Facility Layout

Facility Layout Defined

• Specific arrangement of physical facilities
• Can be defined as the process by which the placement of
departments, workgroups within departments, workstations,
machines, and stock-holding points within a facility are determined.
• Required when
1. A new facility is constructed
2. There is a significant change in demand
3. A new good or service is introduced to the customer benefit package
4. Different processes, equipment, and/or technology are installed.
• Objective of facility layout:
• To minimize delays in materials handling and customer movement
• To maintain flexibility
• To use labor and space effectively
• To promote high employee morale and customer satisfaction
• To minimize energy use and impact on environment
• To provide for good housekeeping and maintenance
• To enhance sales as appropriate in manufacturing and service facilities

• It support the ability of the operations to accomplish its mission.

Machine Objectives of Facility Layout
Arrangement of areas within a facility to:
• Minimize material-handling costs • Facilitate entry, exit, and placement of
• Utilize space efficiently material, products, and people
• Incorporate safety and security measures
• Utilize labor efficiently
• Eliminate bottlenecks • Promote product and service quality
• Facilitate communication and interaction • Encourage proper maintenance activities
• Provide a visual control of activities
• Reduce manufacturing cycle time
• Reduce customer service time • Provide flexibility to adapt to changing
conditions
• Eliminate wasted or redundant movement
• Increase capacity
This process requires the following inputs:
• Specification of objectives of the system in terms of output and
flexibility
• Estimation of product or service demand on the system
• Processing requirements in terms of number of operations and
amount of flow between departments and work centers
• Space requirements for the elements in the layout
• Space availability within the facility itself
Basic Production Layout Formats

Process Layout
Product Layout
(also called
(also called
job-shop or
flow-shop
functional
layout)
layout)

Group
Fixed-Position Technology
Layout (Cellular)
Layout
Process Layout
• Similar equipment or functions are grouped together, ex: all lathes in one area, all
drilling machines in one area.

• A part being worked on then travels, according to established sequence of

operations, from area to area.

• Used in hospitals, such as maternity ward, ICU, ICCU etc.

Manufacturing Process Layout
Process Layout of an Automobile Service Station

Final Underbody Engine Repairs Paint Booth

Inspection Repairs Car washing
& cleaning

Office

Dents Repair
Spare Interiors, Door
Oil Replacement Wheel Electrical
Parts Repairs, etc.
Alignment Repairs
Store
Advantages & Disadvantages of Process Layout
A low output rate Routing &
and, thus, high cost scheduling is tedious
Work-In-Process
of item per unit and time consuming
(WIP) Inventory is
usually high in for different
batch processing products
High cost of supervision
Material handling is Disadvantages because of special
time consuming as no treatment to every product
fixed route is there Process to be processed
Layout

Maintenance cost is The system promotes

Advantages creativity on part of
low because of low
cost general purpose workers due to variety of
machines tasks performed by them

The system is flexible to Breakdown of a machine

design changes in does not lead to halt in
products or processes in production as substitute
comparison to product machines are kept ready
layout for such situations
Product Layout
• Is an arrangement based on the sequence of operations that is performed
during the mfg. of a good or delivery of a service.
• Difference between process and product layout is the pattern of work flow.
• Equipment or departments are dedicated to a particular product line
• Duplicate equipment is employed to avoid backtracking, and a straight-line
flow of material movement is achievable.
• Used when the batch size of a given product or part is large relative to the
no. of different products or parts produced.
 A Product Layout

In

Out
 Comparison of Product
and Process Layouts
Product Process
• Description  Sequential  Functional
arrangement of grouping of
activities activities
 Continuous, mass  Intermittent, job
• Type of process
production, mainly shop, batch
assembly production, mainly
fabrication
• Product  Standardized, made  Varied, made to
to stock order
• Demand  Stable  Fluctuating
• Volume  High  Low
• Equipment  Special purpose  General purpose
 Comparison of Product
and Process Layouts
Product Process
• Workers  Limited skills  Varied skills
• Inventory  Low in-process, high  High in-process, low
finished goods finished goods
• Storage space
 Small  Large
• Material handling
• Aisles  Fixed path (conveyor)  Variable path (forklift)
• Scheduling  Narrow  Wide
• Layout decision  Part of balancing  Dynamic
• Goal  Line balancing  Machine location
 Equalize work at each  Minimize material
• Advantage station handling cost
 Efficiency  Flexibility
Advantages & Disadvantages of Product Layout
Lesser supervision & labor A high output rate and,
training costs (as labor is thus, low cost of item High efficiency of labor &
trained only for a per unit equipment
specialized task)

