Beruflich Dokumente
Kultur Dokumente
OVERVIEW
Introduction Manufacturing Facility Layouts Objectives (Significance), Factors & Principles Types of Manufacturing Facility Layouts Service Facility Layouts Wrap-Up: What World-Class Producers Do
INTRODUCTION
Planning the layout of machines and assembly lines have always been given priority in our operations International competition and technological advancements, though, have led to significant changes in the planning process We use computers to create productive layout and design alternatives. For example, computer software packages are used to help determine total cost relationships, the material departments most effective combination of move and stores and to reduce the cost of in-process materials
CONCEPT
the location of all machines, utilities, employee workstations, customer service areas, material storage areas, restrooms, lunchrooms, internal walls, offices, and computer rooms for the flow patterns of materials and people around, into, and within buildings
LOCATE ALL AREAS IN AND AROUND BUILDINGS Equipment Work stations Material storage Rest/break areas Utilities Eating areas Offices
CHARACTERISTICS OF THE FACILITY LAYOUT DECISION Location of these various areas impacts the flow through the system. The layout can affect productivity and costs generated by the system. Layout alternatives are limited by
the
amount and type of space required for the various areas the amount and type of space available the operations strategy
Provide ease of supervision Provide for employee safety & health Allow ease of maintenance Allow high machine utilization Improve productivity of workers
PRINCIPLES OF LAYOUT
The Principle of minimum travel Principle of sequence Principle of usage Principle of compactness Principle of safety & satisfaction Principle of flexibility Principle of minimum investment
Involves grouping together of like-machines in 1 department Ex.: machines performing drilling operations are installed in drilling department., those performing milling operations are installed in milling dept. and so on
L L L L L
L L L L L
M M
M M
D D
D D
D D
D D
G G
G G
Grinding Department Receiving and Shipping
G G
P P
Painting Department
A
Assembly
BASIC ADVANTAGE
It is easier to handle breakdown of equipment by transferring work to another machine/station Minimize material handling costs Utilize space efficiently Utilize labor efficiently Facilitate communication and interaction between workers, workers and supervisors Provide a visual control of activities
BASIC DISADVANTAGE
This type of layout requires more floor space Production time is more as work-in-progress has to travel from place-to-place in search of machines
PRODUCT (ASSEMBLY LINE) LAYOUTS Operations are arranged in the sequence required to make the product It involves arrangement of machines in 1 line depending upon the sequence of operations. Materials are fed into the 1st machine & finished products come out of last machine
PRODUCT (ASSEMBLY LINE) LAYOUTS Ex.: sugarcane fed at 1 end of the mill and sugar coming out at other end. Operations and personnel are dedicated to producing one or a small number of products Product layout is followed in plants manufacturing standardized products in large scale
PRODUCT LAYOUT
IN
OUT
IN
4 5
Workers 6
OUT
10
BASIC ADVANTAGE
It requires less floor area per unit of production Work-in-progress is reduced Allows wide span of supervision Low material handling costs Routing and scheduling is automatic High labor and equipment utilization
BASIC DISADVANTAGE
Any breakdown of equipment along the production line can disrupt the whole system Workers may not be motivated to quality Hard to change volume Highly susceptible to breakdowns Capacity for quick repair a necessary expense
When only 1 or few standardized products are to be produced, one will go for product layout while when many types or kinds of products are to be produced, 1 will go for process layout by grouping the machines based on production process For Customized products one would go for Product layout rather than Process Layout.
