Layout Planning

Facility Layout

Facility Layout means planning for:

• Location of machines
• Workstations
• Utilities
• Restrooms
• Offices
• Warehouses
 Facility Layout Planning

• Criteria for Manufacturing operations layout:

 Flexibility for Products’ volume
 Products variety & future expansion
 Eliminating unproductive materials-handling
 Ease for Plant Operations & Maintenance
 Safety, Health & Environment considerations
 Fulfillment of Other Statutory requirements
 Facility Layout Planning

• Criteria for layout in Retail Services:

 Customer comfort & convenience
 Aesthetics & Appeal value
 Attractive display of merchandise
 Classification & Clustering
 Stock Rotation for shelf life
 Adequate passage for movement
 Unobstructed visual communication
 Facility Layout Planning

• Criteria for Warehouse layout:

 Place for Loading & Unloading operations
 Storage according to Classification Codes
 Consideration for physical size, shape
and weight of materials under storage
 Consideration for shelf life & preservation
 Adequate passage for materials movement
 Centralized workstation for warehouse keeper
 Facility Layout Planning

• Criteria for Office layout:

 Inline with existing organization structure
 Aesthetics & Appeal value
 Elimination of unproductive movement of
personnel including visitors
 Privacy of workstations, records & documents
 Reception, Meeting Place & Pantry
 Load-Distance Method in
Designing Manufacturing Process Layouts
• Load means Volume (Quantity or Number) of operations
carried out at the work station.
• Sequence of Processing means pre-designed process flow for
carrying out operations
• Distance refers to physical distance of movement from one
work station to another in the process chain
• Load – Distance means the quantum of work associated with
each sequential operation carried out on the load
In short Load X Distance = Load Distance
 Sequential Distance Calculation
Layout Option A Layout Option B
5 3 4
1 2 5

9 6 1
3 4 6

2 7 8
7 8 9
Sequential Movement of Products During
Work in Process Assembly
Sequential
Product Sequence
Distance
X 4-6-3-
7-8-9

Y 5-2-1-
7-9

Z 3-4-7-
8-9
 Sequential Distance Calculation
Layout Option A Product Sequence Sequential
Distance

1 2 5 X 4-6-3- 10+10+10
+10+10+1
7-8-9 0
= 60

3 4 6 Y 5-2-1- 10+10+10
+10+10+1
7-9 0
= 60

7 8 9 Z 3-4-7- 10+10+10
+10+10
8-9 = 50
 Load-Distance Calculation
Layout Option A Product Load Load
X 1000 Distance
1000 X 60
=60,000
X 4-6-3- 10+10+10
+10+10+1
7-8-9 0
= 60 Y 3000 3000 X 60
=180,000
Y 5-2-1- 10+10+10
+10+10+1
7-9 0 Z 1000 1000 X 50
=60 50,000

Z 3-4-7- 10+10+10
+10+10
8-9 = 50
Total Load Distance =290,000
 Sequential Distance Calculation
Layout Option B Product Sequence Sequential
Distance

5 3 4 X 4-6-3- 10+10+10
+10+10+1
7-8-9 0+10+10+
10
= 90
9 6 1 Y 5-2-1- 10+10+10
+10+10+1
7-9 0+10+10+
10
=90
2 7 8
Z 3-4-7- 10+10+10
+10+10+1
8-9 0+10+10
= 80
 Load-Distance Calculation
Layout Option B Product Load Load
X 1000 Distance
1000 X 90
=90,000
X 4-6-3- 10+10+10
+10+10+1
7-8-9 0+10+10+
10 Y 3000 3000 X 90
= 90 =270,000

Y 5-2-1- 10+10+10
+10+10+1
7-9 0+10+10+ Z 1000 1000 X 80
10 80,000
=90

Z 3-4-7- 10+10+10
+10+10+1
8-9 0+10+10
Total Load Distance =440,000
= 80
 Sequential Distance Calculation
Layout Option A Layout Option B
5 3 4
1 2 5

9 6 1
3 4 6

2 7 8
7 8 9

Load Distance: 290,000 Load Distance: 440,000

 Closeness Rating
Closenes Importance
• Closeness Rating Technique is an s Rating
effective tool in Service Layout 1 Absolutely
Planning Necessary
• Layout of work stations is
2. Highly Important
designed on the basis of
desirable Closeness ( Nearness )
of a set of functions associated 3. Important
with the operation.
• Closeness is prioritized or rated
according to the necessity & 4. Slightly Important
importance as follows:

