layout design

To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.

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 LayoutProcess Layout

Chapter 7Chapter 7


Implementchanges

6

Redesign Process (Revise layout)

5

Redesigning a Process Redesigning a Process Through Layout RevisionThrough Layout Revision

Documentprocess

3

Definescope

2

Evaluateperformance

4

Figure 7.1Figure 7.1

Identify opportunity

1


Absolute LocationsAbsolute Locations

(a) Original layout(a) Original layout

Frozen foods

Dry groceries

Bread Vegetables

Meats



Absolute LocationsAbsolute Locations

(b) Revised layout(b) Revised layout

Frozen foods

Dry groceries

BreadVegetables

Meats



Layout TypesLayout 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


Layout TypesLayout Types

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


Station 1 Station 2 Station 3 Station 4


Group TechnologyGroup Technology

Machine 1

Machine 2

Machine 3

Machine 4Machine

5

Materials in

Finished goods out


One Worker, Multiple MachinesOne Worker, Multiple Machines




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 without GT cells(a) Jumbled flows in a job shop without GT cells



(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 MShipping

D

Receiving

G



Department Area Needed (ft2)

1. Administration 3,5002. Social services 2,6003. Institutions 2,4004. Accounting 1,6005. Education 1,5006. Internal audit 3,400

Total 15,000

100'

150'

Office of Budget Office of Budget ManagementManagement

3 6 4

1 2 5




Trips 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


Office of Budget Office of Budget ManagementManagement Departments 1 and 6 close together Departments 3 and 5 close together Departments 2 and 3 close together


100'

150'

1 5

6

100'

150'

3 6 4

1 2 5




100'

150'

1 5

6 3

100'

150'

3 6 4

1 2 5




100'

150'

1 5

6 32

4

100'

150'

3 6 4

1 2 5



100'

150'

3 6 4

1 2 5

Departments 1 and 6 close together Departments 3 and 5 close together Departments 2 and 3 close together


100'

150'

1 5

6 32

4


Distance MeasuresDistance Measures

Euclidian DistanceEuclidian Distance

Rectilinear DistanceRectilinear Distance

ddABAB = (= (xxAA –– x xBB))22 + ( + (yyAA – – yyBB))22

ddABAB = |= |xxAA –– x xBB| + || + |yyAA – – yyBB||



100'

150'

3 6 4

1 2 5

Load Distance Analysis

Current Plan Proposed Plan

Dept Closeness Distance DistancePair Factor, w d wd Score d wd Score

1,2 3 1 3 2 61,3 6 1 6 3 181,4 5 3 15 1 51,5 6 2 12 2 121,6 10 2 20 1 102,3 8 2 16 1 82,4 1 2 2 1 12,5 1 1 1 2 23,4 3 2 6 2 63,5 9 3 27 1 94,5 2 1 2 1 25,6 1 2 2 3 3

ld =112 ld = 82Example 7.2



100'

150'

3 6 4

1 2 5



Out-and-Back WarehouseOut-and-Back Warehouse


Dock Aisle

Storage area

Storage area

3 5 5 6 4 2 7

1 5 5 4 4 2 7


Zone SystemsZone Systems


Click to add titleZones Zones Control

station Shipping doors

Tractor trailer

Tractor trailer

Overflow

Feeder lines

Feeder lines


Line BalancingLine Balancing

Green Grass, Inc.Green Grass, Inc.Big BroadcasterBig Broadcaster


Line BalancingLine Balancing Big BroadcasterBig Broadcaster



AA Bolt leg frame to hopperBolt leg frame to hopper 4040 NoneNoneBB Insert impeller shaftInsert impeller shaft 3030 AACC Attach axleAttach axle 5050 AADD Attach agitatorAttach agitator 4040 BBEE Attach drive wheelAttach drive wheel 66 BBFF Attach free wheelAttach free wheel 2525 CCGG Mount lower postMount lower post 1515 CCHH Attach controlsAttach controls 2020 D, ED, EII Mount nameplateMount nameplate 1818 F, GF, G

