Discussion on Capacity Planning, Facility Location and Facility Layout
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Chapter101.pptxChapter 10
Chapter overview
This chapter defines layout planning and its importance.
Process and product layouts are identified, described, and compared.
The steps for designing product and process layouts are described and demonstrated.
Two additional layouts, the hybrid layout and group technology (cell) layout, are explained.
objectives
Define layout planning and explain its importance.
Identify and describe different types of layouts.
Describe the steps involved in designing a process layout.
Describe the two special cases of process layout.
Describe the steps involved in designing a product layout.
Explain the meaning of group technology (cell) layouts.
Layout planning
Layout planning is important because it can significantly affect the productivity and service quality.
Some consequences of poor layout are increased costs, confused and frustrated customers, and poor communication and information flows.
I often think of grocery stores or home improvement stores when thinking of layout planning. Are like items grouped together? Is there another item that will compliment what I already want to buy?
Four layout types
A process layout groups similar processes or functions. Process layouts use general purpose resources, are less capital and more labor intensive, are flexible, have slower processing rates, have higher material handling costs, are more difficult to schedule, and need more space.
A product layout arranges resources in a line flow. Product layouts use specialized resources, are capital intensive, have higher processing rates, lower material handling costs, need less space, and are relatively inflexible.
A hybrid layout combines aspects of both product and process layouts.
A fixed-position layout is used when the product can not be moved. The workers and equipment move around the products as needed.
Designing a process layout
To design a process layout, we have to gather information, develop a diagram of the space to be used, and develop a detailed layout of the space.
We need information regarding the amount of space needed for each resource, and the closeness measures between resources, such as number of trips or closeness ratings concerning the desirability of locating each department pair close together.
The diagram of the space is used to make sure that the space is large enough for all resources.
As an example, in a grocery store, all the fruit and vegetables are located together, while all the freezer items are located together.
Designing a product layout
Identify tasks and their immediate predecessors.
Determine output rate.
Determine cycle time.
Compute the theoretical minimum number of stations.
Assign tasks to workstations.
Compute efficiency, idle time, and balance delay.
In some cafeterias, there is a one line flow starting with the pickup of a tray and silverware. The food and drink areas are typically in this order:
Salads, Dressing, Bread, Entrees, Vegetables, Dessert, Drinks, Cash Register at the end
Cycle time and how it affects output
Cycle time is the maximum production time at any workstation on the line.
A product is moved from one station to the next in one cycle time.
One unit will be finished on the line in one cycle time.
The cycle time has an inverse relationship with the production rate.
For example, when the cycle time increases, the production rate decreases.
Questions?
