Ch11 Facility Layout

Facility Layout Planning and Design
Sections: 1. Types of Production Plant Layouts 2. Other Types of Layouts 3. Systematic Layout Planning
Chapter 11
Work Systems and the Methods, Measurement, and Management of Work by Mikell P. Groover, ISBN 0-13-140650-7. 2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Facility Layout
Refers to the size and shape of a facility as well as the relative locations and shapes of the functional areas (e.g., departments), equipment, workstations, storage spaces, aisles, and common areas (e.g., restrooms) Concerned with problems of Laying out a new facility Making changes in an existing facility Also called plant layout Usually associated with production plants
Objectives in Layout Planning

Efficient movement of materials and people Logical work flow and minimum travel distances Efficient utilization of space Safety and satisfaction of those who use the facility Flexibility to meet changing future requirements Advancing the operational mission of the facility
Types of Production Plant Layouts

1. 2. 3. Process layout Product layout Fixed-position layout Also: Hybrids of the three basic types
Important Factors in Plant Layout

Q = production quantity - number of units of a given part or product that the facility produces Low production - 1 to 100 units Medium production - 100 to 10,000 units High production - 10,000 to millions of units P = product variety - number of different product designs or types made in the plant
P - Q Relationship in Plant Layout
Process Layout
Layout in which equipment is arranged according to function Suited to low and medium production quantities and medium to high product variety Different parts or products are processed through different operations in batches Each batch follows its own routing No common work flow followed by all work units Material handling activity is significant
Process Layout
Product Layout
Layout in which workstations and equipment are located along the line of flow of the work units Suited to high production quantities and low product variety Work units typically moved by powered conveyor At each workstation, a small amount of the total work content is accomplished on each work unit Each station specializes in its task, thus achieving high efficiency
Product Layout for Assembled Product
Comparisons
Feature Annual Q Product variety Production rate Efficiency Labor skill Work-in-process Equipment Advantages Disadvantages Process Layout Low or medium Medium to high Low Low Skilled High WIP General purpose Versatility to deal with product variety Low production rate Batch production Product Layout High Low High High Unskilled Lower WIP Special purpose High production rate High efficiency Risk of obsolescence Limited variety
Fixed-Position Layout
Layout in which product remains in one location during fabrication, and workers and equipment are brought to the product Suited to low production quantities and high product variety Reason for keeping product in one location: Product is big and heavy Typical plants: assembly and fabrication Much manual labor Equipment is portable or mobile
Fixed-Position Layout
Hybrid Layouts
Cellular - attempts to combine the best features of process and product layouts Combinations of fixed position and either Process layout or Product layout
Cellular Layout
Layout in which work units flow between stations, as in a production line, but each station can cope with a variety of part styles without the need for time-consuming changeovers Combination of product and process layouts Tries to combine efficiency of product layout with versatility of process layout Neither objective is achieved perfectly, but it is more efficient than a process layout and more versatile than a product layout Based on principles of group technology
Cellular Layout
Other Combination Layouts

Fixed-position and process layout Shipyard - ships made in modules Parts fabricated in process layout Modules built in fixed-position layout Fixed-position and product layout Commercial airplanes (e.g., Boeing 747) Fabrication begins with fuselage and proceeds through 7 or so stations where specialized workers assemble parts and modules to airplane
Layout Types for P-Q Combinations
Other Types of Layouts

Warehouses Projects Service facilities Offices
Warehouse Layout
Principal function of warehouse layout = storage of merchandise, commodities, or other items Must plan the layout for other functions also Four main warehouse functions: Receiving Storing Order picking Shipping
Warehouse Layout
Centralized receiving and shipping in a single dock area
Warehouse Layout
Decentralized receiving and shipping to achieve flow-through in the storage facility
Project Layout
Usually refers to construction project Work teams and equipment are brought to the work site Layout is temporary because project has scheduled completion date Project layout vs. fixed-position layout: Product is large and heavy In fixed-position layout, when product is completed, it is transported away In project layout, product remains, workers and equipment are transported away
Service Facility Layouts

Most service layouts based on process layout Personnel and equipment are organized according to function Example: department store Organized according to type of merchandise Shoe department Jewelry department, etc. Efficient flow of people (customers) is sacrificed to maximize customer exposure to merchandise
Office Layout
Usually an approximation of a process layout Personnel are typically grouped according to function Within a given department, a work flow pattern exists and can be used to determine proper locations of personnel and offices Basic decisions about layout: Walled offices vs. open office concept
Walled Office Layout

