FACILITIES

Dr. J. R. SHARMA
@IMT, NAGPUR

Outline

Basic Layouts
Categories of Layouts
Designing Product Layouts
Designing Process Layouts
Hybrid Layouts

FACILITIES
Facility Layout refers to the arrangement / placement of
resources within an existing or proposed facility.
Facilities must be planned, located and then laid out.
Facilities decision affects workers efficiency, rate of
production, quality of production, level of automation, and how
responsive is the system to changes in product design
Basic objective of the layout decision is to ensure smooth flow
of work, material, people and information through the system or
a particular traffic pattern in case of a service orgn.
Provides competitive edge by enabling and leveraging the latest
process concepts.
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Facility Layout
Arrangement of areas within a facility to:

Minimize material-handling costs

Utilize space efficiently

Utilize labor efficiently

Eliminate bottlenecks
Facilitate communication and interaction

Reduce manufacturing cycle time

Reduce customer service time
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Facility Layout
Eliminate redundant movement
Increase capacity
Facilitate entry, exit, and placement of material,
products, and people
Incorporate safety and security measures
Promote product and service quality
Encourage proper maintenance activities
Provide a visual control of activities
Provide flexibility to adapt to changing conditions
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BASIC LAYOUTS
Process layouts
Functional layout / Job shop / Flexible
Group similar activities together according to process they perform

Product layouts
Assembly lines or Flow lines / Efficient
Arrange activities in line according to sequence of operations

Fixed-position layouts
Projects like house, ship or aircraft building, etc.
Are used for projects in which product cannot be moved
Equipments and other things are moved, not the product

Hybrid layouts

Process Layout in Services

Furniture

Shoes

House-wares

Womens dresses

Cosmetics and
jewelry

Childrens
department

Sportswear

Entry and display

area

Mens
department

Manufacturing Process Layout

Lathe Department

Milling
Department

Drilling Department

Grinding
Department

Receiving and
Shipping

Painting Department

Assembly
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Product Layout
In

Out

Fixed - Position Layouts

Typical of projects house, ships
Product is too fragile, too bulky, or
too heavy to move
Product remains stationary
throughout the entire production
cycle
Equipment, workers, materials,
other resources brought to the site
and utilization is low
Highly skilled labor
Often low fixed
Typically high variable costs
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Designing Product Layouts

Objective - to balance the assembly line
Line Balancing - tries to equalize the amount of work at each workstation
Precedence Requirements - physical restrictions on the order in which
operations are performed
Work Station - any area along the assembly line that requires at least a
worker or a machine
Work Elements - work elements are so small an act that they cannot be
spilt any more
Cycle Time - maximum amount of time a product is allowed to spend at
each workstation or time between two completed items rolling off the
assembly line
Flow Time total time taken by the product to flow from one end to the
other of an assembly line
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Cycle Time Example

Tc =

Tc =

production time available

desired units of output
(8 hours x 60 minutes / hour)
(120 units)

Tc =

480
120

= 4 minutes

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Flow Time vs Cycle Time

Cycle time = max time spent at any station

Flow time = time to complete all stations

3 minutes

4 minutes

3 minutes

Flow time = 3 + 4 + 3 = 10 minutes

Cycle time = max (3, 4, 3) = 4 minutes
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Efficiency of Line
Efficiency
j

t
i=1

E = n*T
c

Minimum number
of workstations
j

i=1

Min. N = T
c

where

ti
j
N
Tc

= completion time for element i

= number of work elements
= actual number of workstations
= cycle time
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Balancing U-Shaped Lines

Precedence diagram:
B

Cycle time = 12 min

(a) Balanced for a straight line

A,B

C,D

9 min

12 min

3 min

Efficiency =

(b) Balanced for a U-shaped line

A,B

24
24
=
= .6666 = 66.7 %
3(12)
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C,D

Efficiency =

24
24
=
= 100 % 12 min
2(12)
24

12 min
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Line Balancing Procedure

Line balancing is a trial and error process:

1. Draw and label the precedence diagram

2. Calculate desired cycle time required for the line
3. Calculate theoretical minimum number of workstations
4. Group elements into workstations, recognizing cycle time and
precedence constraints
5. Calculate efficiency of the line
6. Determine if the theoretical minimum number of workstations or
an acceptable efficiency level has been reached. If not, go back to
step 4.

