Facility Layout

Objectives of Facility Layout

• Smooth Flow
• Flow of material and people - entry, storage, process, WIP, finished goods store and exit/delivery
• Minimum material-handling
• Minimize material handling, avoid non adjacent loads use overhead cranes, conveyors
• Maximum space efficiently
• Orientation of machines, common working space between machines and equipment, O/H fittings,
racking,
• Maximum labor efficiently
• Movements, ergonomics, daylight, noise levels, working temperatures, ventilation,..
• Eliminate wasted or redundant movement
• Eliminate bottlenecks
• First machine out-put is 20 parts per hour 2nd machine out put is 30 parts per hour and the target is
to assemble 50 pcs per hour.
 Objectives of Facility Layout

• Easy to maintain – cleanliness, safety, scrap generation, spillage,

• Provide visual controls - Entry, exit, hazard, escape route, Assembly point, speed of the
machine.
• Provide flexibility - to adapt to changing conditions
• Incorporate safety - emergency exit, approach to fire extinguishers, ventilation, marked
walk way, smoke detectors, anti-slip floor, occupational health, environmental pollution
• Follow Government regulations on plant design and layout
Fire, electricity, municipal, Environment, Police,
 Basic Layouts

➢ Fixed Position layout

➢ Product layout
➢ Process layout
➢ Flexible manufacturing layout
➢ Cellular layout
➢ Mixed model assembly layout
➢ Free flow layout
➢ Grid layout
➢ Spine layout
➢ Loop layout
➢
1. Fixed-position layouts
•
Used for projects in which product cannot be moved
•
Fragile, bulky, heavy items
•
Equipment, workers & materials brought to site
•
Highly skilled labor
•
Typically low fixed cost & high variable costs
2. Process layouts / Functional layout
• Group similar activities together according to process or function they perform.
Minimize the material handling
3. Product layouts
• Arrange activities in line according to sequence of operations for a particular product or
service. Equalize the amount of work at each station.
Comparison of Product and Process Layouts
Product layout Process layout
Description Sequential activities Functional groups
Type of Process Continuous mass production Batch production - fabrication
Product Standardized made to stock Varied made to order
Demand Stable Fluctuating
Volume High Low
Equipment Special purpose General Purpose
Workers Limited skill Varied skill
Inventory Low in-process, high - finished High in-process, low - finished
Material Handling Fixed path (conveyors) Variable path (Fork lift)
Layout decision Line balancing Machine layout
Goal Equalize work at each station Minimize material handling
Advantage Efficiency Flexibility
Hybrid Layouts

4. Cellular layouts

Group of dissimilar machines in work centers (called cells) processes families of

parts with similar shapes or processing requirements

5. Flexible manufacturing system

Automated machining and material handling systems which can produce an
enormous variety of items

6. Mixed-model assembly line

Processes more than one product model in one line

Types of Store Layouts
1. Product layout - Line Balancing
Designing Product Layouts

• Objective - Line balancing

•

a. Equalize the amount of work at each workstation

b. Precedence requirements, physical restrictions on the order in which operations are
performed
c. Cycle time – maximum time spent at each station
d. Maximize the efficiency of the line
Line Balancing Procedure

1. Draw and label a precedence diagram

2. Calculate desired cycle time required for line
3. Calculate theoretical minimum number of workstations
4. Group elements into workstations, recognizing cycle time and precedence constraints
5. Calculate efficiency of line
6. Determine if theoretical minimum number of workstations or an acceptable efficiency
level has been reached. If not, go back to step 4.
 Flow Time vs Cycle Time

• Cycle time = max time spent at any station

• Flow time = time to complete all stations
Desired Cycle Time (Takt time) for producing 120 units in 8 hours
Cd = Desired cycle time

production time avai

Cd = desired units of out

(8 h
Cd =
/
48
Cd = = 4 minutes / Unit 12

Takt = total time available

total customer demand
Line Balancing

Example 1- A briefcase manufacturing company assembles its stylish cases in six primary
work elements
Workas Element
mentioned below Precedence Time in Mins.

