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Layout Design

The document discusses production system design and facility layout. It describes that production system design involves process planning, technology choice, capacity planning, layout decision, location choice, and work design. There are three basic types of facility layouts: process layout which groups machines by the process they perform, product layout which arranges workstations linearly to produce a specific product, and fixed position layout used when the product cannot be moved. The document then provides an example of using line balancing to determine the optimal number of workstations needed to produce a product within a given cycle time.

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Sinem Düden
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53 views34 pages

Layout Design

The document discusses production system design and facility layout. It describes that production system design involves process planning, technology choice, capacity planning, layout decision, location choice, and work design. There are three basic types of facility layouts: process layout which groups machines by the process they perform, product layout which arranges workstations linearly to produce a specific product, and fixed position layout used when the product cannot be moved. The document then provides an example of using line balancing to determine the optimal number of workstations needed to produce a product within a given cycle time.

Uploaded by

Sinem Düden
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Production

System Design
Production System
Design entails:
• Process planning
• Technology choice
• Capacity planning
• Layout decision
• Location choice
• Work design
Production System
Design entails:
• Process planning
• Technology choice
• Capacity planning
• Layout decision
• Location choice
• Work design
Facility
Layout
Design
Basic Types of Layouts
 Process Layout
 Machines grouped by process they perform
 Product Layout
 Linear arrangement of workstations to
produce a specific product
 Fixed Position Layout
 Used in projects where the product cannot
be moved
Basic Types of Layouts
 Process Layout
 Machines grouped by process they perform
 Product Layout
 Linear arrangement of workstations to
produce a specific product
 Fixed Position Layout
 Used in projects where the product cannot
be moved
Process Layout
Milling
Lathe Department Department Drilling Department
M M D D D D
L L

M M D D D D
L L

G G G P
L L

G G G P
L L
Grinding Painting Department
Department
L L
Receiving and A A A
Shipping Assembly
Product layout

Work Work Work


station 1 station 2 station 3

A, B C D
0.3 0.4 0.3
minute minute minute
• Layout decisions impact the initial
investment and operating costs of
any facility.
- impacts capacity decisions : no
of workers and/or machines needed
- impacts internal transportation
costs
Product Layout

• Line Balancing

– Assignment of tasks which need to be


done to produce/assemble one unit of a
product to individual workstations
without exceeding the set cycle time
limit to minimize the number of
workstations
Product Layout

• Line Balancing

– Assignment of tasks which need to be


done to produce/assemble one unit of a
product to individual workstations
without exceeding the set cycle time
limit to minimize the number of
workstations
• Workstation: A physical stage in
production/assembly where a number of
tasks are done by one worker

• Cycle Time : Maximum workload (in time


units) allowed at a workstation
• Maximum throughput:1/CT
• Theoretically minimum # of workstations
Line Balancing
WORK ELEMENT PRECEDENCE TIME (MIN)
A Press out sheet of fruit — 0.1
B Cut into strips A 0.2
C Outline fun shapes A 0.4
D Roll up and package B, C 0.3
• Operating time: 40 hrs per week
• Demand per week: 6000 units
Line Balancing
WORK ELEMENT PRECEDENCE TIME (MIN)
A Press out sheet of fruit — 0.1
B Cut into strips A 0.2
C Outline fun shapes A 0.4
D Roll up and package B, C 0.3

0.2
40 hours x 60 minutes B / hour 2400
CT = = = 0.4 minute
6,000 units 6000
0.1 A D 0.3
0.1 + 0.2 + 0.3 + 0.4 1.0
N= = = 2.5 workstations
0.4 0.4
C
0.4
Line Balancing
WORK ELEMENT PRECEDENCE TIME (MIN)
A Press out sheet of fruit — 0.1
B Cut into strips A 0.2
C Outline fun shapes A 0.4
D Roll up and package B, C 0.3

0.2
40 hours x 60 minutes B / hour 2400
CT = = = 0.4 minute
6,000 units 6000
0.1 A D 0.3
0.1 + 0.2 + 0.3 + 0.4 1.0
N= = = 2.5 workstations
0.4 0.4
C 3 workstations
0.4
Line Balancing
WORK ELEMENT PRECEDENCE TIME (MIN)
A Press out sheet of fruit — 0.1
B Cut into strips A 0.2
C Outline fun shapes A 0.4
D Roll up and package B, C 0.3

