Proceess Layout

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D D

D D

G G

G G

G G

M M

M M

M M

A A

A A

L

L L

L L

L L

L

Process LayoutChapter 7Chapter 7


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Implement

changes6

Redesign Process(Revise layout)

5

Redesigning a Process

Through Layout Revision

Docum

entprocess3

Definescope

2

Evaluate

performance4

Figure 7.1Figure 7.1

I

dentifyopportunity1


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StrategicIssues

Facilitating the flow ofmaterials

Increasing the efficient utilization of

labor and equipment

Reducing hazards to workers Improving employee morale

Improving communication


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Layout Types

FoundryMilling

machines

LathesGrinding

Painting Drills

Office

Welding

Forging

(a) Layout of a job shop(a) Layout of a job shopFigure 7.3Figure 7.3


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Frdelarmed en funktionell verkstad:

flexibel, anpassningsbar till varierandeproduktionsfrhllande, ltt att styra om produktionen till

att tillverka nya produkter

lg strningsknslighet, om en maskin gr snder kanman arbeta i en annan

genom specialisering erhlls personal medspecialistkunnande

hgt maskinutnyttjande kan stadkommas

Flexible-Flow layout (funktionell verkstad)


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Nackdelarmed en funktionell verkstad:

hg kapitalbindning, mycket produkter iarbete och stora mellanlager

lnga oskra genomloppstider

svra planerings, lednings ochadministrationsproblem

ofta lnga transportvgar

genom specialisering, kan den enskildeoperatren bli lst till sin maskin


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Layout Types

(b) Layout of a production line(b) Layout of a production line


Station 1 Station 2 Station 3 Station 4


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Frdelarmed linjetillverkning:

kort genomloppstid

mindre kapitalbindning

mindre transporter

arbetet lttare att planera och administrera n i en

funktionell verkstad (nr installationen r klar)

Line-Flow layout (linjetillverkning)


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Group Technology

Machine

1

Machine

2Machine

3

Machine

4Machine

5

Materials in

Finished

goods out


One Worker, Multiple MachinesOne Worker, Multiple Machines


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Group Technology


Drilling

D D

D D

Grinding

G G

G G

G G

Milling

M M

M M

M M

Assembly

A A

A A

Lathing

Receiving and

shipping

L

L L

L L

L L

L

(a) Jumbled flows in a job shop withoutGT cells(a) Jumbled flows in a job shop withoutGT cells


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Group Technology

(b) Line flows in a job shop with three GT cells(b) Line flows in a job shop with three GT cells

Cell 3

L M G G

Cell 1 Cell 2

Assembly

area

A A

L M DL

L M ShippingD

Receiving

G



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Designing Process Layouts Step 1: GatherInformation

Space Requirements by Center

Available Space

Closeness Factors

Other Considerations

Step 2: Develop a Block Plan

Step 3: Design a Detailed Layout

Aids for Process Layout Decisions


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Department Area Needed (ft2)

1. Administration 3,500

2. Social services 2,600

3. Institutions 2,400

4. Accounting 1,600

5. Education 1,500

6. Internal audit 3,400

Total 15,000

100'

150'

Office of Budget

Managem

ent

3 6 4

1 2 5



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Office of Budget

Managem

entTrips between Departments

Department 1 2 3 4 5 6

1. Administration

2. Social services

3. Institutions

4. Accounting

5. Education

6. Internal audit

3 6 5 6 10

8 1 1

3 9

2

1

100'

150'

3 6 4

1 2 5


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Office of Budget

Managem

enty Departments 1 and 6 close together

y Departments 3 and 5 close together



100'

150'

1 5

6

100'

150'

3 6 4

1 2 5


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Office of Budget

Managem





100'

150'

1 5

6 3

100'

150'

3 6 4

1 2 5


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Office of Budget

Managem





100'

150'

1 5

6 32

4

100'

150'

3 6 4

1 2 5


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Office of Budget

Managem

ent

100'

150'

3 6 4

1 2 5





100'

150'

1 5

6 32

4


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Distance Measures

Euclidian DistanceEuclidian Distance

Rectilinear DistanceRectilinear Distance

ddABAB = (= (xxAAxxBB))22 + (+ (yyAA yyBB))

22

ddABAB = |= |xxAAxxBB| + || + |yyAA yyBB||


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Office of Budget

Managem

ent

100'

150'

3 6 4

1 2 5

Load Distance Analysis

Current Plan Proposed Plan

Dept Closeness Distance Distance

Pair Factor, w d wd Score d wdScore

1,2 3 1 3 2 6

1,3 6 1 6 3 18

1,4 5 3 15 1 51,5 6 2 12 2 12

1,6 10 2 20 1 10

2,3 8 2 16 1 8

2,4 1 2 2 1 1

2,5 1 1 1 2 2

3,4 3 2 6 2 6

3,5 9 3 27 1 9

4,5 2 1 2 1 2

5,6 1 2 2 3 3

ld= 112 ld= 82Example 7.2


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Office of Budget

Managem

ent

100'

150'

3 6 4

1 2 5



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Office of Budget

Managem

ent

100'

150'

3 6 4

1 2 5



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Out-and-Back Warehouse


Dock Aisle

Storage area

Storage area

3 5 5 6 4 2 7

1 5 5 4 4 2 7


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Zone Systems


Click to add title

Zones Zones Control

station Shipping

doors

Tractor

trailer

Tractor

trailer

Overflow

Feeder

linesFeeder

lines


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Designing Product Layouts Line Balancing

Precedence Diagram

Desired Output rate Cycle Time

Theoretical Minimum

Idle Time, Efficiency, and Balance Delay

Finding a Solution


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Line Balancing

Green Grass, Inc.Green Grass, Inc.