Easier material handling No need of routing or scheduling

and lesser inventory costs Advantages once the line is operational (as it
is already done during the design
Product of the line)
Layout
Maintenance cost is fairly
high to ensure smooth Disadvantages Monotonous repetitive tasks lead
running of the line to frustration on part of workers

Inflexible to design changes in Breakdown of a machine or high

products or processes (the absenteeism of workers leads to halt
changes in line are usually in production
expensive)
Assembly line

• Special case of product layout.

• Refers to progressive assembly linked by some material handling

device.
 An Assembly Line (Product
Layout)
Racks containing Racks containing Racks containing
headlight sub-assembly backlight sub-assembly steering wheels
sub-assembly
Workstation 1 Workstation 2 Workstation 3

Car 1 Car 2 Car 3

Conveyor
A U-shaped Assembly Line

1 2 3

4
The entry &
exit points are
nearby A single worker
5

8 7 6
Assembly Line Balancing

• Technique to group tasks among workstations so that each

workstation has – in the ideal case – the same amount of work
Information Set of tasks to be performed and the time
required for
assembly required to perform each task
line
balancing
The precedence relations among the tasks
– i.e. the sequence in which the tasks must
be performed, and
The desired output rate or forecast of
demand for the assembly line
• Cycle time
• The interval between successive outputs coming off the assembly line.

• Could be the manufactured goods or service-related outcomes

 Assembly Lines Balancing Concepts

Question: Suppose you load work into the three work

stations below such that each will take the corresponding
number of minutes as shown. What is the cycle time of
this line?

Station 1 Station 2 Station 3

Minutes
per Unit 6 7 3
Answer: The cycle time of the line is always determined by the work
station taking the longest time. In this problem, the cycle time of the line
is 7 minutes. There is also going to be idle time at the other two work
stations.
Example of Line Balancing

• You’ve just been assigned the job a setting up an

electric fan assembly line with the following tasks:

Task Time (Mins) Description Predecessors

A 2 Assemble frame None
B 1 Mount switch A
C 3.25 Assemble motor housing None
D 1.2 Mount motor housing in frame A, C
E 0.5 Attach blade D
F 1 Assemble and attach safety grill E
G 1 Attach cord B
H 1.4 Test F, G
Example of Line Balancing:
Structuring the Precedence Diagram
Task Predecessors Task Predecessors
A None E D

B A F E
C None G B
D A, C H E, G

A B G
H

C D E F
Example of Line Balancing: Precedence Diagram
Question: Which process step defines the maximum rate of
production?

2 1 1
A B G 1.4
H

C D E F
3.25 1.2 .5 1
Answer: Task C is the cycle time of the line and therefore, the
maximum rate of production.
Example of Line Balancing: The Bottleneck

Production time per day 420 mins

Max Production = = = 129 units
Bottleneck time 3.25 mins / unit

Task Time (Mins) Description Predecessors

A 2 Assemble frame None
B 1 Mount switch A
C 3.25 Assemble motor housing None
D 1.2 Mount motor housing in frame A, C
E 0.5 Attach blade D
F 1 Assemble and attach safety grill E
G 1 Attach cord B
H 1.4 Test E, G
Example of Line Balancing: Determine Cycle Time

Question: Suppose we want to assemble 100 fans

per day. What would our cycle time have to be?

Answer:
Production time per period
Required Cycle Time, C =
Required output per period

420 mins / day

C= = 4.2 mins / unit
100 units / day
Example of Line Balancing: Determine Theoretical
Minimum Number of Workstations

Question: What is the theoretical minimum number of

workstations for this problem?