A Tan leather - 20
B Dye leather A 12
C Shape case B 7
D Mold hinges and fixture - 10
E Install hinges and fixtures C,D 15
F Assemble case E 18

a. Construct a precedence diagram for the manufacturing of brief case

 Work Element Precedence Time in
Mins.
A Tan leather - 20
B Dye leather A 12
C Shape case B 7
D Mold hinges and fixture - 10
E Install hinges and fixtures C,D 15 10
F Assemble case E 18 15 18
D
E F
precedence diagram
A B C

20 12
7

Desired cycle time = (40 X 60) / 50 = 48 minutes per case

Flow time = 20+12+7+10+15+18 = 82 mins
Nmin = (20+12+7+10+15+18) / 48 = 1.70 ~ 2
 Work Element Preceden Time in Desired cycle time = (40 X 60) / 50 = 48 minutes per
ce Mins.
case
A Tan leather - 20
Flow time = 20+12+7+10+15+18 = 82 mins
B Dye leather A 12
Nmin = (20+12+7+10+15+18)
10 / 48 = 1.70 ~ 2
C Shape case B 7 18
D 15
D Mold hinges and - 10
E F
fixture
A B C
E Install hinges and C,D 15
fixtures 20 12
7
F Assemble case E 18
 Work Element Preceden Time in
ce Mins.
A Tan leather - 20
B Dye leather A 12
C Shape case B 7
D Mold hinges and - 10
fixture
E Install hinges and C,D 15
fixtures
F Station Time
Assemble case E Eligible 18 Will fit Assign
Revised
Idle
Remaining Task Time Time
time
Remaining
1 48 A, D A,D A(20) 28 -
28 B,D B,D B(12) 16 -
16 C,D C (7) 9 9
2 48 D D D(10) 38
38 E E E(15) 23 -
23 F F F(18) 5
 Station 1 Station 2

a, b, c d, e, f

Station Time Eligible Will fit Assign Idle

Revised
Remaining Task Time Time
time
Remaining
1 48 A, D A,D A(20) 28 -
28 B,D B,D B(12) 16 -
16 C,D D (10) 6 6
2 48 C C C (7) 41
41 E E E(15) 26 -
26 F F F(18) 8
Idle time = 14
 Station Eligible Will fit Assign Cumulativ Idle
Task Time e Time 10
Time 15 18
D
E F

A B C

20 12
Station - 1 A, D A,D A(20) 20 - 7

B,D B,D B(12) 32 -

C,D D (10) 42 Takt time (Desired cycle time)
total time
42 6 = (40 X 60) / 50 = 48 min./ case
C C (7) 7
Station - 2
C
start after
35
minutes

E E E(15) 22 -
F F F(18) 40
total time 40 40 8
Total idle
time 96 - 82 System utilisation = 41/48 =
total time = = 14 minutes
40 + 42 = 82 85.41%
minutes
 Example 2
Using the information given in the table,
a). Draw a precedence diagram
b). Compute the cycle time for an out-put of 400 units in 8 hours shift
c). Determine the minimum number of work stations required
d). Compute the resulting percentage of idle time and the efficiency

Work Element Predecessor Time (min)

a - 0.2
b a 0.2
c - 0.8 a b e
d c 0.6
e b 0.3
c d f g h
f d, e 1.0
g f 0.4
h g 0.3
Total time 3.8
Cycle time =
8 x 60 /400 1.2; Nmin = 3.8/1.2 = 3.17 ~ 4
 Cycle time =
8 x 60 /400 1.2; Nmin = 3.8/1.2 = 3.17 ~ 4
Percentage idle time =
1.0/4*1.2 = 0.2083 = 20.83
Efficiency = 100 – 20.83 = 79.17
Station Time Eligible Will fit Assign Idle
Revised
Remaining Task Time Time
time
Remaining
1 1.2 a, c a, c a(0.2) 1.00 -
Work Assignment to 1.0 c, b b, c c(0.8) 0.2 -
work station 0.2 b, d b b(0.2) 0 -
2 1.2 e, d e, d d(0.6) 0.6 -
0.6 e e e(0.3) 0.3 0.30
3 1.2 f f f(1.0) 0.2 0.2
4 1.2 g g g(0.4) 0.8 -
0.8 h h h(0.3) 0.5 0.5
Idle time = 1.0
 a b e

c d f g h

Station 1 Station 2 Station 3 Station 4

a, b, c d, e f g, h
Computerized Line Balancing

• Software Packages :
• IBM’s COMSOAL (Computer Method for Sequencing Operations for Assembly Lines)
• GE’s ASYBL (Assembly Line Configuration Program)
•

