Layout Requirements: List of departments Projection of work flows Distance between locations Amount of money to be invested List of special considerations 1. Construct a from-to matrix 2. Determine space requirements for each department 3. Develop an initial schematic diagram. Determine the cost of this layout 5. By trial-and-error (or more sophisticated means), try to improve the initial layout 6. Prepare a detailed plan that evaluates factors in addition to transportation cost To-From Diagram Product Layout
3 A Flow Line for Production or Service Work Cells Reorganizes people and machines into groups to focus on single products or product groups Group technology identifies products that have similar characteristics for particular cells Volume must justify cells Cells can be reconfigured as designs or volume changes 1 15 Group Technology: Workcells Cellular Manufacturing Layout Part A Lathe Gear cut Part B Part C Lathe Grind Grind Assembly Part D Gear cut A U-Shaped Production Line Advantages of Work Cells In Out Workers Reduced work-in-process inventory Less floor space required Reduced raw material and finished goods inventory Reduced direct labor Heightened sense of employee participation Increased use of equipment and machinery Reduced investment in machinery and equipment
4 Fixed-Position Layout Layout Variables to Evaluate Example: Airplanes Design is for stationary project Workers and equipment come to site Complicating factors Limited space at site Changing material needs Equipment utilization People utilization Inventory Inspection Transportation Cycle time Computer Programs for Layout Computerized Layout CRAFT SPACECRAFT CRAFT 3-D MULTIPLE CORELAP ALDEP COFAD FADES - expert system Computerized Layout Design Product Layouts: Line Balancing Line Balancing is the process of assigning tasks to workstations in such a way that the workstations have approximately equal time requirements. Objectives Maximize efficiency Minimize number of work stations 2 25
5 Precedence Diagram Precedence diagram: Tool used in line balancing to display elemental tasks and sequence requirements 0.1 min. a 0.7 min. 1.0 min. b c d e 0.5 min. 0.2 min. Assembly Line Balancing Equations Cycle time = Cycle time Minimum Minimum number of of work stations Efficiency = = Production time available Production time available Demand per day Demand per day ΣTask times times Cycle time time ΣΣ Task times (Actual number of of * (Cycle time) * (Cycle time) work stations) Line Balancing Rules Some Heuristic (intuitive) Rules: Assign largest tasks first Assign tasks in order of most following tasks. Assign tasks in order of greatest positional weight. Positional weight is the sum of each task s time and the times of all following tasks. Improving Line Balance Smaller time elements Better methods analysis Better tools Buffers Parallel workstations
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