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The table below defines the precedence relationships and element times for a
new model toy. (a) Construct the precedence diagram for this job. (b) If the ideal
cycle time = 1.0, what is the theoretical minimum number of workstations
required to minimize the balance delay (c) Assign work elements to stations. (d)
Compute the balance delay for your solution.
Work element

Te (minute)

Immediate predecessors

1
2
3
4
5
6
7
8
9
10

0.5
0.3
0.8
0.2
0.1
0.6
0.4
0.5
0.3
0.6

1
1
2
2
3
4,5
3,5
7,8
6,9
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A manual assembly line is to be designed to make a small consumer product. The

work elements, their times, and precedence constraints are given in the table
below. The workers will operate the line for 400 minutes per day and must produce
300 products per day. (a) Determine the ideal minimum number of workstations on
the line. (b) Balance the line. (c) Compute the balance delay for your solution
Element

Time Te

Element

Time Te

0.4 min.

Preceded
by:
-

0.2 min.

Preceded
by:
3

1
2

0.7 min.

0.3 min.

0.5 min.

0.9 min.

5,6

0.8 min.

0.8 min.

7,8

1.0 min.

2, 3

10

0.5 min.

6,9

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Designing Process Layouts

Goal: Minimize movement or Material handling costs
Focus: Most and Least interdepartmental movement
Relationship Diagramming
based on location preference between areas

used when quantitative data is not available

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Systematic Layout Planning

Based on location preference between areas

Use when quantitative data is not available

Schematic diagram that uses weighted lines to

denote location preference

Richard Muthers Grid

Format for displaying manager & analysts
preferences for department locations

Preference information is coded into six

categories associated with the five vowels A, E,
I, O, U and letter X
Diamond shaped grid is used and the vowels
match the first letter of the closeness rating for
locating two departments next to each other

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Relationship Diagramming:

A
E
I
O
U
X

Absolutely necessary
Especially important
Important
Okay
Unimportant
Undesirable

Production

O
A

Offices

Stockroom
Shipping and
receiving

X
U

O
O

Locker room

O
Toolroom

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Relationship Diagrams: Example (cont.)

(a) Relationship diagram of original layout

Offices

Stockroom

Locker
room

Toolroom

Shipping
and
receiving

Production

Key: A
E
I
O
U
X
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Relationship Diagrams: Example (cont.)

(b) Relationship diagram of revised layout

Stockroom

Shipping
and
receiving

Offices

Toolroom

Production

Locker
room

Key: A
E
I
O
U
X
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Hybrid Layouts

Cellular Layouts - Group dissimilar machines into work centers (called

cells) that process families of parts with similar shapes or processing
requirements. The layout within the cells resembles a small assembly
line and the layout between the cells is generally a process layout

Backbone of modern hi-tech industries

Combines the flexibility of process layout (between the cells) and

efficiency of product layout (within the cells)
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

Mixed-Model Assembly Line - Processes more than one product

model in one line
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Parts Families

A family of
similar parts

A family of related
grocery items
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Designing Service Layouts

Service layouts are mostly process layout to cater to customer variability

Are concerned with - circulation of traffic through the facility; minimizing flow of
paper work; maximize customer exposure to as many goods as possible

Takes into consideration - allocation of space, location of displays, efficiency of

checkout procedures, and protection against all kind of losses

Back office (invisible) for efficiency and functionality and front office (full view of
the customers) for its aesthetics and functionality

Types:
Free flow layouts - encourage browsing, increase impulse purchasing, are flexible
and visually appealing

Grid layouts - encourage customer familiarity, are low cost, easy to clean and secure,
and good for repeat customers

Loop and Spine layouts - both increase customer sightlines and exposure to
products, while encouraging customer to circulate through the entire store
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Types of Store Layouts

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Computerized Layout Solutions

CRAFT- Computerized Relative Allocation of Facilities Technique
CORELAP - COmputerized RElationship LAyout Planning
PROMODEL and EXTEND (Simulation based)
3-D Modeling and CAD
Service-scape
SLIM: Store Labor and Inventory Management

COSMOS: Computerized Optimization and Simulation Modeling for

Operating Supermarkets this considers demand rates, shelf space,
profitability and stock out probabilities in the layout design

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Computerized Line Balancing

IBM COMSOAL (Computer Method for Sequencing
Operations on Assembly Line)
GE ASYBL (Assembly Line Configuration Program)
Use heuristics to assign tasks to workstations
Longest operation time
Shortest operation time
Most number of following tasks
Least number of following tasks
Ranked positional weight
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THANK YOU

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