Operations required to produce a particular family (group) of parts are arranged in the sequence required to make that family Machines are grouped into cells
Part Family W
Part Family X
Part Family Y
Part Family Z
Parts Families
Process layout
Process layout groups machines of same type together There are as many machines centers as there are types of machines The machines are interchangeable
Cell layout
Machine which are needed which are needed to produce each family of parts are grouped together and is called a cell Machine in a cell are dedicated to working only on certain parts. Machines are not interchangeable
BREAKTHROUGH
Compaq has introduced notebook computers that has boasted the latest in design, speed and power The company has developed a system that enables it to respond nimbly to retailers and businesses rather than just supply them from inventory stockpiles The key to this approach is cell manufacturing which is being used alongwith traditional assembly line techniques for most compaq models Each cell has 3 people who work at a workstation, where computers are built, tested and shipped
One of the greatest advantages of cell manufacturing is that it allows an individual workstation to manufacture a different computer model each day, if thats what is needed And with 48 cells replacing 1 assembly line, its easier for compaq to produce the hundreds of different models it offers
Compaq has found that cell workstations increase employee output by 23% and product quality by 25% Despite these gains, cell manufacturing remains expensive because full set of tools have to be deployed at each workstation and cell workers must be better trained and paid then assembly-line workers For now, compaq is using a combination of assembly-line and cell manufacturing
The companys Presario computers were produced with traditional and less costly assembly-line methods in the first few months when the demand was exceptionally strong But when orders taper off, Compaq can switch over to cell manufacturing and gear up the assembly-line for its next generation of products
FIXED-POSITION LAYOUTS
Product remains in a fixed position, and the personnel, material and equipment come to it Used when the product is very bulky, large, heavy or fragile Ex .: Ship-building
BASIC ADVANTAGE
Investment on layout becomes very small The worker identifies himself with the product & takes pride when the work is completed The high cost & difficulty in transporting a bulky product are avoided
BASIC DISADVANTAGE
Mobile equipment may increase per-unit cost Scheduling activities becomes key challenge Arrivals of material and equipment are critical Storage space can be a problem Coordination requires narrow management span Accounting, purchasing, and inventory control functions are very complex
Actually, most manufacturing facilities use a combination of layout types. An example of a hybrid layout is where departments are arranged according to the types of processes but the products flow through on a product layout. Ex.: Soap manufacturing plant. Machines producing soap are arranged on product layout basis while production of ancillary services viz. glycerine, water treatment plant, heating are arranged on process layout basis
Shoes
Facilities
TEMPLATE
Templates are patterns which consist of a thin plate of wood or metal, which serves as guide in mechanical work. A plant layout template is a scaled presentation of a physical object in a layout. The templates are fixed to plan drawing and are moved around the drawing to explore the various layout possibilities until a layout, which eliminates unnecessary handling and backtracking of materials and offers flexibility to admit revisions at the least cost, emerges. The template method is useful in developing an existing department or when the configuration of building is already established through other techniques.
SEQUENCE ANALYSIS
Operation sequence analysis helps to arrange department graphically analyzing layout problem.
Is a technique that nearly equally divides the work to be done among the workers and minimises the number of employees required to complete a project
These costs are minimized using mechanized material handling equipments such as belts, cranes and conveyors to automate product flows and keeping the flow distances as short as possible by locating the work centers for sequential processing activities in adjacent areas. Good layout provides workers with a satisfying job and permit them to work effectively at the highest skill level for which they are being paid. Good communication systems and well placed supporting activity locations are critical to the success of any facility.
Worker effectiveness
Do offices have any kind of layout? Do office-space planners use graphic, schematic and load-distance models? The answer is Yes, and the characteristics of office-layout planning make it easier than factory-layout planning for the beginning operations management student to understand Office-space planners have an impressive assortment of computer-aided design (CAD) software and hardware at their disposal The Quaker-Oats Company in Chicago (US) used a CAD system to design its new home office. The layout featured sunny, flexible spaces
To plan its office space, Xerox-Canada chose to use a firm specializing in office design for its offices in Edmonton, Alberta Xerox specified that all work centers be at right angles for maximum efficiency, that window glare be eliminated and that the environment suggest to customers a soft-sell approach A great deal of attention was given to detail, confort and aesthetics in this office design Designing an office, thus goes far beyond allocating space and selecting furniture. Noise-control, aesthetics, information-flow and networked computer work-stations have created complex challenges for todays office-space planners
training of workers Sophisticated preventive-maintenance programs Flexible machines Empowered workers trained in problem solving Layouts small and compact