• Use heuristics to assign tasks to workstations

•

• Longest operation time

• Shortest operation time
• Most number of following tasks
• Least number of following tasks
• Ranked positional weight
 2. Designing Process Layouts

• Goal of Process Layout - Minimize material handling costs or distance travelled by

material or people
• Other factors
• Location of entrance, loading dock, elevators, windows, reinforced flooring, noise level,
safety, size and location of rest rooms, user familiarity, vastu etc.
• Material orientation or people orientation
• Initial cost in setting up the layout
• Expected operating cost
• Amount of effective capacity utilization
• Ease of modifying the system
• Standardization of layout, ex. McDonald, gas stations, super markets,
• No algorithms exists to identify the best layout arrangement under all circumstances
• Planners must rely on heuristic rules to guide trial-and –error efforts.
 2. Designing Process Layouts Procedure

1. Block Diagramming - used when quantitative data is available and objective is to

minimize nonadjacent loads
2. Relationship Diagramming – used when quantitative data is not available and layout is
based on location preference between area,
1. Note:
2. Unit load - quantity in which material is normally moved
3. Nonadjacent load - distance farther than the next block
• Steps in block diagramming
•

1. Create load summary chart

2. Calculate composite (two way) movements
3. Develop trial layouts minimizing number of nonadjacent loads
Block Diagramming: Example 1

The average number of loads transported per month, between the five departments of a
wood furniture factory is given in the below table.
The current layout of the facility is shown schematically on the 2 X 3 grid. You are asked
to evaluate the current layout in terms of non adjacent loads, and if necessary provide a
new layout on 2 X 3 grid. Load Summary Chart
FROM/TO DEPARTMENT
1
Department 1 2 3 4 5
2
1 — 100 50
2 — 200 50
3 60 — 40 50
4 100 — 60
5 50 —
From to Composite Loads
1 1 Department 1 2 3 4 5
0
1 2 100
1 3 50+60 = 110
1 4 0
1 5 0
2 3 200 2 3 200 loads
2 4 50+100 = 150 2 4 150 loads
1 3 110 loads
3 4 40 1 2 100 loads
3 5 50+50 =100 4 5 60 loads
4 5 60 3 5 100 loads
3 4 40 loads
1 4 0 loads
1 5 0 loads
 Department 1 2 3 4 5

2 3 200 loads
2 4 150 loads
1 3 110 loads 110
1 2 100 loads
4 5 60 loads Nonadjacent Loads 110+40=1
100 200
3 5 100 loads 1
3 4 40 loads 150
100
0
1 4 0 loads
60
1 5 0 loads
2 5 0 loads 40
Grid 1
Nonadjacent Loads: 0
1

Grid 2
 Load Summary Chart
FROM/TO DEPARTMENT
1
Department 1 2 3 4 5
2
1 — 100 50
2 — 200 50
3 60 — 40 50
4 100 — 60
5 50 —

(a) Initial block diagram

(b) Final block diagram

1
1 2 4

3 5 3
 Block Diagramming: Example 2
Given the following load summary chart, design a layout on a 2 X 3 grid that will minimize
the non-adjacent loads

Load
Summ
ary
Chart
From / to 1 2 3 4 5
1 - 50 25
2 - 20 100
3 30 10 - - 75
4 40 -
5 60
 Composite
Load
loads
Sum
mary
• 2 0
Chart • 3 80
From / to 1 2 3 4 5 • 4 0
1 - 50 25 •
25
5
2 - 20 100
3 30 10 - - 75 23 30

