Facility LayoutFacility Layout

Dr. Everette S. Gardner, Jr.

Facility Layout 2

Machine shop process layout Receiving Grin-

Mills ders Raw matl. Large number

of storage Assem- low volume

bly products Drills

Planers

Finished Inspec- goods

Lathes Automatics tion storage

Part A Part B

Facility Layout 3

Product layout

Raw matl. Fabrication Rec- storage line-part B eiving Fabrication Planer

line-part A Finished Lathe

goods Drill storage Mill

Mill Drill

Grinder Mill

Assembly line Automatic

Small numberof

high volumeproducts

Facility Layout 4

Possible solutions to the process layout problem6 Department problem has 6! or 720 possible

solutions: A B C

D E F

I.E., there are 720 different arrangements of the 6 departments on the 6 locations on the grid.

Facility Layout 5

Possible solutions to the process layout problem (cont.)Problem complexity grows exponentially:

Nbr. depts. Solutions 10 3,628,800

15 1.31 x 10^12 20 2.43 x 10^18 50 3.04 x 10^64

Facility Layout 6

Solutions considered by Craft

• N! solutions to problem with N depts.

• Craft considers only

N(N-1) pairs of exchanges, 2 starting with each

dept.

Facility Layout 7

Craft initial layout of furniture plant

A B C

D E

F G

I H

JTOTAL COST = $2524.68

Facility Layout 8

Craft final layout

A E C I G F B H J D

TOTAL COST = $766.68

Facility Layout 9

Synopsis of assembly line balancing

1. Set up a precedence table.

2. Compute required cycle time:C = (production time) / (required output in units)

3. Compute minimum cycle time:CMIN = time for longest task

4. Compute minimum number of stations:SMIN = (sum of all times) / C

Facility Layout 10

Synopsis of assembly line balancing (cont.)5. Select rule by which tasks are assigned to work

stations.Examples:(1) select tasks with longest operation times first or(2) select tasks with largest number of following tasks first

6. Assign tasks to the first work station until the sum of the task times are equal to the cycle time, or no other tasks are feasible. Repeat for stations 2, 3, … until tasks are assigned.

7. Evaluate the efficiency of the balance:E = (sum of all times) / (actual nbr. of stations x C)

Facility Layout 11

Line balancing quiz

0.4 0.3 1.1 1.1 0.5 0.7 0.3 1.2 0.4 0.8

Balance this production line to achieve an output of 367 units per day. Available production time is 8 hrs. less a 40 min. lunch break. Use the largest number of following tasks rule to select tasks for work stations. Break ties with the longest operation time.

A

B

C

D

E

F

G

H

I J

Facility Layout 12

Multiple solutions in line balancing

6 4

7 3 5 5 5

2

A

B

C

D

E

F

G

H

Facility Layout 13

Multiple solutions in line balancing (cont.)

84

25

3 1 2 3 4 5 6 7

Stations

Num

ber o

f sol

utio

ns

Facility Layout 14

Volvo layouts

Rotatinground tablewith definitecycle time --facilitates teamwork

Facility Layout 15

Volvo layouts (cont.)

Horseshoeconveyorsections to enable workercommunications

Facility Layout 16

Volvo layouts (cont.)

Interim storage Storage areas to separate

line into definitesupervisory groups

Supervisor Supervisor B A

Facility Layout 17

Volvo layouts (cont.)

Machines groupedin banks of 3so workers canexchange jobs andassist each otherin set-up

Facility Layout 18

Volvo continued

Connections of subassembly islands feed parts/components to end-assembly islands—each island functions as a separate team

E

S

S

S

E

E

S

S

S