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Lecture - 2: Learning Objectives To Analyze The Facility Layout Process For Smooth Flow of Service

The document discusses process analysis of facility layouts. It provides examples and steps to analyze a process layout using process diagrams. Key steps include: 1) Drawing a process diagram using standard notations to represent operations, decisions, waits, and flows 2) Identifying the bottleneck operation that limits the system capacity 3) Calculating the capacity of each operation and the overall system capacity 4) Determining if the service system is balanced and how to balance it if needed, such as by adding servers or combining operations It then provides an example of analyzing and improving a process layout for passenger boarding at an airport.

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26 views12 pages

Lecture - 2: Learning Objectives To Analyze The Facility Layout Process For Smooth Flow of Service

The document discusses process analysis of facility layouts. It provides examples and steps to analyze a process layout using process diagrams. Key steps include: 1) Drawing a process diagram using standard notations to represent operations, decisions, waits, and flows 2) Identifying the bottleneck operation that limits the system capacity 3) Calculating the capacity of each operation and the overall system capacity 4) Determining if the service system is balanced and how to balance it if needed, such as by adding servers or combining operations It then provides an example of analyzing and improving a process layout for passenger boarding at an airport.

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Lecture 2

PROCESS ANALYSIS OF FACILITY LAYOUTS










Learning Objectives
To analyze the facility layout process for smooth flow of service
6.4 Process Analysis of Product Layout
To balance the service line in a product layout it is important to identify the
bottleneck operation and to determine the system capacity. It can be determined by
analyzing the process with the help of process diagrams.
The notations typically used in process diagrams are given below.
1. Operation: A rectangle encloses the operation name and cycle time (CT)

2. Decision: A diamond encloses the operation name and cycle time (CT)


3. Wait: A triangle represents customers waiting or inventory of goods


4. Flow: An arrow shows movement of customers, goods, or information

6.4.1 Terms Used in Process Analysis
1) Cycle time (CT): Average time between completions of successive units. For
an operation, CT is the average service time to perform the activity. Cycle time
for entire service system is the time between successive customers exiting
during a busy period. So it depends on the bottleneck activity.
2) Bottleneck: Bottleneck operation is the slowest operation with longest CT
which limits the production or service time. Bottleneck operation determines
the CT of entire service system.
3) Capacity: Capacity is a measure of output per unit of time when system is
fully busy, for example, applications processed per hour; customers served in 8
hours of shift. The unconstrained capacity of any operation is measured as
reciprocal of CT i.e., 1/CT. The system capacity is the inverse of CT of
bottleneck activity.
4) Capacity Utilization: Capacity Utilization is a measure of actual output
achieved relative to the process capacity when fully busy.
5) Throughout time: Throughput time is the total time taken to complete a
process from time of arrival to time of exit. It is determined as sum of the
critical path operation times plus the average time spent in all queues. If we
omit waiting time from throughput time, the rest of the time (critical path) is
called rush order flow time.
Example: After a customer arrives to Delhi Airport from overseas, it requires a
sequence of activities to be performed before boarding a domestic flight. The
activities with their average time in seconds are given below in the table 6.1.
TABLE 6.1: ACTIVITIES TO BE PERFORMED WHILE BOARDING
FLIGHT
Activity
Number
Activity
Average Time
(seconds)
1 Deplane 36
2 Immigration 60
3 Baggage Claim 90
4 Customs 40
5 Check-in baggage 40
6 Boarding domestic flight 45

All the activities except baggage claim needs to be performed in the sequence
mentioned in the table 6.1.
1) What is the bottleneck activity?
2) What is the capacity of system in terms of member of passengers processed
per hour?
3) Is the service system balanced? If not, how to balance it?
Solution:
Step 1
Draw the process diagram using following notation in Figure 6.4.
Activity Number
Cycle time (seconds) Capacity per hour

Figure 6.4: Notation to represent activity
By using notation in Figure 6.4 draw the process diagram as shown in Figure 6.5

FIGURE 6.5: PROCESS DIAGRAM OF PASSENGER BOARDING
DOMESTIC FLIGHT FROM OVERSEAS TRAVEL
The activity number 3 is the bottleneck activity which is Baggage claim, the
slowest operation taking 90 seconds.
We can find the capacity of each operation in terms of passengers served per hour.
It takes 36 seconds for a passenger to deplane at activity 1 that is Deplane.
1
Capacity of activity 1 60 60
36
100passengers per hour
=
=

Similarly we can determine capacity of each operation and write on the lower right
hand side box in process diagram.

The capacity of the system is the capacity of bottleneck activity 3 i.e., 40
passengers per hour.
The service line is not balanced one because we see that the time taken by each
activity is not same, which leads to idle time for some of the activities.
To balance the line we can suggest two ways
1) We can add extra server to the bottleneck activity to increase the capacity
2) We can merge some activities or combine some activities.
Option 1) will certainly increase the number of workers or servers at activity 3.The
revised layout will look as shown in Figure 6.6.

FIGURE 6.6 FIRST REVISION OF PROCESS FLOW DIAGRAM
Now the capacity at activity 3 is 80 passengers per hour. But the bottleneck will
shift to activity 2 and 6 with system capacity of 60 passengers per hour. We can
apply option 2) that is combining activity 2 and 4. The revised layout will look like
as shown in Figure 6.7. The total time at 2 and 4 will be 100 seconds with capacity
of 72(36+36) passengers per hour. The average cycle time will be 50 seconds.