Characterized by many private offices with permanent walls defining the floor plan Locations and sizes of offices related to position and importance of occupant Top-level executive 425 sq ft Middle-level executive 350 sq ft Supervisor 200 sq ft Office employee 75 to 100 sq ft* * Not necessarily private offices
Open Office Concept

Office layout consists of large open area Modular furniture and partitions used to designate and separate workstations Workers organized to promote efficient work flow Advantages: Lower construction costs Easier supervision of employees Flexibility to make changes in layout Better control of heating, cooling, lighting Improved communications among workers
Levels of Detail in Plant Layout

a) Site layout - shows building location on property b) Block layout - shows arrangement and sizes of departments in building c) Detailed layout - shows workstations and equipment in each department d) Workstation layout - indicates arrangement of equipment, workbench, WIP inventory, and worker floor space for each workstation type
Levels of Detail in Layout Design
Systematic Layout Planning

Developed by Richard Muther Most widely used layout planning approach Most applicable to process layout design Most appropriate for designing a new plant (green field facility)
Steps in SLP
1. Determine requirements and collect data 2. Analyze material flows 3. Define activity relationships and develop activity relationship chart 4. Construct activity relationship diagram 5. Determine space requirements 6. Construct space relationship diagram 7. Make adjustments and add allowances 8. Develop block layout 9. Develop detailed layout
Step 1. Requirements and Data

Starting specifications in plant layout design: Specific product or set of products will be produced Particular set of manufacturing and/or assembly processes will be performed Specified quantities of parts and products will be produced Rarely are specifications for two plants the same
Muthers P-Q-R-S-T Requirements

P - product - what products and products Q - quantity - how many of each product R - routing - manufacturing processes through which parts and products will be routed S - supporting services Utilities, restrooms, offices, etc. T - time issues: How many shifts per week? By when must the building project be completed?
P-Q Curve
Shape of P-Q curve can provide information about the type of plant layout that will be required
P-Q Curve is a Pareto Chart
The actual data in the P-Q curve represent discrete products
P-Q Curve for Process Layout
Curve indicates that multiple products with medium quantities are produced
P-Q Curve for Product Layout
P-Q curve indicates that one product is made in high quantities
Step 2. Analyze Material Flows

Possible charting techniques to analyze material flows: Operation chart - shows sequence of processing, assembly, and inspection operations for products Flow process chart - shows processing steps and other details for parts production From-To chart - shows quantities and directions of material flows between departments Part routing matrix - shows which operations each part is routed through during production
Step 3. Activity Relationships

Indicate relative need to place activities or departments in close proximity to each other Defined by closeness ratings A - absolutely necessary for departments to be next to each other E - especially important I - important O - ordinary U - unimportant X - Undesirable to locate departments near each other
Activity Relationship Chart
Closeness Rating Factors

1. Material flow - most important, sometimes the only factor 2. Need for contact between personnel 3. Use of same equipment 4. Sharing of common records 5. Sharing of supervision or technical staff 6. Use of same utilities 7. High noise level 8. Emission of fumes, odors
Step 4. Activity Relationship Diagram

Graphical means of displaying the closeness ratings among pairs of activities (departments) Uses nodes to represent activities Nodes are connected by lines indicating the closeness ratings Closeness ratings are identified by Color Different types of lines Analyst attempts to rearrange nodes so that nodes with high closeness ratings are located near each other
Activity Relationship Diagram
Blocks represent departments
Lines represent closeness ratings
Revised Activity Relationship Diagram
Blocks rearranged to bring departments with high closeness ratings closer together
Step 5. Space Requirements

Objective is to determine area requirements for each activity (department) Procedure: 1. List all workstation types Identify by subscript i 2. Determine floor space requirement for each station type Let Ai = area for station type i 3. Determine number of stations of each type ni = Min Int WLi / ATi
Space Requirements
4. If workload for station i consists of multiple parts or products, WLi = QijTcij where Qij = quantity of part type j, Tcij = cycle time of part type j 5. Determine total area required for each workstation type TAi = niAi
Space Requirements
6. Determine total are in each department by summing areas for all station types in that department DAk = TAi where DAk = area of department k and summation is carried out over all workstation types in department k
Step 6. Space Relationship Diagram