5. Unimportant

6. Undesirable
Reasons for Closeness

Code Reason

1 Type of customer

2 Ease of supervision

3 Common personnel

4 Contact necessary

5 Share same price

6 Psychology
 Relative Importance of Closeness
Line Numerical
Value Closeness
code weights
A Absolutely necessary 16

E Especially important 8

I Important 4

O Ordinary closeness OK 2

U Unimportant 0

X Undesirable 80
 Initial Relationship Diagram

1 E 3 The
Thenumber
numberof oflines
lines
here
hererepresent
representpaths
paths
I U U required
requiredtotobe
betaken
takeninin
4 transactions
transactionsbetween
between
the
thedepartments.
departments. The The
2 5
A more
morelines,
lines,the
themore
more
Note the
theinteraction
interactionbetween
between
Notehere
hereagain,
again,Depts.
Depts.(1)
(1)and
and
(2) departments.
departments.
(2)are
arelinked
linkedtogether,
together,and
and
Depts.
Depts.(2)
(2)and
and(5)
(5)are
arelinked
linked
together
togetherby
bymultiple
multiplelines
linesor
or
required
requiredtransactions.
transactions.
 Systematic Layout Planning:
Initial and Final Layouts

5 2 4 2
3 20 ft
3 1 5 1 4
Note
Noteininthe
the
50 ft Final
FinalLayout
Layout
that
thatDepts.
Depts.
Initial Layout Final Layout (1)
(1)and
and(5)
(5)
are
arenot
notboth
both
Ignoring space and Adjusted by square
building constraints placed
placed
footage and building
size
directly
directlynext
next
to
toDept.
Dept.(2).
(2).
 Common Facilities in a Hospital

Admin D3 OPD D4 Pharmacy D8

Emergency D7 Billing D1 Indoor D9

Lab D5 OT D2 X-Ray D6
 Closeness Logic

Rating 1: Most Important Rating 6: Least Important

• D1 = D4 • D2 # D3
• D1 = D9 • D2 # D8
• D4 = D3 • D4 # D9
• D4 = D8 • D5 # D6
• D8 = D9
Rating5: Unimportant
Rating 2: Important • D6 / D7
• D1 – D2 • D6 / D8
• D5 – D7 • D4 / D7
• D7- D9 • D3 / D7
• D2 / D4
• D2 / D7
• D1 / D8
Proposed Layout

D3 D4 D8

D7 D1 D9

D5 D2 D6
 Assembly Lines Balancing Concepts

Question:
Question:Suppose
Supposeyou
youload
loadwork
workinto
intothe
thethree
threework
work
stations
stationsbelow
belowsuch
suchthat
thateach
eachwill
willtake
takethe
thecorresponding
corresponding
number
numberof ofminutes
minutesas
asshown.
shown. What
Whatis isthe
thecycle
cycletime
timeof
of
this
thisline?
line?

Station 1 Station 2 Station 3

Minutes
per Unit 6 7 3
Answer:
Answer:TheThe cycle
cycle time
timeof
of the
the line
line is
is always
always
determined
determinedby bythe
thework
workstation
stationtaking
takingthethelongest
longest
time.
time. In
Inthis
thisproblem,
problem, the
thecycle
cycletime
timeof of the
theline
lineis is77
minutes.
minutes. There
Thereisisalso
alsogoing
goingto tobe beidle
idletime
timeatat the
the
other
othertwo
twowork
workstations.
stations.
 Example of Line Balancing

• You’ve just been assigned the job a setting up

an electric fan assembly line with the following
tasks:
Task Time (Mins) Description Predecessors
A 2 Assemble frame None
B 1 Mount switch A
C 3.25 Assemble motor housing None
D 1.2 Mount motor housing in frame A, C
E 0.5 Attach blade D
F 1 Assemble and attach safety grill E
G 1 Attach cord B
H 1.4 Test F, G
 Example of Line Balancing:
Structuring the Precedence Diagram

Task Predecessors Task Predecessors

A None E D
B A F E
C None G B
D A, C H E, G

A B G
H

C D E F
 Example of Line Balancing: Precedence Diagram

Question:
Question:Which
Whichprocess
processstep
stepdefines
definesthe
the
maximum
maximumrate
rateof
ofproduction?
production?
2 1 1
A B G 1.4
H

C D E F
3.25 1.2 .5 1
Answer:
Answer: Task
TaskCCis
isthe
thecycle
cycletime
timeofofthe
theline
lineand
and
therefore,
therefore,the
themaximum
maximumrate
rateof
of production.
production.
 7A-28

Example of Line Balancing: Determine Cycle Time

Question:
Question:Suppose
Supposewewewant
want to
toassemble
assemble
100
100fans
fansper
perday.
day. What
Whatwould
wouldour
our cycle
cycle
time
timehave
haveto
tobe?
be?