4 40 - 24 100

5 60 25 60
34 40
•
75
5
45 0
 Example -3 (minimizing transport cost or distance)
Develop a process layout that will minimize the total distance travelled by patients at
a medical clinic, using the following information on projected department visit by
patient and distance between locations. Assume a distance of 35 meters between the
reception and each patient location. Use following format
Distance
between
Room A
locations
Room B
(meters)
Room C
Room D From / To A B C D E F
Room E A 40 80 100 120 160
Room F
B - 40 60 80 120
C Number - 20 40 80
of Trips
1. Cardiology D between - 20 40
2. Orthopedic E locations - 40
3. General F (Nos.) -
Medicine
From / To Receptio 1 2 3 4 5 6
4. Radiology lab n
5. Pediatrics
 Dist
anc
e
bet
wee
n
loca
tion
s
(me
ters
Number
)of Trips
From / Abetween
B C D E F
To locations
(Nos.)
A - 40 80 100 120 160
From / To Receptio 1 2 3 4 5 6
B - 40 60 80 120
n
C
Reception - 20 - 50 20210 40
20 80
10 130
1D 10 - 0 - 40 20
110 40
80 50
E - 40
2 40 - 0 50 40 120
F -
3 10 - 10 250 10
 Dist No. of  Order of
anc Trips Assignmen
e Between t
bet 0 10
1–2 40
wee 7
n 1–3
110 3
loca 1–4 80
tion
5
1–5
s 50 6
(me 1–6
0 10
ters
Number 2–3
)of Trips 50 6
2–4
From / Abetween
B C D E F 40 7
2–5
To locations 120 2
2–6
A -(Nos.)40 80 100 120 160 10 9
3–4
From
B / To Receptio
- 1 40 2 3
60 4
80 5120 6 1
3–5 250
n
C - 20 40 80 1 9
Reception - 20 50 210 20 10 130 3–6
D - 20 40
4–5
040 7
1 10 - 0 40 110 80 50
E - 40 90 4
2 40 - 0 50 40 120 4–6
F -
5–6
20 8
 No. of  Order of
A/3 B/5 C/2 Trips Assignmen
OR A/3 B/5 C/1
Between t
1–2 0 10
D/2 E/6 F/4
D/1 E/4 F/6 1–3 40 7 (tied)
1–4 110 3
1–5 80 5
A/3 B/5 C/1
A B C 1–6 50 6 (tied)
2–3 0 10 (tied)
D/4 E/6 F/2
2–4 50 6 (tied)
D E F
2–5 40 7 (tied)
Departments 2–6 120 2
Room A 1. Cardiology 3–4 10 9 (tied)
Room B 2. Orthopedic
3–5 250 1
Room C 3. General Medicine
Room D 4. 2D Echo 3–6 10 9 (tied)
Room E 5. Pathology lab 4–5 40 7 (tied)
Room F 6. Radiology lab 4–6 90 4
5–6 20 8
 Dist
A/3 B/5 C/1 ance
bet
wee
D/4 E/6 F/2 n
loca
tion
s
A B C (met
ers)
D E F From / To A /3 B/5 C//1 D/4 E/6 F/2
Distan
A/3
ce - 40 80 100 120 160
C1-C1= 0 betwe
B/5 - 40 60 80 120
en
C/1 - 20 40 80
1-2 = C1-F2 = 80 depar
1-3 =C1-A3 =80 D/4
tment - 20 40
1-4 =C1-D4= 20 s
E/6 - 40
1-5=C1-B5=40 F(mete
/2 -
rs)
2-3 = F2-A3 =160 From To 1 2 3 4 5 6
2-4 =F2-D4 =40 1 - - 80 80 20 40 40
 Distan
ce
A/3 B/5 C/1 betwe
en
depar
D/4 E/6 F/2
tment
s
(mete
A B C rs)
From To 1 2 3 4 5 6
1 - - 80 80 20 40 40
D E F Number
2 - of Trips - 160 40 120 40
3 - between 100 40 120
locations
4 - 60 20
(Nos.)
5 - 80
From / To Receptio 1 2 3 4 5 6
6 - n
Reception - 20 50 210 20 10 130
1 10 - 0 40 110 80 50
2 40 - 0 50 40 120
Dist ber
anc of
e Trips
bet betw
wee een
n locat
dep ions
art (Nos
men .)
ts From Rece 1 2 3 4 5 6
(me / To p.
ters From To 1 2 3 4 5 6
) Recep - 20 50 210 20 10 130
1 . - 0 3200 2200 3200 2000
Fro To 1 2 3 4 5 6 2 1 - 0 0 40 2000
m 10 - 110 4800
80 4800
50
3 2 40 - 0 1000
50 10000
40 1200
120
1 - - 80 80 20 40 40
4 3 10 - 10 2400
250 1800
10
2 - - 160 40 120 40
5 4 0 - 40 1600
90
3 - 100 40 120
6 5 10 - 20
4 - 60 20
5 - distance traveled per day = 40,200
80 6 30 -
Total meters
6 -
Example 4
Relationship diagramming – (Muther's grid) Closeness rating

