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Facility Layout & Design

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 Objectives of Facility Layout

 A facility layout problem may have many

objectives. In the context of manufacturing
plants, minimizing material handling costs is the
most common one.
 Other objectives include efficient utilization of
 space

 labor

 Eliminate
 bottlenecks

 waste or redundant movement

 Objectives of Facility Layout

 Facilitate
 organization structure

 communication and interaction between workers

 manufacturing process

 visual control

 Minimize
 manufacturing cycle time or customer flow time

 investment

 Provide
 convenience, safety and comfort of the employees

 flexibility to adapt to changing conditions

 Requirements for a Good
Layout
 Understand capacity and space requirements.
 Understand information flows.
 Understand cost of people and product flows.
 Select appropriate material handling equipment.
 Consider environment and aesthetics.
 Consider safety and regulations.
 Systematic Layout Planning
Muther (1961)
0 Data gathering
1 Flow 2 Activities
Analysis
3 Relationship
4 Space diagram 5 Space
requirements available
6 Space relationship
diagram
Search 7 Reasons to 8 Restrictions
modify
9 Layout alternatives

Selection 10 Evaluation
 Layout Types
Product layout
Process or Functional layout
Project or Fixed-position layout
Cellular Manufacturing
Group Technology

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 Product Layout
Facility
organized around product
Design minimizes line imbalance
 Delay between work stations
Types:Fabrication line; assembly line
Examples
 Autoassembly line
 Paper manufacturing.

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 Product Type Layout

Lathe Drill Grind Drill

W
A
S a
s r
t s
o Drill e
Press Bend e h
r
a m o
g b u
se
e l
y
Mill Drill

Lathe Lathe Drill

 Process Layout
+ Allows specialization - focus on one
skill
+ Allows economies of scale - worker
can watch several machines at once
+ Design places departments with
large flows of material or people
together
+ High level of product flexibility 9
 Process Layout

Milling

Assembly
Grinding
& Test

Drilling Plating
Process Layout - work travels
to dedicated process centers

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 Project or Fixed-Position
Design is for stationary project
Workers & equipment come to site
Complicating factors
 Limitedspace at site
 Changing material needs

Examples
 Shipbuilding
 Highway construction
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Fixed-Position Layout

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 Fixed Position Layout

Lathe Press Grind

W
S a
t r
o e
r h
a o
g u
e s
e
Weld Paint Assembly

Layout Types: Manufacturing - 13

 What Is Cellular Manufacturing?
 Equipment and workstations arranged in a
sequence that supports smooth material flow, with
min. transport or delay

 A Manufacturing Cell consists of people and

machines or workstations required for performing
the process steps

 For example - if a process for a product requires

cutting, followed by drilling and finishing, the cell
would arrange equipment in that order

 Helps companies achieve High-variety production

 Cellular Manufacturing
Defined
“…The cells are arranged to easily facilitate
all operations. Parts are handed off from
operation to operation eliminating setups
and unnecessary costs between
operations.”
 Cellular Layout (Work Cells)
• Every cell contains a group of machines
brought together to make a product or
machines are dedicated to the production
of a family of parts.
These layouts are also called as group
technology layouts.
Example: Assembly line set up to produce
3000 identical parts in a job shop

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 Cellular Manufacturing

 Typical
objectives of cellular
manufacturing:
 To shorten manufacturing lead times

 To reduce WIP

 To improve quality

 To simplify production scheduling

 To reduce setup times

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 Cellular Layouts

Machines
Enter

Worker 2
Worker
Worker 1 3

Exit

Key: Product route

Worker route
 Group Technology/Cellular/Product Family
Layout
Lathe Drill Grind Assembly

W
S a
t re
o Mill Assembly Weld Paint h
r o
a u
g se
e
Press Lathe Drill Press Assembly

Grind Drill Assembly Drill Grind

 Advantages of Cellular Layouts

• Reduced material handling and transit time

• Reduced setup time
• Reduced work-in-process inventory
• Better use of human resources
• Better scheduling, easier to control and automate
 Disadvantages of Cellular Layouts

• Sometimes cells may not be formed because of

inadequate part families.

• Some cells may have a high volume of

production and others very low. This results in
poorly balanced cells.
 Disadvantages of Cellular Layouts

• When volume of production changes, number of

workers are adjusted and workers are
reassigned to various cells. To cope with this
type of reassignments, workers must be multi-
skilled and cross-trained.