Answer:
Answer:
Production time per period
Required Cycle Time, C =
Required output per period

420 mins / day

C= = 4.2 mins / unit
100 units / day
 7A-29

Example of Line Balancing: Determine Theoretical Minimum Number of

Workstations

Question:
Question:What
Whatisisthe
thetheoretical
theoreticalminimum
minimumnumber
number
of
ofworkstations
workstationsfor
forthis
thisproblem?
problem?

Theoretical Min. Number of Workstations, N t

Answer:
Answer:
Sum of task times (T)
Nt =
Cycle time (C)

11.35 mins / unit

Nt = = 2.702, or 3
4.2 mins / unit
 7A-30

Example of Line Balancing: Rules To Follow for Loading Workstations

• Assign tasks to station 1, then 2, etc. in sequence. Keep

assigning to a workstation ensuring that precedence is
maintained and total work is less than or equal to the cycle
time. Use the following rules to select tasks for assignment.

• Primary: Assign tasks in order of the largest number of

following tasks

• Secondary (tie-breaking): Assign tasks in order of the

longest operating time
 7A-31

Task Followers Time (Mins)

A 6 2
2 1 1
1.4 C 4 3.25
A B G
H D 3 1.2
B 2 1
C D E F
E 2 0.5
F 1 1
3.25 1.2 .5 1
G 1 1
H 0 1.4

Station 1 Station 2 Station 3

 7A-32

Task Followers Time (Mins)

A 6 2
2 1 1
1.4 C 4 3.25
A B G
H D 3 1.2
B 2 1
C D E F
E 2 0.5
F 1 1
3.25 1.2 .5 1
G 1 1
H 0 1.4

Station 1 Station 2 Station 3

A (4.2-2=2.2)
 7A-33

Task Followers Time (Mins)

A 6 2
2 1 1
1.4 C 4 3.25
A B G
H D 3 1.2
B 2 1
C D E F
E 2 0.5
F 1 1
3.25 1.2 .5 1
G 1 1
H 0 1.4

Station 1 Station 2 Station 3

A (4.2-2=2.2)
B (2.2-1=1.2)
 7A-34

Task Followers Time (Mins)

A 6 2
2 1 1
1.4 C 4 3.25
A B G
H D 3 1.2
B 2 1
C D E F
E 2 0.5
F 1 1
3.25 1.2 .5 1
G 1 1
H 0 1.4

Station 1 Station 2 Station 3

A (4.2-2=2.2)
B (2.2-1=1.2)
G (1.2-1= .2)

Idle= .2
 7A-35

Task Followers Time (Mins)

A 6 2
2 1 1
1.4 C 4 3.25
A B G
H D 3 1.2
B 2 1
C D E F
E 2 0.5
F 1 1
3.25 1.2 .5 1
G 1 1
H 0 1.4

Station 1 Station 2 Station 3

A (4.2-2=2.2) C (4.2-3.25)=.95
B (2.2-1=1.2)
G (1.2-1= .2)

Idle= .2
 7A-36

Task Followers Time (Mins)

A 6 2
2 1 1
1.4 C 4 3.25
A B G
H D 3 1.2
B 2 1
C D E F
E 2 0.5
F 1 1
3.25 1.2 .5 1
G 1 1
H 0 1.4

Station 1 Station 2 Station 3

A (4.2-2=2.2) C (4.2-3.25)=.95
B (2.2-1=1.2)
G (1.2-1= .2)

Idle= .2 Idle = .95

 7A-37

Task Followers Time (Mins)

A 6 2
2 1 1
1.4 C 4 3.25
A B G
H D 3 1.2
B 2 1
C D E F
E 2 0.5
F 1 1
3.25 1.2 .5 1
G 1 1
H 0 1.4

Station 1 Station 2 Station 3

A (4.2-2=2.2) C (4.2-3.25)=.95 D (4.2-1.2)=3

B (2.2-1=1.2)
G (1.2-1= .2)

Idle= .2 Idle = .95

 7A-38

Task Followers Time (Mins)

A 6 2
2 1 1
1.4 C 4 3.25
A B G
H D 3 1.2
B 2 1
C D E F
E 2 0.5
F 1 1
3.25 1.2 .5 1
G 1 1
H 0 1.4

Station 1 Station 2 Station 3

A (4.2-2=2.2) C (4.2-3.25)=.95 D (4.2-1.2)=3

B (2.2-1=1.2) E (3-.5)=2.5
G (1.2-1= .2)

