facility layout chapter 10 pages 343-355, 366-367
TRANSCRIPT
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Facility Layout
Chapter 10 pages 343-355, 366-367
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MGMT 326
Foundations
of Operatio
nsIntroductio
n
Strategy
ManagingProjects
QualityAssuran
ce
Facilities
Products &
Processes
ProductDesign
ProcessDesign
ManagingQuality
Statistical
ProcessControl
Just-in-Time & Lean Systems
FacilityLayout
Capacity
and Locatio
n
Planning& Control
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Presentation Outline
Importance of layout planning Types of layouts
Comparing process and product layouts
Designing process layouts Designing cellular layouts Office layouts
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What Is Layout Planning?
Layout planning is determining the best physical arrangement of resources within a facility
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Why is layout planning important?
Eliminates unnecessary costs for space and materials handling
Reduces work-in-process inventory Produces goods and services faster Reduces distances that workers must
travel in the workplace Improves communication and morale Increases retail sales Improves brand image
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Types of Layouts Process layouts: Group similar resources together Product layouts: Designed to produce a specific
product, or a small number of products efficiently Hybrid layouts: Combine aspects of both process
and product layouts Examples: cellular layout, grocery store
Fixed-Position layouts: Product is too large to move Examples: building construction, shipyard Resources must be brought to where they are
needed
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Process and Product Layouts
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Process Layouts Used in project and batch
manufacturing (intermittent processes) Also used in department stores, offices,
hospitals, and universities Able to make or sell a variety of
products Use general purpose resources Less automation than in product layouts
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Process Layouts (2)
Material handling costs per unit are higher than in product layouts
Scheduling production is more complex than in product layouts
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Product Layouts
Used in assembly lines and continuous manufacturing (repetitive processes)
A cafeteria line is a product layout In manufacturing, product layouts are
used to produce one product, or a small group of products, efficiently
Uses special purpose resources More automation than in process
layouts
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Product Layouts (2)
Material handling costs per unit are lower than in process layouts
Scheduling production is simpler than in process layouts
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Designing Process Layouts Step 1: Gather information:
Space needed, space available, importance of proximity between various units
Step 2: Develop alternative block plans: Using trial-and-error or decision support tools 2 approaches
Relationship (REL) chart From-to matrix
Can use both Decision support systems are heuristic methods
Usually give a "good" solution Solution may not be optimal (best solution)
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Designing Process Layouts (2)
Step 3: Develop a detailed layout Consider exact sizes and shapes of
departments and work centers including aisles and stairways
Tools like drawings, 3-D models, and computer-assisted design (CAD) software are often used
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Process Layout Example
Block layout for a sports medicine clinic
ARadiology
BLaboratory
CLobby & Waiting
DExamining
Rooms
ESurgery & Recovery
FPhysical Therapy
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Process Layout Example (2)
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Process Layout Example (3)
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Proposed Layout
Process Layout Example (4)
ARadiology
BExamining
Rooms
CLobby & Waiting
DSurgery &Recovery
ELaboratory
FPhysical Therapy
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Process Layout Example (5)
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Cellular Layouts
Used to make parts in Just-in-Time Manufacturing
Based on group technology Group technology (GT): A method of
organizing parts into families with similar manufacturing requirements
A manufacturing cell is created for each part family
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An Example of Group Technology
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© Wiley 2007
Process Flows before the Use of GT Cells
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© Wiley 2007
Process Flows after the Use of GT Cells
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Office Layouts Almost half the U. S. work force works in
an office Human interaction and communication
are the primary considerations in office layouts
People who need to interact frequently should be close to each other
One key layout tradeoff is between closeness and privacy
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Office Layouts (2)
Open concept offices promote understanding and trust.
A few closed rooms are needed for private discussions, such as personnel matters.
Moveable walls provide flexibility to change the layout when needed.
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Office Layout Example3D Systems
Hi-tech company – provides equipment and materials for rapid product design and manufacturing
Rock Hill headquarters handles product design, sales, training, and administration
Open office plan Conference room Areas for informal meetings Product showroom for customers Cyber café and fitness center for employees