Theoretical Min. Number of Workstations, N t

Answer:

Sum of task times (T)

Nt =
Cycle time (C)

11.35 mins / unit

Nt = = 2.702, or 3
4.2 mins / unit
Example of Line Balancing: Determine the Efficiency of the
Assembly Line

Sum of task times (T)

Efficiency =
Actual number of workstations (Na) x Cycle time (C)

11.35 mins / unit

Efficiency = =.901
(3)(4.2mins / unit)
Group Technology (Cellular Layout):

 group dissimilar machines into work centers (called cells) that process families of
parts with similar shapes or processing requirements
 111 Lathe 2222 Fitting 2222 Paint 111
3333 Machines shop Shop 2222
3333

1 1
1 3 1
1 1
2 1 3 1
1 1
2 1 3 1
2
3333 3333
2222 Drilling Welding
Foundry 4444 Machines 4444 Shop 4444
4444

Process Layout of a Factory

Manufacturing Cell 1

111 Lathe Drilling Fitting Welding Paint 111

Manufacturing Cell 2

2222222222 Foundry Lathe Fitting Paint 2222

Manufacturing Cell 3

3333333333 Lathe Fitting Drilling Welding 3333

Manufacturing Cell 4

444444444444444444444 Foundry Drilling Welding 4444

Cellular Layout
Cellular Layouts

1. Identify families of parts with similar flow paths

2. Group machines into cells based on part families

3. Arrange cells so material movement is minimized

4. Locate large shared machines at point of use

Group Technology (Cellular Layout): Benefits

1. Better human
relations

2. Improved
operator
expertise
3. Less in-process
inventory and
material handling

4. Faster
production setup
Advantages and Disadvantages of Cellular Layouts

• Advantages • Disadvantages
• Reduced material handling and transit • Inadequate part families
time • Poorly balanced cells
• Reduced setup time • Expanded training and
• Reduced work-in- process inventory scheduling of workers
• Better use of human resources • Increased capital investment
• Easier to control
• Easier to automate
Fixed Position Layout

Question: What are our primary considerations for a

fixed position layout?

Answer: Arranging materials and equipment

concentrically around the production point in
their order of use.
Schematic Diagram to show Fixed-position Layout of a Space
Shuttle

Raw Computer
Materials Experts

Equipments Assemblies

Technicians Fuel
Retail Service Layout
• Goal--maximize net profit per square foot of
floor space
• Servicescapes
• Ambient Conditions
• Spatial Layout and Functionality
• Signs, Symbols, and Artifacts
Question Bowl
Which of the following is a process that involves
developing a relationship chart showing the degree
of importance of having each department located
adjacent to every other department?
a. Systematic layout planning
b. Assembly-line balancing
c. Splitting tasks
d. U-shaped line layouts
e. None of the above

Answer: a. Systematic layout planning

Question Bowl
If the production time per day is 1200 minutes and the
required output per day is 500 units, which of the
following will be the required workstation cycle time for
this assembly line?
a. 2.4 minutes
b. 0.42 minutes Answer: a. 2.4
c. 1200 units minutes
d. 500 units (1200/500=2.4
e. None of the above minutes)
Question Bowl
You have just finished determining the cycle time for an
assembly line to be 5 minutes. The sum of all the
tasks required on this assembly is is 60 minutes.
Which of the following is the theoretical minimum
number of workstations required to satisfy the
workstation cycle time?
a. 1 workstation
b. 5 workstations
c. 12 workstations
Answer: c. 12
d. 60 workstations
e. None of the above workstations
(60/5=12)
Question Bowl
If the sum of the task times for an assembly line is 30
minutes, the actual number of workstations is 5, and
the workstation cycle time is 10 minutes, what is the
resulting efficiency of this assembly line?
a. 0.00
b. 0.60
c. 1.00
d. 1.20
e. Can not be computed from the data above

Answer: b. 0.60 (30/(5x10)=0.60)

Question Bowl
Which of the following are ways that we can
accommodate a 20 second task in a 18 second cycle
time?
a. Share the task
b. Use parallel workstations
c. Use a more skilled worker
d. All of the above
e. None of the above

Answer: d. All of the above

Question Bowl
Which of the following are “ambient conditions” that should
be considered in layout design?
a. Noise level
b. Lighting
c. Temperature
d. Scent
e. All of the above

Answer: e. All of the above