Big BroadcasterBig Broadcaster


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Line Balancing Big BroadcasterBig Broadcaster

AA Bolt leg frame to hopperBolt leg frame to hopper 4040 NoneNone

BB Insert impeller shaftInsert impeller shaft 3030 AA

CC Attach axleAttach axle 5050 AA

DD Attach agitatorAttach agitator 4040 BB

EE Attach drive wheelAttach drive wheel 66 BB

FF Attach free wheelAttach free wheel 2525 CC

GG Mount lowerpostMount lowerpost 1515 CC

HH Attach contro

ls

Attach contro

ls 2020

D, E

D, EII Mount nameplateMount nameplate 1818 F, GF, G

TotalTotal 244244

WorkWork TimeTime ImmediateImmediateElementElement DescriptionDescription (sec)(sec) Predecessor(s)Predecessor(s)

4040

3030

B

A

Example 7.3Example 7.3


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AA Bolt leg frame to hopperBolt leg frame to hopper 4040 NoneNone

BB Insert impeller shaftInsert impeller shaft 3030 AA

CC Attach axleAttach axle 5050 AA

DD Attach agitatorAttach agitator 4040 BB

EE Attach drive wheelAttach drive wheel 66 BB

FF Attach free wheelAttach free wheel 2525 CC

GG Mount lowerpostMount lowerpost 1515 CC

HH Attach controlsAttach controls 2020 D, ED, E

II Mount nameplateMount nameplate 1818 F, GF, G

TotalTotal 244244

WorkWork TimeTime ImmediateImmediateElementElement DescriptionDescription (sec)(sec) Predecessor(s)Predecessor(s)

4040

66

2020

5050

1515

1818

E3030

2525

4040H

I

D

B

F

C

A

G



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4040

66

2020

5050

1515

1818

E3030

2525

4040H

I

D

B

F

C

A

G

Desired output rate = 2400/week

Plant operates 40 hours/week


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4040

66

2020

5050

1515

1818

E3030

2525

4040H

I

D

B

F

C

A

G



r= 2400/40 = 60 units/hour



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4040

66

2020

5050

1515

1818

E3030

2525

4040H

I

D

B

F

C

A

G



r= 2400/40 = 60 units/hour

c= 1/60 = 1 minute/unit

= 60 seconds/unit



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cc= 60 seconds/unit= 60 seconds/unit

4040

66

2020

5050

1515

1818

E3030

2525

4040H

I

D

B

F

C

A

G



TM= 244 seconds/60 seconds= 4.067 or 5 stations



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4040

66

2020

5050

1515

1818

E3030

2525

4040H

I

D

B

F

C

A

G



TM= 244 seconds/60 seconds= 4.067 or 5 stations

Efficiency = [244\5(60)]100 = 81.3%



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TM= 5 stationsTM= 5 stations

Efficiency = 81.3%Efficiency = 81.3%

4040

66

2020

5050

1515

1818

E3030

2525

4040H

I

D

B

F

C

A

G

Cumm Idle

Station Candidate Choice Time Time

S1 A A 40 20



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S1

40

66

2020

5050

1515

1818

E3030

2525

4040H

I

D

B

F

C

A

G

Cumm Idle


S1 A A 40 20



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S1

40

66

2020

5050

1515

1818

E3030

2525

4040H

I

D

B

F

C

A

G

Cumm Idle


S1 A A 40 20

S2 B,C C 50 10



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S1

S2

40

66

2020

50

1515

1818

E3030

2525

4040H

I

D

B

F

C

A

G

Cumm Idle


S1 A A 40 20

S2 B,C C 50 10



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S1

S2

40

66

2020

50

1515

1818

E3030

2525

4040H

I

D

B

F

C

A

G

Cumm Idle


S1 A A 40 20

S2 B,C C 50 10S3 B,F,G B 30 30



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S1

S2

40

66

2020

50

1515

1818

E30

2525

4040H

I

D

B

F

C

A

G

Cumm Idle


S1 A A 40 20

S2 B,C C 50 10S3 B,F,G B 30 30



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S1

S2

40

66

2020

50

1515

1818

E30

2525

4040H

I

D

B

F

C

A

G

Cumm Idle


S1 A A 40 20

S2 B,C C 50 10S3 B,F,G B 30 30

E,F,G F 55 5



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S1

S2

S3

40

66

2020

50

1515

1818

E30

25

4040H

I

D

B

F

C

A

G

S1 A A 40 20

S2 B,C C 50 10S3 B,F,G B 30 30

E,F,G F 55 5

Cumm Idle




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S1

S2

S3

S5S4


40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G


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NL8. En produkt bestr av 9 st detal er (D1-D9) vilka monteras ihop enligt strukturen

nedan:

A

D7

E

D4B

C G

D5

DD8

D1

D2

D3

D6

D9

F


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Documents

Proceess Layout