CHAPTER 3
Plant/Facility Layout
Definition
The overall arrangement of machines, departments, work centers, equipment, material handling, service facilities and aisles to facilitate the movement of work, customers or materials through the system. Objective of Plant Layout Reduce Bottlenecks in moving people or material Bottleneck an operation that limits output in the production sequence. Bottleneck centre has less capacity than the prior and following work centers.
Minimize Material Handling Cost Reduce Hazard To Personnel Utilize Labor Efficiently Increase Morale Utilize Available Space Effectively and Efficiently. Provide Flexibility
Factors That Influence Layout
1. Type of product good of services, the aspect of product design and quality standard and whether for stock or made to order products. 2. Volume of production capacity utilization, provision for expansion. 3. Type of production process technology used, types of material handled and the process of producing the goods, service creation and delivery.
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Types of Production/Operation
Continuous/Flow shop Intermittent/Job shop Project
Types of Production
Continuous/Flow shop Intermittent/Job shop
High product volume Use special purpose equipment Capital intensive operations Low product volume Use general purpose equipment Labor intensive
Few schedule changes due to few Frequent schedule changes due to highly standardize output large variety of outputs Small product mix Standardize product made to inventory Operators are less broadly skilled Fixed cost high and variable cost low Large product mix Made to order products and not stored Operators are broadly skilled Fixed costs tend to be low and variable cost high
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Types of Layout
1. 2. 3. 3 basic types of layouts Product layout Process layout Fixed layout
Product Layout
Product layout is defined as the arrangement of facilities according to the needs processing requirement and in the same sequence as the operations necessary for producing the products or service. Also known as line layout or assembly layout It is appropriate for producing one standard product, in large volume Suitable for products that require continuous production operations. Eg television sets, washing machines and automobiles assembly.
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Advantages and Disadvantages of Product Layout
Advantages
Reduce material handling cost Low work in progress inventory Reduced total processing time high output, low unit cost Task is simplified low training cost and time Simple production planning and control
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Disadvantages
Lack of process flexibility Expensive equipment special purpose equipment The operation are too interdependent Low workers morale and productivity
Process Layout
Process layout is the arrangement of facilities and equipment in groups according to the function performed. It is appropriate for intermittent operations when work flow is not consistent for all output. Variable of workflow occurs when a variety of products or variations on single product are produced. Work centers or department are grouped together according to functional type Prevalent in banks, hospital and department store.
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Process-Oriented Layout
Patient A - broken leg ER triage room Surgery Emergency room admissions Patient B - erratic heart pacemaker Laboratories
Radiology
ER Beds
Pharmacy
Billing/exit
Figure 9.3
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Advantages/Disadvantages of Process Layout
Advantages
Flexibility of equipment and personnel Smaller investment in equipment Workers are more knowledgeable Less vulnerable to equipment failure
Disadvantages
High material handling cost High work in process inventory Large storage space Large aisles required High production cost per unit Long processing time Complex requirement for scheduling and control
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Comparison Between Product and Process Layout
Product layout
Efficiency Machines are arranged in a sequence manner Continuous production process
Process Layout
Flexibility Machines are arranged in groups according to functions Intermittent production process, jobshop, batch production
Standardize product made to stock Varied, product made to order Stable demand High Volume Special purpose equipment Workers have limited skillsperform special tasks Fluctuating demand Low volume General purpose equipment Workers have varied skills perform diverse tasks.
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Fixed Position layout
Fixed position layout is the arrangement of facilities and equipment so that resources needed in the form of workers, equipment and materials flow to the item being produced or serviced. Also referred to as project layout Eg. Home plumbing , construction of dams, bridges, ships and home building.
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Product Layout Analysis
Three important requirements in designing an effective and efficient production line. 1. It meets the required capacity of demand able to generate the desired number of output 2. The sequence is technically feasible in sequence to facilitate the production flow 3. It is an efficient line reduce cost of idleness and increase capacity
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Important definitions
Precedence diagram It shows the elemental task to be performed and sequence requirements. The amount of time required to perform a task. Could be in minutes or seconds. Number in the minutes in each hour that a work station is working. The longest task time.
Task time
Productive times per hour
Cycle time
Work station
Physical location where particular set of task are performed
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Important definitions
Minimum numbers of work stations The least number of workstations that can provide the required production. Actual number of work stations The total number of workstations required on the entire production line, calculated as the next higher integer value of the number of workstations working. The workstation that has the longest task time. The process of assigning tasks to workstation in order to equalize the performance time at all workstations in such a way that 17 idle time is minimized
Bottleneck station Line balancing
Production Layout Analysis
1. 2. 3. 4. Cycle time Capacity Efficiency and Idleness Assembly Line Balancing
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