TotalTotal 244244

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

Example 7.3Example 7.3




TotalTotal 244244


4040

A





TotalTotal 244244


4040

3030

B

A





TotalTotal 244244


4040

5050

B

C

A

3030





TotalTotal 244244


4040

5050

3030

4040

D

B

C

A





TotalTotal 244244


4040

66

5050

E3030

4040

D

B

C

A





TotalTotal 244244


4040

66

5050

E3030

2525

4040

D

B

FC

A





TotalTotal 244244


4040

66

5050

1515

E3030

2525

4040

D

B

FC

A

G





TotalTotal 244244


4040

66

2020

5050

1515

E3030

2525

4040H

D

B

FC

A

G





TotalTotal 244244


4040

66

2020

5050

1515

1818

E3030

2525

4040H

I

D

B

FC

A

G





4040

66

2020

5050

1515

1818

E3030

2525

4040H

I

D

B

FC

A

G




4040

66

2020

5050

1515

1818

E3030

2525

4040H

I

D

B

FC

A

G

Desired output rate = 2400/weekPlant operates 40 hours/week



4040

66

2020

5050

1515

1818

E3030

2525

4040H

I

D

B

FC

A

G


r = 2400/40 = 60 units/hour




4040

66

2020

5050

1515

1818

E3030

2525

4040H

I

D

B

FC

A

G


r = 2400/40 = 60 units/hour

c = 1/60 = 1 minute/unit= 60 seconds/unit




cc = 60 seconds/unit = 60 seconds/unit

4040

66

2020

5050

1515

1818

E3030

2525

4040H

I

D

B

FC

A

G






4040

66

2020

5050

1515

1818

E3030

2525

4040H

I

D

B

FC

A

G


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





4040

66

2020

5050

1515

1818

E3030

2525

4040H

I

D

B

FC

A

G



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




cc = 60 seconds/unit = 60 seconds/unitTM = 5 stationsTM = 5 stationsEfficiency = 81.3%Efficiency = 81.3%

4040

66

2020

5050

1515

1818

E3030

2525

4040H

I

D

B

FC

A

G



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





4040

66

2020

5050

1515

1818

E3030

2525

4040H

I

D

B

FC

A

G

Cumm IdleStation Candidate Choice Time Time





4040

66

2020

5050

1515

1818

E3030

2525

4040H

I

D

B

FC

A

G


S1 A A 40 20





40

66

2020

5050

1515

1818

E3030

2525

4040H

I

D

B

FC

A

G


S1 A A 40 20





S1

40

66

2020

5050

1515

1818

E3030

2525

4040H

I

D

B

FC

A

G


S1 A A 40 20





S1

40

66

2020

5050

1515

1818

E3030

2525

4040H

I

D

B

FC

A

G


S1 A A 40 20

S2 B,C C 50 10





S1

40

66

2020

50

1515

1818

E3030

2525

4040H

I

D

B

FC

A

G


S1 A A 40 20

S2 B,C C 50 10





S1

S240

66

2020

50

1515

1818

E3030

2525

4040H

I

D

B

FC

A

G


S1 A A 40 20

S2 B,C C 50 10





S1

S240

66

2020

50

1515

1818

E3030

2525

4040H

I

D

B

FC

A

G


S1 A A 40 20

S2 B,C C 50 10

S3 B,F,G B 30 30





S1

S240

66

2020

50

1515

1818

E30

2525

4040H

I

D

B

FC

A

G


S1 A A 40 20

S2 B,C C 50 10

S3 B,F,G B 30 30





S1

S240

66

2020

50

1515

1818

E30

2525

4040H

I

D

B

FC

A

G


S1 A A 40 20

S2 B,C C 50 10

S3 B,F,G B 30 30E,F,G F 55 5



S1

S2



40

66

2020

50

1515

1818

E30

25

4040H

I

D

B

FC

A

G


S1 A A 40 20

S2 B,C C 50 10

S3 B,F,G B 30 30E,F,G F 55 5





S1

S2S3

40

66

2020

50

1515

1818

E30

25

4040H

I

D

B

FC

A

G

S1 A A 40 20

S2 B,C C 50 10

S3 B,F,G B 30 30E,F,G F 55 5






S1S3

S240

66

2020

50

1515

1818

E30

25

4040H

I

D

B

FC

A

G





S1

S2S3

S5S4


40

6

20

50

15

18

E30

25

40H

I

D

B

FC

A

G


Solved Problem 1Solved Problem 1

B FE

A C D B

FE

A

C

D

Figure 7.14Figure 7.14 Figure 7.15Figure 7.15

TRIPS BETWEEN DEPARTMENTSDEPT A B C D E F

A — 8 3 9 5B — 3C — 8 9D — 3E — 3F —


Solved Problem 2Solved Problem 2

2020

E

145145

H

130130

I

2525

D

8080

B

1515

F

5050

C

4040

A

120120

G115115

J


layout design

Documents

accompany

ritzman operations

line balancingwork

s1 s2 s3

s1 s2

budget management

line balancingd

xa xb