Facilities Layout and Materials Handling

Facility layout
Physical configuration of departments, workstations, and equipments in the conversion
process.
The arrangement of physical resources used to create the product.
Different types of layout:
Process layout- group similar resources together
Product layout- designed to produce a specific product efficiently
Hybrid layout- combine aspects of both process and product layouts
Fixed-Position layout- product is too large to move. Products generally circulate within
the production facilities (machines, workers, etc.); in this particular type of layout, the
product does not move, it is the different resources that are moved to perform the
operations on the product
Product Layout vs Process Layout
Product Layout
o Used for systems with high production volumes and a low variety of products.
Facilities are organized according to the sequence of the successive
manufacturing operations.
Continuous flow: The correct operations flow is reached through the
layout design and the equipment and machinery specifications.
Repetitive flow (assembly line): The correct operations flow will be based
in a line balancing exercise, in order to avoid
o The plant layout will be based in allocating a machine as close as possible to the
next one in line, in the correct sequence to manufacture the product.
o
Process Layout
o Useful when the production process is organized in batches.
o Personnel and equipment to perform the same function are allocated in the
same area.
o The different items have to move from one area to another one, according to the
sequence of operations previously established.
o The variety of products to produce will lead to a diversity of flows through the
facility.
o The variations in the production volumes from one period to the next one (short
periods of time) may lead to modifications in the manufactured quantities as
well as the types of products to be produced.

Quantitative Techniques in Plant Layout

Designing product layouts requires consideration of:

 Sequence of tasks to be performed by each workstation

Logical order
Speed considerations line balancing
Step 1: Identify tasks & immediate predecessors
Example 10.4 Vicki's Pizzeria and the Precedence Diagram
Immediate
Task Time
Work Element Task Description
Predecessor
(seconds
A
B
C
D
E
F
G
H
I

Roll dough
Place on cardboard backing
Sprinkle cheese
Spread Sauce
Add pepperoni
Add sausage
Add mushrooms
Shrinkwrap pizza
Pack in box

None
A
B
C
D
D
D
E,F,G
H
Total task time

50
5
25
15
12
10
15
18
15
165

Step 2: Determine output rate: Vicki needs to produce 60 pizzas per hour
Step 3: Determine cycle time: The amount of time each workstation is allowed to

Cycle time (sec./unit)

available time sec./day 60 min/hr x 60 sec/min

60 sec./unit
desired output units/hr
60 units/hr
complete its

tasks

Limited by the bottleneck task (the longest task in a process):

Maximum output

available time
3600 sec./hr.

72 units/hr,or pizzas per hour

bottleneck task time 50 sec./unit

Step 4: Compute the Theoretical Minimum number of Stations: TM = number of

stations needed to achieve 100% efficiency (every second is used)

TM

task times
cycle time

165 seconds
2.75, or 3 stations
60 sec/station

Step 5: Assign tasks to workstations (balance the line)

Start at the first station & choose the longest eligible task following
precedence relationships
Continue adding the longest eligible task that fits without going over the
desired cycle time
When no additional tasks can be added within the desired cycle time, begin
assigning tasks to the next workstation until finished
Workstation
1

Eligible task
A
B
C
D
E, F, G
E, F
F
H
I

Task Selected
A
B
C
D
G
E
F
H
I

Task time
50
5
25
15
15
12
10
18
15

Idle time
10
5
35
20
5
48
38
20
5

 Step 6: Compute efficiency, idle time & balance delay

Efficiency (%) is the ratio of total productive time divided by total time
Efficiency (%)

t
NC

165 sec.
100 91.7%
3 stations x 60 sec.

Balance delay (%) is the amount by which the line falls short of 100%
Balance delay 100% 91.7% 8.3%

Different computer software for facilities layout

CRAFT
o Computerized Relative Allocation of Facilities Technique)
CRAFT 3-D
MULTIPLE
CORELAP
o Computerized Relationship Layout Planning
ALDEP
o Automated Layout Design Program
COFAD
FADES