Draw a lay out for a hospital with the following

department
1. Cardiology
2. Orthopedic
A B C
3. Gynecology
4. General Medicine
5. Radiology lab D E F

6. Pediatrics
7. Pathology lab H
8. ECG and 2D Echo lab G
9. Mortuary E F
10. Operation theater
(Muther's grid) Closeness rating A = Absolutely important
E = Essential
I = Important
1. Cardiology O = Ordinary importance / OK
U = Un-important
2. Orthopaedics X = undesirable
3. Gynaecology

4. General Medicine

5. Radiology

6. Paediatrics

7. Pathology

8. ECG and 2D Echo

9. Mortuary

10. Operation Theatre

 (Muther's grid) Closeness rating
1
1. Cardiology 2
3
2. Orthopaedics 4
5
3. Gynaecology 6
4. General Medicine 7
8
5. Radiology 9
1
6. Paediatrics
0
7. Pathology 1
3 2
8. ECG and 2D Echo 4
5
9. Mortuary 6
7
10. Operation Theatre 8
10 9
 (Muther's grid) Closeness rating A = Absolutely important
E = Essential
I = Important
O = Ordinary importance / OK
1
1. Cardiology 2 U = Un-important
U 3 X = undesirable
2. Orthopaedics U 4
O 5
3. Gynaecology
U 6
4. General Medicine
A 7
O 8
5. Radiology A 9
X 10
6. Paediatrics A
7. Pathology 1
2
8. ECG and 2D Echo 4 3
9. Mortuary 6 5
8 7
10. Operation Theatre
9
10
 A = Absolutely important
(Muther's grid) Closeness rating E = Essential
I = Important Link A Link X
1 O = Ordinary importance / OK
1. Cardiology 2 U = Un-important 1-6 1-9
U 3 X = undesirable
2. Orthopedic U 4 1-8 2-9
U O 5
3. Gynecology O U 6 1-10 3-9
O A A 7
4. General Medicine 8 2-5 4-9
U O O
U A O A 9 2-10 5-9
5. Radiology A E U X 10
E I X A 3-10 6-9
U
6. Pediatrics U I X A 1
U X A 2 4-6 7-9
E
7. Pathology lab A X U 3 5-10 8-9
U X A 4
8.ECG and 2D echo X I 5 6-8 9-10
X I 6
9. Mortuary E 7
X 8
10. Operation theater 9
10
 Link A Link X

1-6 1-9
1-8 2-9
1-10 3-9
2-5 4-9
2-10 5-9
3-10 6-9
4-6 7-9
5-10 8-9
Rel Dept. Dept. Dept. Dept. Dept. Dept. Dept. Dept.8 Dept. Dept.10
6-8
. 1 2 3 4 5  6 7 9
A 6,8,10 5,10 10 6 10, 8 - - - - 9-10

E - - 7 7 - 7 - - 10 -
I - - 6,8 8 - 10 10 - - -
O 4,7 4,6,7 4 - - - - - - -
U 2,3,5 3,8 5 5,10 5,6,7 - 8 - - -
X 9 9 9 9 9 9 9 9 -  
 6
5
6 8
1 8 2 10
10 4 6
5 10

Rel. Dept. 1 Dept.2 Dept.3 Dept. 4 Dept.5 Dept. Dept. 7 Dept.8 Dept.9 Dept.10
  6

A 6,8,10 5,10 10 6 10, 8 - - - -

E - - 7 7 - 7 - - 10 -
I - - 6,8 8 - 10 10 - - -
O 4,7 4,6,7 4 - - - - - - -
U 2,3,5 3,8 5 5,10 5,6,7 - 8 - - -
X 9 9 9 9 9 9 9 9 -  
3 6 1 9