• Sometimes, machines are duplicated in different

cells. This increases capital investment.
Group Technology (GT) Defined
A manufacturing philosophy in which similar parts are
identified and grouped together to take advantage of
their similarities in design and production
 Similarities among parts permit them to be classified into
part families
 In each part family, processing steps are similar

 The improvement is typically achieved by organizing the

production facilities into manufacturing cells that
specialize in production of certain part families
 Part Family
A collection of parts that possess
similarities in geometric shape and
size, or in the processing steps used in
their manufacture
 Part families are a central feature of
group technology

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parts shown are
different in size,
shape, and material,
but quite similar in
terms of
manufacturing
All parts are
machined from
cylindrical stock by
turning; some parts
require drilling and/or
milling
Part Families

Similar prismatic parts requiring similar milling operations

Dissimilar parts requiring similar machining operations (hole drilling, surface milling

Identical designed parts requiring completely different manufacturing processes

 Ways to Identify Part Families
1. Visual inspection
 Using best judgment to group parts into appropriate
families, based on the parts or photos of the parts
2. Parts classification and coding
 Identifying similarities and differences among parts
and relating them by means of a coding scheme
3. Production flow analysis
 Using information contained on route sheets to
classify parts

©
1- Visual Inspection Method
Parts classification and Coding

• similarities among parts are identified, and

these similarities are related in a coding
system.
•It consists of a sequence of symbols
•The symbols are usually alphanumeric,
although most systems use only numbers.
•Two categories of part similarities

1.Part Design attributes

2. Part Manufacturing attributes

 Part Design Attributes
 Major dimensions
 Basic external/internal shape
 Material type
 Part function
 Tolerances
 Surface finish
 L/D ratio
©
 Part Manufacturing Attributes
 Major process
 Operation sequence
 Batch size
 Machine tools
 Cutting tools

©
 Parts classification and Coding

The three basic coding structures are

 Hierarchical structure, or monocode

 Chain-type structure, or polycode

 Hybrid structure
 Hierarchical structure
Also known as a monocode
The interpretation of each successive symbol is
dependent on the preceding symbols.
 Chain type structure or Polycode

Each symbol in the sequence is always the same,

Does not depend on the value of preceding symbols.
Hybrid structure

a combination of hierarchical and chain-

type structures.
 Opitz Classification System

 Basic code = nine (9) digits

 Digits 1 through 5 = form code – primary
shape and design attributes

 Digits 6 through 9 = supplementary code –

attributes that are useful in manufacturing

 Digits 10 through 13 = secondary code –

production operation type and sequence
Opitz Classification and Coding System
Digits (1-5) for Rotational parts in the Opitz System
Example: Optiz part coding System
• Given the rotational part design below, determine the form code in the
Optiz parts classification and coding system.

Solution
• Length-to-diameter ratio: L/D = 1.5 Digit 1 = 1

• External shape: both ends stepped with screw thread on one end Digit 2 = 5

• Internal shape: part contains a through hole Digit 3 = 1

• Plane surface machining: none Digit 4 = 0

• Auxiliary holes, gear teeth, etc.: none Digit 5 = 0

The form code in the Optiz system is 15100

 Basic Layout Types
Product Volume vs. Product Variety

High
Product Planning
Department

Product Layout
Medium Product Family
Volume

Planning
Department
Fixed Location Layout Process Layout
Group Technology Layout
Fixed Materials Process Planning
Low Location Planning Department
Department

Low Medium High

Variety
Flexible Manufacturing System
Highly automated GT manufacturing cell,
consisting of a group of processing
workstations, interconnected by an
automated material handling and storage
system, and controlled by a distributed
computer system
What does flexible mean?
1. Can identify and operate different part/product styles
2. Quick changeover of process/operating instructions
3. Quick changeover of physical setup

FMS operations:
1. Processing operations
2. Assembly operations
 Activity Relationship Chart

 A graphical tool used to represent

importance of locating pairs of operations
near each other.

 Letter codes used to describe importance are

A- absolutely necessary
E- especially important
I - important
O - ordinarily important
U- unimportant
X- undesirable
Closeness Rating: multiple
criteria

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 Legend
5 8 7
A Rating

E Rating
10 9 6
I Rating

O Rating
4 2 3
U Rating

X Rating
Fig 6 Activity relationship 1
diagram
 Assembly Line Balancing
General Procedure
1. Determine cycle time - The time between
production of successive units. (May be
measured in seconds, minutes, etc.)

2. Calculate the theoretical minimum number of

workstations, denoted N. (May not be
achievable.)

3. Assign tasks to workstations to “balance” the

line. Compute the efficiency.
9-47
 Assembly Line Balancing
Equations
Production time available
Cycle time =
Production rate

Minimum  Task times

number of = N = Rounded up
work stations Cycle time

 Task times
Efficiency =
(Actual number
* (Cycle time)
of work stations)

9-48
 Assembly Line Balancing
Heuristics
 Most following tasks.
 Choose task with largest number of following
tasks.

 Longest (or shortest) task time.

 Choose task with longest (or shortest) operation
time.

 Ranked positional weight.

 Choose task where the sum of the times for each
following task is longest.
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Figure 6.10 Precedence Diagram
Precedence diagram: Tool used in line balancing to
display elemental tasks and sequence requirements
0.1 min. 1.0 min.
A Simple Precedence
a b Diagram

c d e
0.7 min. 0.5 min. 0.2 min.
 Line Balancing
Immediate
Task Time Predecessor
A 0.2 min. -
B 0.6 min. A,C Suppose we want to
C 0.5 min. - produce 450 units/day
D 0.3 min. -
E 1.0 min. B,D and 8 hours are available
F 0.2 min. D each day.
G 0.9 min. E,F
3.7 min.

cycle time  480 minu tes / day 1.0667 minu tes / unit
450 units / day
N  3.7 minu tes  3.47 ... or 4 workstatio ns
1.0667 minu tes

9-51