Idle= .2 Idle = .95

 7A-39

Task Followers Time (Mins)

A 6 2
2 1 1
1.4 C 4 3.25
A B G
H D 3 1.2
B 2 1
C D E F
E 2 0.5
F 1 1
3.25 1.2 .5 1
G 1 1
H 0 1.4

Station 1 Station 2 Station 3

A (4.2-2=2.2) C (4.2-3.25)=.95 D (4.2-1.2)=3

B (2.2-1=1.2) E (3-.5)=2.5
G (1.2-1= .2) F (2.5-1)=1.5

Idle= .2 Idle = .95

 7A-40

Task Followers Time (Mins)

A 6 2
2 1 1
1.4 C 4 3.25
A B G
H D 3 1.2
B 2 1
C D E F
E 2 0.5
F 1 1
3.25 1.2 .5 1
G 1 1
H 0 1.4

Station 1 Station 2 Station 3

A (4.2-2=2.2) C (4.2-3.25)=.95 D (4.2-1.2)=3

B (2.2-1=1.2) E (3-.5)=2.5
G (1.2-1= .2) F (2.5-1)=1.5
H (1.5-1.4)=.1
Idle= .2 Idle = .95 Idle = .1
Which station is the bottleneck? What is the effective cycle time?
 7A-41

Example of Line Balancing: Determine the Efficiency of the Assembly Line

Sum of task times (T)

Efficiency =
Actual number of workstations (Na) x Cycle time (C)

11.35 mins / unit

Efficiency = =.901
(3)(4.2mins / unit)
 7A-42

Manufacturing Cell:
Benefits

1. Better human relations

2. Improved operator expertise

3. Less in-process inventory and material

handling

4. Faster production setup

 7A-43

Manufacturing Cell:
Transition from Process Layout

1. Grouping parts into families that follow a

common sequence of steps
2. Identifying dominant flow patterns of
parts families as a basis for location or
relocation of processes
3. Physically grouping machines and
processes into cells
 Project Layout

Question:
Question:What
Whatare
areour
ourprimary
primary
considerations
considerationsfor
foraaproject
projectlayout?
layout?

Answer:
Answer:Arranging
Arranging materials
materials and
and equipment
equipment
concentrically
concentrically around
around the
the production
production point
point in
in
their
their order
order of
of use.
use.
 7A-45

Retail Service Layout

• Goal--maximize net profit per square foot

of floor space
• Servicescapes
– Ambient Conditions
– Spatial Layout and Functionality
– Signs, Symbols, and Artifacts
 7A-46

Question Bowl

Which of the following is a process that involves

developing a relationship chart showing the degree
of importance of having each department located
adjacent to every other department?
a. Systematic layout planning
b. Assembly-line balancing
c. Splitting tasks
d. U-shaped line layouts
e. None of the above

Answer: a. Systematic layout planning

 7A-47

Question Bowl

If the production time per day is 1200

minutes and the required output per day i
500 units, which of the following will be
the required workstation cycle time for
this assembly line?
a. 2.4 minutes
b. 0.42 minutes Answer: a. 2.4
c. 1200 units minutes
d. 500 units
(1200/500=2.4
e. None of the above
minutes)
 7A-48

Question Bowl

You have just finished determining the cycle

time for an assembly line to be 5 minutes.
The sum of all the tasks required on this
assembly is is 60 minutes. Which of the
following is the theoretical minimum
number of workstations required to satisfy
the workstation cycle time?
a. 1 workstation
b. 5 workstations
c. 12 workstations Answer: c. 12
d. 60 workstations workstations
e. None of the above (60/5=12)
 7A-49

Question Bowl

If the sum of the task times for an assembly line

is 30 minutes, the actual number of
workstations is 5, and the workstation cycle
time is 10 minutes, what is the resulting
efficiency of this assembly line?
a. 0.00
b. 0.60
c. 1.00
d. 1.20
e. Can not be computed from the data above

Answer: b. 0.60 (30/(5x10)=0.60)

 7A-50

Question Bowl

Which of the following are ways that we

can accommodate a 20 second task in a
18 second cycle time?
a. Share the task
b. Use parallel workstations
c. Use a more skilled worker
d. All of the above
e. None of the above
Answer: d. All of the above
 7A-51

Question Bowl

Which of the following are “ambient

conditions” that should be considered in
layout design?
a. Noise level
b. Lighting
c. Temperature
d. Scent
e. All of the above

Answer: e. All of the above