Designing
Layouts
Designing
Layouts
OUTLINE
Designing Process Layouts
Designing Product Layouts
Designing GT (Cellular) Layouts
Manufacturing Process Layout
Milling
Lathe Department Department Drilling Department
L L M M D D D D
L L M M D D D D
L L G G G P
L L G G G P
Grinding Painting Department
L L Department
Receiving and A A A
Shipping Assembly
A Product Layout
IN
OUT
Comparison PRODUCT LAYOUT PROCESS LAYOUT
1. Description Sequential arrangement Functional
Of Product grouping
And Process of machines of machines
Layouts 2. Type of Process Continuous, mass Intermittent, job shop
production, mainly batch production,
assembly mainly fabrication
3. Product Standardized Varied,
made to stock made to order
4. Demand Stable Fluctuating
5. Volume High Low
6. Equipment Special purpose General purpose
7. Workers Limited skills Varied skills
PRODUCT LAYOUT PROCESS LAYOUT
8. Inventory Low in-process, High in-process,
Comparison high finished goods low finished goods
Of Product 9. Storage space
10. Material
Small
Fixed path
Large
Variable path
And Process handling (conveyor)
Layouts 11. Aisles
(forklift)
Narrow Wide
12. Scheduling Part of balancing Dynamic
13. Layout decision Line balancing Machine location
14. Goal Equalize work at Minimize material
each station handling cost
15. Advantage Efficiency Flexibility
Designing Process Layouts
Objective: Minimize Total material handling costs
minimize nonadjacent loads
Block Diagramming use when quantitative data is available
based on location preference between areas
Relationship Diagramming use when quantitative data is not available
Create Create load summary chart
Block
Diagramming
Calculate Calculate
movements
composite (two way)
Develop Develop trial layouts minimizing
number of nonadjacent loads
Block Diagramming Example
LOAD SUMMARY CHART
DEPARTMENT
DEPT. 1 2 3 4 5
1 100 50
2 200 50
3 60 40 50
4 100
5 50 60
Initial & Final Designs
Block Diagrams
Used when quantitative data
Relationship is not available
Diagramming
Muther’s grid displays
preferences
Denote location preferences
with weighted lines
Ranking A - absolutely necessary
System For E - especially important
Departments
I - important
O - okay
U - unimportant
X - undesirable
Relationship Diagramming
Example
Production
O
Offices A
U I
Stockroom O E
A X A
Shipping and Receiving U U
U O
Locker Room O
O
Toolroom
Original Layout
Revised Layout
Product layouts or assembly lines
Designing
Product Develop precedence diagram of tasks
Layouts
Jobs divided into work elements
Assign work elements to workstations
Try to balance the amount work of each
workstation
Precedence diagram
•network showing required
Line Balancing order of tasks
Cycle time
•maximum time product
spends at any one
workstation
Flow Time vs Cycle Time
Flow time = time to complete all stations
Cycle time = max time spent at any station
1 2 3 Flow time = 4 + 5 + 4 = 13
Cycle time = max (4, 5, 4) = 5
4 min 5 min 4 min
Drawing A Precedence Example
Work element Precedence time
A. Press out sheet of fruit - 0.1
B. Cut into strips A 0.2
C. Outline fun shapes A 0.4
D. Roll up and package B, C 0.3
B 0.2
0.1 A D 0.3
C
0.4
Computing Cycle Time
C = maximum time product spends at station
production time available
C=
desired units of output
Produce 6,000 units per 40 hour week
40 hours x 60 minutes / hour 2,400
C= = = 0.4 minutes
6,000 units 6,000
Balancing The Line
Workstation Task Time (remaining) Feasible tasks
1 A 0.1 (0.3) B
B 0.2 (0.1) none
2 C 0.4 (0.0) none
3 D 0.3 (0.1)
1 2 3
A, B C D
0.3 min 0.4 min 0.3 min
Calculating Efficiency
j j
t i t i
Theoretical min # stations = i =1
Efficiency = i =1
C nC
0.1+ 0.2 + 0.3 + 0.4 0.1+ 0.2 + 0.3 + 0.4
= = 2.5 = = 83.3%
0.4 3(0.4)
Solution Trial and error method of
Methods line balancing
Computerized line
balancing
U-shaped Line Improves
Efficiency
Hybrid Layouts
Cellular layouts
Flexible Manufacturing Systems
Mixed Model Assembly Lines
Cellular Layouts
Identify families of parts with similar flow paths
Group machines into cells based on part families
Identifying dominant flow patterns of parts families as a basis for location or
relocation of processes.
Arrange cells so parts movement is minimized
Locate large shared machines at point of use
A GT Cell
Machine 2
Machine 3
Machine 1
Materials in
Finished
goods out
Machine 4
Machine 5
Group Technology Layout
Product layouts with low-volume processes.
Creates cells not limited to just one worker and groups parts or products
with similar characteristics into families and sets aside groups of machines
for production.
Goal is to minimize setup or changeovers for similar processing
requirements
Original Process Layout
Assembly
4 6 7 9
5 8
2 10 12
1 3 11
A B C Raw materials
Part Routing Matrix
MACHINES
PARTS 1 2 3 4 5 6 7 8 9 10 11 12
A x x x x x
B x x x
C x x x
D x x x x x
E x x x
F x x x
G x x x x
H x x x
Part Routing Matrix
Reordered To Highlight Cells
MACHINES
PARTS 1 2 4 8 10 3 6 9 5 7 11 12
A x x x x x
D x x x x x
F x x x
C x x x
G x x x x
B x x x
H x x x
E x x x
Cellular Layout Solution
Assembly
8 10 9 12
11
4 Cell1 6 Cell 3
Cell 2
7
2 1 3 5
Raw materials A C B
Reduced material handling and transit time
Advantages Of Reduced setup time
Cellular
Layouts Reduced work-in-process inventory
Better use of human resources
Improved operator expertise
Easier to control
Easier to automate
Disadvantages Of Cellular
Layouts
Inadequate part families
Poorly balanced cells
Expanded training and scheduling of workers
Increased capital investment
Flexible Manufacturing Systems
Automated machining Automated material Automated tool
operations handling changers
Designed around size
Can process wide
Computer controlled of parts processed &
variety of items
system average processing
quickly
time for parts
FMS Layouts
Open Field FMS Layout
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
Your best quote that reflects your
approach… “It’s one small step for
man, one giant leap for mankind.”
- NEIL ARMSTRONG