CT = 0.4
0.2
B N=3

0.1 A D 0.3

C
0.4
Line Balancing
REMAINING REMAINING
WORKSTATION ELEMENT TIME ELEMENTS

CT = 0.4
0.2
B N=3

0.1 A D 0.3

C
0.4
Line Balancing
REMAINING REMAINING
WORKSTATION ELEMENT TIME ELEMENTS
1 A 0.3 B, C

CT = 0.4
0.2
B N=3

0.1 A D 0.3

C
0.4
Line Balancing
REMAINING REMAINING
WORKSTATION ELEMENT TIME ELEMENTS
1 A 0.3 B, C
B 0.1 C, D

CT = 0.4
0.2
B N=3

0.1 A D 0.3

C
0.4
Line Balancing
REMAINING REMAINING
WORKSTATION ELEMENT TIME ELEMENTS
1 A 0.3 B, C
B 0.1 C, D
2 C 0.0 D

CT = 0.4
0.2
B N=3

0.1 A D 0.3

C
0.4
Line Balancing
REMAINING REMAINING
WORKSTATION ELEMENT TIME ELEMENTS
1 A 0.3 B, C
B 0.1 C, D
2 C 0.0 D
3 D 0.1 none

CT = 0.4
0.2
B N=3

0.1 A D 0.3

C
0.4
Line Balancing
REMAINING REMAINING
WORKSTATION Work
ELEMENT Work
TIME Work
ELEMENTS
station 1 station 2 station 3
1 A 0.3 B, C
B A, B C
0.1 D C, D
2 C 0.0 D
0.3 0.4 0.3
3 D minute 0.1
minute
none
minute

CT = 0.4
0.2
B N=3

0.1 A D 0.3

C
0.4
Line Balancing
REMAINING REMAINING
WORKSTATION Work
ELEMENT Work
TIME Work
ELEMENTS
station 1 station 2 station 3
1 A 0.3 B, C
B A, B C
0.1 D C, D
2 C 0.0 D
0.3 0.4 0.3
3 D minute 0.1
minute
none
minute

CT = 0.4
0.2
B N=3

0.1 + 0.2 + 0.3 + 0.4 1.0


E= 0.1 A = D0.833
= 0.3 = 83.3%
3(0.4) 1.2

C
0.4
AIC Netbooks
Process Layouts
Manufacturing Process Layout
Milling
Lathe Department Department Drilling Department
M M D D D D
L L

M M D D D D
L L

G G G P
L L

G G G P
L L
Grinding Painting Department
Department
L L
Receiving and A A A
Shipping Assembly
Manufacturing Process Layout
Milling
Lathe Department Department Drilling Department
M M D D D D
L L

M M D D D D
L L

G G G P
L L

G G G P
L L
Grinding Painting Department
Department
L L
Receiving and A A A
Shipping Assembly
Manufacturing Process Layout
Milling
Lathe Department Department Drilling Department
M M D D D D
L L

M M D D D D
L L

G G G P
L L

G G G P
L L
Grinding Painting Department
Department
L L
Receiving and A A A
Shipping Assembly
Designing Process Layouts
 Minimize material handling
costs
 Block Diagramming
 Minimize nonadjacent loads
 Use when quantitative data
is available
 Relationship Diagramming
 Based on location preference between areas
 Use when quantitative data is not available
Muther relationships
• Degrees of closeness

– A : Absolutely necessary
– E : Very important
– I : Important
– O : Ordinary importance
– U : Unimportant
– X : Undesirable
Factors
• Use same equipment/facilities
• Share same personnel/records
• Sequence of work flow
• Ease of communication
• Unsafe or unpleasant conditions
• Similar work performed
Designing Process Layouts
 Minimize material handling
costs
 Block Diagramming
 Minimize nonadjacent loads
 Use when quantitative data
is available
 Relationship Diagramming
 Based on location preference between areas
 Use when quantitative data is not available
Hybrid Layouts
 Cellular layouts
 Group machines into machining cells
 Flexible manufacturing systems
 Automated machining & material
handling systems
 Mixed-model assembly lines
 Produce variety of models on one line

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