Extension of activity relationship diagram in which nodes representing departments are now assigned areas that are proportional to areas calculated in previous step Shapes of nodes may be changed to fit the nodes into the diagram (e.g., use rectangular blocks rather than round nodes) But relative positions of blocks remain as in the last iteration of the activity relationship diagram
Space Relationship Diagram
Same diagram as before but block sizes are proportional to areas
Step 7. Adjustments and Allowances

Personnel requirements - rest rooms, locker rooms, food services, plant entrances and exits Material handling methods - may affect floor space and building height Storage facilities - treat as separate department or add allowance Aisle space - add a percentage allowance Offices - for individual departments Building features - walls, column locations Site conditions - parking, landscaping
Limitations
Budget - construction costs may impose limitation on building size Building codes - may affect location of building on property as well as structural and utility details Safety requirements - some included in building codes, others covered by OSHA Existing building - if layout is planned around an existing building, then shape and size of building is a limitation on plant layout design
Step 8. Develop Block Layout

Develop alternative layout plans based on space relationship diagram Different shapes and aspect ratios Evaluate alternatives Select the best Compromise between competing objectives, modifying considerations, and practical limitations
Block Layout
Rectangular building shape
Block Layout
Approximates space relationship diagram
Evaluating the Layouts

Numerical scoring methods to evaluate the block layout: Adjacency score Layout efficiency rating
Adjacency Score
Computed by summing the numerical closeness rating values for all contacting pairs of departments
AS xij CRij
n n i 1 j 1
where xij = adjacency variable (= 1 if common border, 0 if no common border), CRij = numerical value of closeness ratings (A = 4, E = 3, I = 2, O = 1, U = 0, X = -5)
Layout Efficiency Rating

LER = AS / ASmax where AS = adjacency score, and
ASmax CRij i 1 j 1 n n
where CRij = CRij if CRij > 0, and CRij = 0 if CRij 0
Step 9. Develop Detailed Layout

Filling in the block layout with the details of how each department will be arranged Locations and areas of workstations and equipment, aisles, department offices, storage areas, etc. Layout design provides a check on the original calculations If details do not fit into spaces correctly, then there may be an error in original space calculations
Design of Product Layouts

Product layout can be considered as one large department to accomplish the step-by-step production of the product Product is usually an assembly, and the layout is usually an assembly line Where there is more than one department, each department can be designed independently, so long as line-of-flow is consistent at connection points
Number of Workstations
nm = Min Int
Twc E r E b MT c
where nm = number of manual stations, Twc = work content time of product, Er = repositioning efficiency, Eb = line balancing efficiency, M = manning level, and Tc = cycle time of line If there are automated stations, n = nm + na where n = total number of stations, na = number of automated stations
Plant Area
Line length L =
Lsi
i 1
Working area A =
Asi
i 1
To this area must be added
Allowances for aisles Storage areas to supply the line with parts Space for personnel requirements

Ch11 Facility Layout

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Ch11 Facility Layout

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Facility Layout Planning and Design

Objectives in Layout Planning

Types of Production Plant Layouts

Important Factors in Plant Layout

P - Q Relationship in Plant Layout

Product Layout for Assembled Product

Other Combination Layouts

Layout Types for P-Q Combinations

Other Types of Layouts

Service Facility Layouts

Walled Office Layout

Open Office Concept

Levels of Detail in Plant Layout

Levels of Detail in Layout Design

Systematic Layout Planning

Step 1. Requirements and Data

Muthers P-Q-R-S-T Requirements

P-Q Curve is a Pareto Chart

The actual data in the P-Q curve represent discrete products

P-Q Curve for Process Layout

P-Q Curve for Product Layout

P-Q curve indicates that one product is made in high quantities

Step 2. Analyze Material Flows

Step 3. Activity Relationships

Activity Relationship Chart

Closeness Rating Factors

Step 4. Activity Relationship Diagram

Activity Relationship Diagram

Blocks represent departments

Lines represent closeness ratings

Revised Activity Relationship Diagram

Step 5. Space Requirements

Step 6. Space Relationship Diagram

Space Relationship Diagram

Same diagram as before but block sizes are proportional to areas

Step 7. Adjustments and Allowances

Step 8. Develop Block Layout

Rectangular building shape

Approximates space relationship diagram

Evaluating the Layouts

Layout Efficiency Rating

where CRij = CRij if CRij > 0, and CRij = 0 if CRij 0

Step 9. Develop Detailed Layout

Design of Product Layouts

To this area must be added

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