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    Layouts

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    pavan hyd
    The document discusses different types of facility layouts used in manufacturing, including product layouts, process layouts, and hybrid layouts. It compares product layouts and process layouts, noting key differences such as the type of production process, product demand and variety, equipment used, and worker skills required. The document also describes approaches for designing process layouts, including block diagramming and relationship diagramming techniques, which aim to minimize material handling costs and distances between departments through analysis and trial layouts.

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    © All Rights Reserved
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    Layouts

    Uploaded by

    pavan hyd
    18 views20 pages
    The document discusses different types of facility layouts used in manufacturing, including product layouts, process layouts, and hybrid layouts. It compares product layouts and process layouts, noting key differences such as the type of production process, product demand and variety, equipment used, and worker skills required. The document also describes approaches for designing process layouts, including block diagramming and relationship diagramming techniques, which aim to minimize material handling costs and distances between departments through analysis and trial layouts.

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    4. Layouts

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    The document discusses different types of facility layouts used in manufacturing, including product layouts, process layouts, and hybrid layouts. It compares product layouts and process layouts, noting key differences such as the type of production process, product demand and variety, equipment used, and worker skills required. The document also describes approaches for designing process layouts, including block diagramming and relationship diagramming techniques, which aim to minimize material handling costs and distances between departments through analysis and trial layouts.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    18 views20 pages

    Layouts

    Uploaded by

    pavan hyd
    The document discusses different types of facility layouts used in manufacturing, including product layouts, process layouts, and hybrid layouts. It compares product layouts and process layouts, noting key differences such as the type of production process, product demand and variety, equipment used, and worker skills required. The document also describes approaches for designing process layouts, including block diagramming and relationship diagramming techniques, which aim to minimize material handling costs and distances between departments through analysis and trial layouts.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 20

    Layouts

    BITS Pilani
    Pilani Campus

    06/10/2020 1
    Outline
    • Basic Layouts
    • Designing Process Layouts
    • Designing Service Layouts
    • Designing Product Layouts
    • Hybrid Layouts

    06/10/2020 Manufacturing Management 2


    Objectives of Facility Layout

    • Minimize material-handling costs


    • Utilize space efficiently
    • Utilize labor efficiently
    • Eliminate bottlenecks
    • Facilitate communication and interaction
    • Reduce manufacturing cycle time
    • Reduce customer service time
    • Eliminate wasted or redundant movement
    06/10/2020 Manufacturing Management 3
    Objectives of Facility Layout
    • Facilitate entry, exit, and placement of material,
    products, and people.
    • Incorporate safety and security measures.
    • Promote product and service quality.
    • Encourage proper maintenance activities.
    • Provide a visual control of activities.
    • Provide flexibility to adapt to changing conditions.
    • Increase capacity.
    06/10/2020 Manufacturing Management 4
    Objectives of Facility Layout
    • Facilitate entry, exit, and placement of material,
    products, and people.
    • Incorporate safety and security measures.
    • Promote product and service quality.
    • Encourage proper maintenance activities.
    • Provide a visual control of activities.
    • Provide flexibility to adapt to changing conditions.
    • Increase capacity.
    06/10/2020 Manufacturing Management 5
    Manufacturing Process Layout

    Manufacturing Management 6
    A Product Layout

    In

    Out

    Manuacturing Management 7-7


    Comparison of Product
    and Process Layouts
    Product Process
    •• Description
    Description  Sequential  Functional grouping
    arrangement of of activities
    activities  Intermittent, job
     Continuous, mass shop, batch
    •• Type of process
    production, mainly production, mainly
    assembly fabrication

    •• Product  Standardized, made  Varied, made to


    to stock order
    •• Demand  Stable  Fluctuating
    •• Volume  High  Low
    •• Equipment  Special purpose  General purpose

    Manufacturing Management
    8
    Comparison of Product
    and Process Layouts
    Product Process
    • Workers
    Workers  Limited skills  Varied skills
    • Inventory
    Inventory  Low in-process, high  High in-process, low
    finished goods finished goods
    • Storage
    Storage space
    space  Small  Large
    • Material
    Material handling
    handling  Fixed path (conveyor)  Variable path (forklift)
    • Aisles
    Aisles  Narrow  Wide
    • Scheduling
    Scheduling  Part of balancing  Dynamic
    • Layout
    Layout decision
    decision  Line balancing  Machine location
    • Goal
    Goal  Equalize work at each  Minimize material
    station handling cost
    • Advantage
    Advantage  Efficiency  Flexibility

    Manufacturing Management
    9
    Fixed-Position Layouts
    • Typical of projects
    • Fragile, bulky, heavy items
    • Equipment, workers & materials brought to
    site
    • Low equipment utilization
    • Highly skilled labor
    • Typically low fixed cost
    • Often high variable costs

    Manufacturing Management
    10
    Designing Process Layouts
    • Goal: 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

    Manufacturing Management 11
    Block Diagramming

    • Unit load • Steps


    • Quantity in which • Create load summary
    material is chart.
    normally moved • Calculate composite
    • Nonadjacent load (two way)
    movements.
    • Distance farther
    than the next block • Develop trial layouts
    minimizing number
    of nonadjacent loads.
    Manufacturing Management
    12
    Block Diagramming: Example
    Load Summary Chart
    FROM/TO DEPARTMENT
    1 2 3
    Department 1 2 3 4 5
    1 — 100 50
    2 — 200 50
    4 5 3 60 — 40 50
    4 100 — 60
    5 50 —

    Manufacturing Management
    13
    Block Diagramming: Example

    Nonadjacent Loads
    2 3 200 loads
    110+40=150
    2 4 150 loads
    1 3 110 loads
    1 2 100 loads 110
    4 5 60 loads
    3 5 50 loads 100 200
    2 5 50 loads 1 2 3
    3 4 40 loads 150 50 50
    1 4 0 loads
    1 5 0 loads 60
    4 5
    40
    Grid 1

    Manufacturing Management 14
    Block Diagramming: Example

    Nonadjacent Loads: 0
    2 3 200 loads
    2 4 150 loads
    1 3 110 loads
    1 2 100 loads
    100 150
    4 5 60 loads 1 2 4
    3 5 50 loads 200 50 40
    2 5 50 loads 110 60
    50
    3 4 40 loads
    3 5
    1 4 0 loads
    1 5 0 loads Grid 2

    Manufacturing Management 15
    Block Diagramming: Example
    • Block Diagram
    – type of schematic layout diagram; includes space requirements
    (a) Initial block diagram (b) Final block diagram

    1 4
    1 2 4 2

    3 5 3 5

    Manufacturing Management 16
    Relationship Diagramming

    • Schematic diagram that uses


    weighted lines to denote
    location preference

    • Muther’s grid
    format for displaying manager
    preferences for department
    locations

    Manufacturing Management 17
    Relationship Diagramming

    A Absolutely necessary
    E Especially important
    I Important
    Production
    O O Okay
    A U Unimportant
    Offices
    U I X Undesirable
    Stockroom O E
    A X A
    Shipping and U U
    receiving
    U O
    Locker room O
    O
    Toolroom

    Manufacturing Management 7-18


    Relationship Diagramming
    (a) Relationship diagram of original layout

    Offices Locker Shipping


    room and
    receiving

    Key: A
    E
    I
    Stockroom Toolroom Production
    O
    U
    X

    Manufacturing Management 7-19


    Relationship Diagramming
    (b) Relationship diagram of revised layout

    Stockroom

    Offices Shipping
    and
    receiving

    Toolroom Production Locker Key: A


    room E
    I
    O
    U
    X

    Manufacturing Management 7-20

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