chapter 6 location, layout and flow -...
TRANSCRIPT
Slack, Brandon-Jones and Johnston, Essentials of Operations Management, 1st Edition, © The authors, 2011
Chapter 6
Location, layout and flow
Slack, Brandon-Jones and Johnston, Essentials of Operations Management, 1st Edition, © Slack, Brandon-Jones and Johnston, 2011
Design
Deliver
Direct
Develop
Operations Management
Slack et al’s model of operations management
Location, layout
and flow
Process design
Product and service design
Slack, Brandon-Jones and Johnston, Essentials of Operations Management, 1st Edition, © The authors, 2011
In Chapter 6 - Layout and flow– Slack et. al. identify the following key questions…….
Where should operations be located?
What is ‘layout and what are the basic types used in
operations?
What type of layout should an operation choose?
How should items be positioned in a workplace?
Key operations questions
Slack, Brandon-Jones and Johnston, Essentials of Operations Management, 1st Edition, © The authors, 2011
An innovative layout in a surgery improves its efficiency
Slack, Brandon-Jones and Johnston, Essentials of Operations Management, 1st Edition, © The authors, 2011
Product flow in Cadbury’sFlow of chocolate in Cadbury’s factory
Flow of customers in Cadbury World
Both Cadbury’s chocolate factory and it’s ‘Cadbury World’ visitor attraction use ‘product’ layout. But what will be different about the layouts and why?
Slack, Brandon-Jones and Johnston, Essentials of Operations Management, 1st Edition, © The authors, 2011
Functional layout in a library - the path of one customer
Entrance Exit
To journal stack
Study desks
On-line and CD-ROM access room
Loan books in subject orderEn
quiri
es
Store room
Counter staffCopying area
Com
pany
repo
rts
Current journals
Reserve collection
Reference section
Slack, Brandon-Jones and Johnston, Essentials of Operations Management, 1st Edition, © The authors, 2011
Department store with sports goods ‘shop-within-a-shop’
Sports shop Menswear
Women’s clothes
Luggage and gifts
Confectionery, newspaper, magazines
and stationary
Books and
videos Footwear
Perfume& jewellery
Elevators
Entrance
Slack, Brandon-Jones and Johnston, Essentials of Operations Management, 1st Edition, © The authors, 2011
An army induction centre which uses product layout
Lecture theatre
Uniform issuing area
Uniform store
Waiting area
Waiting area
Doctor
Doctor
Doctor
Doctor
Doctor
Doctor
Bloodtest
Bloodtest
Bloodtest
X-ray
X-ray
X-ray
Records: personal
history and medical details
Slack, Brandon-Jones and Johnston, Essentials of Operations Management, 1st Edition, © The authors, 2011
A product layout in a paper manufacturing operation
Slack, Brandon-Jones and Johnston, Essentials of Operations Management, 1st Edition, © The authors, 2011
A restaurant complex with all four basic layout types
Fixed-position layout service restaurant
Cell layout buffet
Line layout
cafeteria
Cool roomFreezer Vegetable prep Grill
Preparation
Ove
n
Functional layout kitchen
Main course buffet
Star
ter
buffe
t
Des
ert
buffe
tService line
Slack, Brandon-Jones and Johnston, Essentials of Operations Management, 1st Edition, © The authors, 2011
Advantages and disadvantages of Fixed position layout
Fixed position layout
Disadvantages
Advantages
Very high product and mix flexibility
Product/customer not moved
High variety of tasks for staff
Very high unit costs
Scheduling space and activities can be difficult
Slack, Brandon-Jones and Johnston, Essentials of Operations Management, 1st Edition, © The authors, 2011
Functional layout
Disadvantages
Advantages
High product and mix flexibility
Relatively robust in the case of disruptions
Easy to supervise
Low utilization
Can have very high WIP
Complex flow
Advantages and disadvantages of Functional layout
Slack, Brandon-Jones and Johnston, Essentials of Operations Management, 1st Edition, © The authors, 2011
Cell layout
Disadvantages
Advantages
Can give good compromise
Fast throughput
Group work can result in good motivation
Can be costly to rearrange existing layout
Can need more plant
Advantages and disadvantages of Cell layout
Slack, Brandon-Jones and Johnston, Essentials of Operations Management, 1st Edition, © The authors, 2011
Product layout
Disadvantages
Advantages
Low unit costs for high volume
Opportunities for specialization of equipment
Can have low mix flexibility
Not very robust in the case of disruptionsWork can be very repetitive
Advantages and disadvantages of Product layout
Slack, Brandon-Jones and Johnston, Essentials of Operations Management, 1st Edition, © The authors, 2011
Regular flow more important
Reg
ular
flow
mor
e fe
asib
le
Volume and variety characteristics of layout types
Low Volume High
High Variety Low
Fixed-position layout
Functional layout
Cell layout
Product layout
Flow becomes continuous
Flow is intermittent
Slack, Brandon-Jones and Johnston, Essentials of Operations Management, 1st Edition, © The authors, 2011
Service functional types
Mass services
Service shops
Manufacturing functional types
Continuous processes
Mass processes
Batch processes
Basic layout types
Fixed position layout
Functional layout
Cell layout
Product layout
The relationship between functional and layout types
Jobbing processes
Professional servicesProject processes
Slack, Brandon-Jones and Johnston, Essentials of Operations Management, 1st Edition, © The authors, 2011
Basic layout types have different fixed and variable costs that seem to determine which one to use.
Volume
Cos
ts
Use productUsecell
Use functionalUse fixed-
position
Fixed-position
Functional Cell
Product
Slack, Brandon-Jones and Johnston, Essentials of Operations Management, 1st Edition, © The authors, 2011
But uncertainty about exact fixed and variable costs means the decision can rarely be made on cost alone
Volume
Cos
ts Fixed-position
Functional
Cell
Product
Use fixed-position
Use functionalUse fixed-position or functional
?
Use functional or cell
?
Use functional or cell or product
?Use product
Slack, Brandon-Jones and Johnston, Essentials of Operations Management, 1st Edition, © The authors, 2011
Using anthropometric data, ergonomics can guide how people interface with their workplace
Workplace layout
Slack, Brandon-Jones and Johnston, Essentials of Operations Management, 1st Edition, © Slack, Brandon-Jones and Johnston, 2011
Forearmsapproximately
horizontal
Seat backadjustability
Good lumbarsupport
Seat heightadjustability
No excess pressure on underside of thighs and backs of knees
Foot support
if neededSpace for
postural change,no obstaclesunder desk
Leg room andclearance to allowpostural changes
Ergonomics in the office environment
Workplace layout
Slack, Brandon-Jones and Johnston, Essentials of Operations Management, 1st Edition, © Slack, Brandon-Jones and Johnston, 2011
Ergonomics in the office environment
Keyboard usable,
adjustable,detachable,
legible
Adequate lighting
Distracting noise
minimizedSoftware appropriate to task, adapted to user, no undisclosed monitoring
Screen: stable image,
adjustable, readable
glare/ reflection free
Windowcovering
Adequate contrast,
no glare or distractingreflections
Work surfaces: allow flexible
arrangements, spacious, glare free
Workplace layout