2 10 8

4 5 7
Department 1 Draw a lay out for the given relationship
X diagram
Department 2 A
O U
Department 3 X O
U O E
Department 4 A E X
A A A A
Department 5 U I E
U O A
Department 6 A A
U A
Department 7 A
E
Department 8
 (Muther's grid) Closeness rating
Link A Link X
Department 1
X 1-3 1-2
Department 2 A
O U 1-8 1-7
Department 3 X O
U 2-7 2-3
O E
Department 4 A E X 2-5
A A A A
Department 5 U I E 3-5
U O A
Department 6 A A 3-6
U A
Department 7 A 3-8
E 4-5
Department 8
4-8
5-7
5-8
 Link A Link X
Department 1
X
Department 2 A 1-3 1-2
O U
Department 3 X O 1-8 1-7
U O E
Department 4 A E X 2-7 2-3
A A A A
Department 5 U I E 2-5
U O A
Department 6 A A 3-5
U A
Department 7 A 3-6
E
Department 8 3-8
Rel. Dept. 1 Dept.2 Dept.3 Dept. 4 Dept. 5   Dept. 6 Dept. 7 Dept. 8 4-5
4-8
A 3,8 7 5,6,8 5,8 7,8, 8 - -
5-7
E 6 6,8 - - - - 8 - 5-8
I - - 7 - - - - -
O 5 3,5, - 7 - - - -
U - - - - - - - -
X 2,7 3 - - - - - -
Department 1
X
Department 2 A
  6 2
O U
Department 3 X O
U O E  3 8 7
Department 4 A E X
A A A A
Department 5 U I E
U O A  1 5 4
Department 6 A A
U A
Department 7 A
E
Department 8
Rel. Dept. 1 Dept.2 Dept.3 Dept. 4 Dept. 5   Dept. 6 Dept. 7 Dept. 8

A 3,8 7 5,6,8 5,8 7,8, 8 - -

E 6 6,8 - - - - 8 -
I - - 7 - - - - -
O 5 3,5, - 7 - - - -
U - - - - - - - -
X 2,7 3 - - - - - -
Layout Planning Packages
1. Construction Programs

CORELAP (Computerized Relationship Layout Planning )

ALDEP (Automated Layout Design Program)
SLP (Systematic Layout Planning)
PLANET LAYOPT, RAMA comp1
2. Improvement Programs
• CRAFT (Computerized Relative Allocation of Facilities Technique)
• PROMODEL (ProModel is a discrete-event simulation technology that is used to plan,
design and improve new or existing manufacturing, logistics and other operational
systems).
• EXTEND (a simulation program for modeling discrete event, continuous, agent-based, and
discrete rate processes).
• Three-D modeling and CAD (integrated layout analysis available in VisFactory and similar
software)
Layout - Vastu
Layout - Vastu
 Layout - Vastu

➢ More open space should be provided in the east and the North side than in the West and
South side.
➢ The sloping of the floors should be towards East, North and Northeast sides and never
towards South, West.
➢ A Thicker walls should be constructed in the South and West Side of the building and
the thinner walls should be in the North and east sides.
➢ The staircase should be in the Southwest side.
➢ The underground water tank should be in Northeast side.
➢ The overhead water tank should be in the Southwest corner.
➢ Toilets must be placed in Northwest or Western corners but should never be constructed
in the Northeast and Southwest corners.
➢ Administrative office and other office blocks can be constructed in North, East.
➢ Staff quarters, Outhouse should be built in the Northwest corner.
➢
 Layout - Vastu
➢ Basement should be constructed in the east, North or Northeast corner of the proposed
building.
➢ Heavy machinery should be placed in the Southwest, West & South zones.
➢ Northeast and centers of the building should be avoided for placing anything heavy.
➢ The heat zone or the burners, boilers, ovens, generators, furnace transformers, chimneys
should be in the Southeast corner.
➢ No garbage should be dumped in the Northeast corner of the building or at the site, north
or the east corner should always be kept free and clean.
➢ In R.C.C. framed structure, the number of columns or the beams should be even and not
odd.
➢ The beam should never run above the machines & the workers.
➢ The finished goods should be stored in the Northwest corner of the area.
➢ A pooja room or a temple should be in the northeast corner and should be kept neat and
clean.
 Next Topic
Product and Service Design