Arranging Machines in a GT Cell

• Hollier Method. This method uses the sums of flow “From”

and “To” each machine in the cell. The method can be
outlined as follows
1. Develop the From-To chart from part routing data. The data
contained in the chart indicates numbers of part moves
between the machines in the cell.
2. Determine the “To/from” ratio for each machine. This is
accomplished by summing all of the “From” trips and “To”
trips for each machine.
 The “From” sum for a machine is determined by adding the
entries in the corresponding row.
 The “To” sum is found by adding the entries in the
corresponding column.
 For each machine to/from ratio is calculated
3. Arrange machines in increasing to/from ratios
Work station design
1. Space requirement

 Space for worker to stand and turn comfortably

 Space for machine considering overhang,

projection, over travel : Table of milling and shaper
or planner

 Space for work piece if projecting out of the

machine: long bar fed to the turret lathe

 Space for bins storing material and processed

goods

 Space for necessary tools, and supplies required

 Space for additional attachments, accessories, jigs

and fixtures

 Space for larger workpieces to load and unload

Work station design contd..
2- Other factors to be considered

 Space for movement of Material Handling system

 Easy access to safety stops in case of emergency

 Easy access to machine for inspection, lubrication and repair

 Convenience for making machine foundations and machine

installation

 Aisle space between one machine and next

 Appropriate ventilation, lighting, safety management

Manual Workstation
Most
frequently
Occasional work area used tools

Usual work area

50cm 80-100cm 25cm

A worker’s reach
Facility Layout Across the Organization

Layout planning is organizationally important for

an efficient operations
 Marketing is affected by layout especially when
clients come to the site
 Human resources is affected as layout impacts
people
 Finance is involved as layout changes can be costly
endeavors

© Wiley 2010 38
Conclusions

 Layout planning is deciding on the best physical

arrangement of all resources that consumes space within
a facility.

 There are four basic types of layouts: process, product,

hybrid, and fixed position.
 Process layouts group resources based on similar
processes.
 Product layouts arrange resources in straight-line fashion.
 Hybrid layouts combine elements of both process and
product layouts.
 Fixed-position layouts occur when the product is larger
and cannot be moved.
© Wiley 2010 39
 Conclusions – con’t

 Process layouts provide much flexibility and allow for the

production of many products with differing
characteristics.
 Product layouts, on the other hand, provide greater
efficiency when producing one type of product.

 The steps for designing process layouts are

(1) gather information about space needs, space
availability, and closeness requirements of departments;
(2) developing a block plan or schematic of the layout;
(3) developing a detailed layout.
40
 Conclusions– con’t

 The steps for designing an product layout are (1) identify

tasks that need to be performed and their immediate
predecessors; (2) determine output rate; (3) determine
cycle time; (4) computing the theoretical minimum
number of work stations, (5) assigning tasks to
workstations; and (6) computing efficiency and balance
delay.
 Hybrids layouts have advantages over other layout types
because they combine elements of both process and
product layouts to increase efficiency.
41
 Conclusions– con’t

 An example of hybrid layouts is group technology or cell

layouts.
 Group technology is the process of crating groupings of
products based on similar processing requirements.
 Cells are created for each grouping of products, resulting
in a more orderly flow of products through the facility.

42
reference

http://kalyan-city.blogspot.com/2012/02/types-of-
production-system-intermittent.html