Layout

Layout Design Considerations

u Higher utilization of space, equipment, and

people
u Improved flow of information, materials, or
people
u Improved employee morale and safer working
conditions
u Improved customer/client interaction
u Flexibility/Efficiency
 Basic Layouts
• Process layouts
• group similar activities together according to process or
function they perform
• Product layouts
• arrange activities in line according to sequence of
operations for a particular product or service
• Fixed-position layouts
• are used for projects in which product cannot be moved
Process Layout in Services

Women’s
Shoes Housewares
lingerie

Women’s Cosmetics and Children’s

dresses jewelry department

Women’s Entry and display Men’s

sportswear area department
 Supermarket Retail Layout

u Objective is to maximize profitability

per square foot of floor space
u Sales and profitability vary directly
with customer exposure
Five Helpful Ideas for Supermarket
Layout
1. Locate high-draw items around the periphery
of the store
2. Use prominent locations for high-impulse and
high-margin items
3. Distribute power items to both sides of an aisle
and disperse them to increase viewing of other
items
4. Use end-aisle locations
5. Convey mission of store through careful
positioning of lead-off department
Manufacturing Process Layout
 A Product Layout

In

Out
 Comparison of Product
and Process Layouts
Product Process
• Description w Sequential w Functional grouping
arrangement of of activities
activities
w Continuous, mass w Intermittent, job
• Type of process
production, mainly shop, batch
assembly production, mainly
fabrication
• Product w Standardized, made w Varied, made to
to stock order
• Demand w Stable w Fluctuating
• Volume w High w Low
• Equipment w Special purpose w General purpose
 Comparison of Product
and Process Layouts
Product Process
• Workers w Limited skills w Varied skills
• Inventory w Low in-process, high w High in-process, low
finished goods finished goods
• Storage space w Small w Large
• Material handling w Fixed path (conveyor) w Variable path (forklift)
• Aisles w Narrow w Wide
• Scheduling w Part of balancing w Dynamic
• Layout decision w Line balancing w Machine location
• Goal w Equalize work at each w Minimize material
station handling cost
• Advantage w Efficiency w Flexibility
 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
 Block Diagramming: Example
Load Summary Chart

FROM/TO DEPARTMENT
1 2 3
Department 1 2 3 4
5
1 — 100 50
2 — 200 50
5 3 60 — 40
4
50
4 100 —
60
5 50
—
 Nonadjacent Loads 110 + 40 = 150
2 3 200 loads
2 4 150 loads
1 3 110 loads
1 2 100 loads 110
4 5 60 loads
3 5 50 loads 100 200
1 2 3
2 5 50 loads
3 4 40 loads 150 50
50
1 4 0 loads
1 5 0 loads 60
4 5
40
Grid 1
 Block Diagramming:
Example
Nonadjacent Loads: 0
2 3 200 loads
2 4 150 loads
1 3 110 loads
1 2 100 loads
4 5 60 loads 100 150
1 2 4
3 5 50 loads
2 5 50 loads 200 50 40 60
3 4 40 loads 110
50
1 4 0 loads 3 5
1 5 0 loads
Grid 2
 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
Relationship Diagramming
A Absolutely necessary
E Especially important
I Important
O Okay
Production
O U Unimportant
A X Undesirable
Offices
U I
Stockroom O E
A X A
Shipping and U U
receiving
U O
Locker room O
O
Toolroom
 Relationship Diagramming
(a) Relationship diagram of original layout

Offices Locker Shipping

room and
receiving

Key: A
E
I
Stockroom Toolroom Production
O
U
X
 Relationship Diagramming
(b) Relationship diagram of revised layout

Stockroom

Offices Shipping
and
receiving

Locker Key: A
Toolroom Production
room E
I
O
U
X
 Process Layout Example

Number of loads per week

Department Assembly Painting Machine Receiving Shipping Testing
(1) (2) Shop (3) (4) (5) (6)

Assembly (1) 50 100 0 0 20

Painting (2) 30 50 10 0

Machine Shop (3) 20 0 100

Receiving (4) 50 0

Shipping (5) 0

Testing (6)
Process Layout Example
Area 1 Area 2 Area 3

AssemblyPainting Machine Shop

Department Department Department
(1) (2) (3)

40’

ReceivingShipping Testing
Department Department Department
(4) (5) (6)
Area 4 Area 5 Area 6

60’
 Process Layout Example
Interdepartmental Flow Graph
100

Assembly
50 Painting
30 Machine
(1) (2) Shop (3)
20 20
10
50 100

Receiving Shipping Testing

(4) 50 (5) (6)
 Process Layout Example
Revised Interdepartmental Flow Graph
30

Painting
50 Assembly
100 Machine
(2) (1) Shop (3)

10
20 20 100
50

Receiving Shipping Testing

(4) 50 (5) (6)
Repetitive and Product-Oriented
Layout
Organized around products or families of similar
high-volume, low-variety products
1. Volume is adequate for high equipment utilization
2. Product demand is stable enough to justify high
investment in specialized equipment
3. Product is standardized or approaching a phase of life
cycle that justifies investment
4. Supplies of raw materials and components are
adequate and of uniform quality
 Product-Oriented Layouts
u Fabrication line
u Builds components on a series of machines
u Machine-paced
u Require mechanical or engineering changes to
balance
u Assembly line
u Puts fabricated parts together at a series of
workstations
u Paced by work tasks
u Balanced by moving tasks

Both types of lines must be balanced so that the time to

perform the work at each station is the same
 Wing Component Example
Performance Task Must Follow
Time Task Listed
Task (minutes) Below
A 10 —
B 11 A This means that
C 5 B tasks B and E
cannot be done
D 4 B until task A has
E 12 A been completed
F 3 C, D
G 7 F
H 11 E Given:
I 3 G, H Demand = 40 units/day
Total time 66
Assume 8 h/day of working
 Station 5
2
C
10 11 3 7
A B F G
4 3
D Station 3 I
Station 3
12 11
Station 6 6
Station
Station
1 E H
Station Station
4 5 Figure 9.14
 Cellular Layouts
1. Identify families of parts with similar flow
paths
2. Group machines into cells based on part
families
3. Arrange cells so material movement is
minimized
4. Locate large shared machines at point of use
Original Process Layout
Assembly

4 6 7 9

5 8

2 10 12

1 3 11

A B C Raw materials
 Part Routing Matrix

Machines
Parts 1 2 3 4 5 6 7
A x x x
B x x
C x x
D x x x
E x x
F x x
G x x
H x
Reordered Routing Matrix

Machines
Parts 1 2 4 8 10 3 6
A x x x x x
D x x x x x
F x x x
C x x
G x x
B
H
E x
Revised Cellular Layout
Assembly

8 10 9 12

11
4 Cell 1 Cell 2 6 Cell 3
7

2 1 3 5

A B C
Raw materials