FIGURE 6.7 SECOND REVISION OF PROCESS OF PRODUCT
LAYOUT
The revised layout will have capacity of 72 passengers per hour which is more than
the original layout but definitely with addition of one worker or server and merging
of two activities.
6.5 Process Analysis of Process layout
As we have seen in the earlier section that the objective of process layout is to
arrange departments or service centers in the most convenient locations, which can
be achieved by placing departments with large interdepartmental flow of people or
paperwork next to one another .
We will use following notations:
i, j : Represents individual department or service center
n : Number of departments or service centers
D
ij
: Distance between departments i and j
N
ij
: Number of customers or number of trips made by customers or
employees per unit time (day, week, month) moving from department i to
department j and from department j to department i.
Our objective is to minimize the movement or distance travelled by the customers
between departments
n n
ij ij
i 1 j 1
Minimize Z N D
= =
=

----------------------- (6.1)
Example:
In a hospital, the management wants to relocate 8 departments within the hospital
facility. The initial layout with facility measurements is presented below in figure
6.8.





FIGURE 6.8: INITIAL PROCESS LAYOUT OF A HOSPITAL
The vertical and horizontal distance between adjacent departments is 30 and 20
respectively.
Diagonal departments are considered adjacent and assigned a distance of 20. Non
diagonal departments will also take the horizontal distance while relocating. We
need to know the interdepartmental flow between all departments in one week,
which is given in table 6.2.
TABLE 6.2: INTERDEPARTMENTAL FLOW IN A HOSPITAL
Interdepartmental flow (N
ij
)
Department
Number
(i)
Department
Name
(j)
Departments
1 2 3 4 5 6 7 8
1 Registration - 100 0 100 0 0 0 0
2 Patient Ward 1 - 50 0 10 20 10 50
3 ICU - 20 20 20 30 0
4 Patient Ward 2 - 20 30 30 30
5 X Ray - 5 0 0
6 Labs/tests - 0 0
7 Surgery - 0
8 Pharmacy -

The interdepartmental flow can be seen in a triangularized form in the table 6.2.
We will use operations sequence analysis heuristics to identify a good layout. The
heuristic will begin with an initial layout as shown in Figure 6.9. We will find the
total movement for this layout using equation (1) and represented in Table 6.3. We
see here the maximum flow distance is between 1 and 4. We can locate 1 and 4
close to each other. We will bring 4 at the place of 5 as shown in figure 6.10 and
will find the total travel distance again.

FIGURE 6.9: INITIAL LAYOUT OF HOSPITAL UNITS
TABLE 6.3: TOTAL FLOW DISTANCE FOR INITIAL LAYOUT
Flow pair Flow distance
1,2 100 20 =2000
1,4 100 60 =6000
2,3 50 20 =1000
2,5 10 20 =200
2,6 20 30 =600
2,7 10 20 =200
2,8 50 40 =2000
3,4 20 20 =400
3,5 20 40 =800
3,6 20 20 =400
3,7 30 30 =900
4,5 20 60 =1200
4,6 30 40 =1200
4,7 30 20 =600
4,8 30 30 =900
5,6 5 20 =100
Total travel distance = 18500

The total travel distance is 18500. After exchanging 4 and 5, the new layout will
look like as shown in figure 6.10. We can see the revised total travel distance is
16700 in Table 6.4. In this new layout we see maximum flow is between 1 and 4,
which already located adjacent to each other. Next maximum flow is between 1
and 2 and between 2 and 8.

FIGURE 6.10: REVISED LAYOUT AFTER FIRST ITERATION
TABLE 6.4: TOTAL FLOW DISTANCE AFTER FIRST ITERATION
Flow pair Flow distance
1,2 100 20 =2000
1,4 100 30 =3000
2,3 50 20 =1000
2,5 10 40 =400
2,6 20 30 =600
2,7 10 20 =200
2,8 50 40 =2000
3,4 20 40 =800
3,5 20 20 =400
3,6 20 20 =400
3,7 30 30 =900
4,5 20 60 =1200
4,6 30 20 =600
4,7 30 40 =1200
4,8 30 60 =1800
5,6 5 40 =200
Total travel distance = 16700

Swap 6 with 8 find the total travel distance as shown in Figure 6.11 and total travel
distance in Table 6.5.

FIGURE 6.11: REVISED LAYOUT AFTER SECOND ITERATION

TABLE 6.5: TOTAL FLOW DISTANCE AFTER SECOND ITERATION
Flow pair Flow distance
1,2 100 20 =2000
1,4 100 3 =300
2,3 50 20 =1000
2,5 10 40 =400
2,6 20 40 =800
2,7 10 20 =200
2,8 50 30 =1500
3,4 20 40 =800
3,5 20 20 =400
3,6 20 20 =400
3,7 30 30 =900
4,5 20 60 =1200
4,6 30 60 =1800
4,7 30 40 =1200
4,8 30 20 =600
5,6 5 30 =150
Total travel distance = 13650

Again departments 1 and 2 are already adjacent to each other.
So we will bring 8 closer or adjacent to 2. We will swap 6 with 8 and get a new
layout. This new layout has total travel distance of 136500 which is very less as
compared to initial layout.
Similarly we can keep on checking each pair for possible improvement in the
layout until we get minimum total travel distance.

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