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FACILITY LAYOUT
Lecture-04
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OUTLINE
Facility layout: [Using QuantitativeMeasures]
Facility layout: [Using Quantitative andQualitative
Measures]
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FLOW PROCESSES
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Layout Evaluation Criteria
The most commonly used quantitativecriterion for evaluating
layout:
TCMF :Total Cost of Material Flow per time period TCtran: Total
Cost of Material Transport per time
period TC : Total Cost of Material Movement per time
period
M
1i
M
1jijijijtranMF dhfTCTCTC
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Total Cost of Material Movement
M: number of activities (facilities) fij : flow volume between
activities i and j,
measured per time period dij: distance between activities i and
j,
measured per time period hij: cost per move between activities i
and
j per unit distance
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FACILITY LAYOUT
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FACILITY LOCATION
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FACILITY LAYOUT
Machine LayoutDepartment Layout
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Machine Layout Relationship between activities:
Quantitative measures (Flow of materials) Other quantitative and
qualitative measures are
possible (e.g. adjacency) Flow Requirements
Unit load (batch) sizes Equivalence Factors
Machine Layout Criterion Total weighted distance Total cost
Combination of Quantitative and Qualitative Criteria.
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FLOW WITHIN DEPARTMENTS
Depends on the type of machine layout Fixed Product Layout
Product Layout
Most flow is between adjacent machines. Depends on whether or
not operators are
shared between machines (end-to-end, front-to-front, U-shaped
flow pattern, etc.)
Group Layout Little flow between groups
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FLOW WITHIN DEPARTMENTS
Process Layout Variable-path material handling Most flow is
between machines Flow pattern depends on machine-aisle
arrangement (Two-way aisles; One-way aisles)
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QAP Model of Machine Layout
Machine layout can be modelled as aQuadratic Assignment Problem
(QAP)
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QAP
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Example:[4 Sites & 4 Facilities]
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QAP
The layout models are NP-complete Optimal algorithms: Branch and
bound,
Decomposition, Cutting plane algorithms These algorithms can
produce optimal solutions
for only small sized problem (M20. Heuristic (non-optimal)
procedures are typically
used to solve QAPs Steepest Descent Pairwise Interchange
(SDPI)
Heuristic
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Steepest Descent
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SLP
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Qualitative Relationships
Material Flow Personnel Flow Same resource Same personnel
Communication Safety Noise Structural
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Systematic Layout Planning
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RELATIONSHIP DIAGRAMMING FOR NEWLAYOUTS
Step-1: Select the first department to enter thelayout (The Dept
with the greatest number ofA)
Step-2:Select the second department to enterthe layout (The Dept
selected should have an Arelationship with the first Dept.)
Step-3:Select the third department to enter thelayout (The third
Dept selected should have thehighest combined relationship with the
twoDepts)
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RELATIONSHIP DIAGRAMMING FOR NEWLAYOUTS
Step-4:Select the fourth department to enter thelayout (The same
logic as in Step-3)
Step-n:Department n is placed according to therules described in
Steps 3 and 4.
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Systematic Layout Planning
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Systematic Layout Planning
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Systematic Layout Planning
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Department Layout Manufacturing Departments
A group of machines and/or workstations Non-Manufacturing
Departments
Shipping/Receiving areas, Storage areas,Offices, Cafeterias,
etc.
Flow Pattern between Departments U-shaped, S-Shaped,
W-Shaped.
Block Layout Representations
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Block Layout Representations
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Non-Manufacturing Departments Offices offices for
administrative, support, and
engineering staff; meeting/conference rooms;etc.
Storage/Warehousing dedicated areas outsidesof each
manufacturing department for thestorage of raw materials,
in-process inventories,and finished goods.
Shipping/Receiving dockboard area, manuveringarea for MHE used
for loading/unloading,buffer/staging areas, container and trash
storage,offices and truckers lounge.
Restrooms located within 200 feet of everypermanent
workstation.
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Non-Manufacturing Departments
Food Services Health Services, looker rooms, and wash
rooms. Plant Services HVAC, pump, generators,
etc. Emergency exits an exit must be within
150 ft of any point in the building.
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Total Facility
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Total Site
