LAYOUT DECISIONS

OBJECTIVES
Minimize movement and material handling costs
Utilize space and labor efficiently
Eliminate bottlenecks
Reduce manufacturing cycle and customer service time
Safety & Security
Promote product and service quality
Encourage proper maintenance activities
Provide a visual control of activities
Provide flexibility
Increase capacity
BASIC LAYOUTS
Process Layout Product Layout Cellular Layout
BASIC LAYOUTS
DESIGNING PROCESS LAYOUTS : BLOCK DIAGRAMMING
UNIT LOAD: Quantity in which NON ADJACENT LOAD: Distance farther than the next
material is normally moved block
DESIGNING PROCESS LAYOUTS : BLOCK DIAGRAMMING
DESIGNING PROCESS LAYOUTS : BLOCK DIAGRAMMING
DESIGNING PROCESS LAYOUTS : RELATIONSHIP DIAGRAM

Schematic Diagram that uses weighted lines to

denote location preference.

Muther’s Grid: Format for displaying manager

preferences for department locations
RELATIONSHIP DIAGRAMMING
RELATIONSHIP DIAGRAMMING
ORIGINAL LAYOUT REVISED LAYOUT
PROCESS TO CELLULAR LAYOUT
CELLULAR MANUFACTURING LAYOUT
The initial issue that must be resolved in CM layout is the cell formation decision:

Which machines are assigned to the manufacturing cells?

Which parts will be produced in each cell?

PARTS
1 2 3 4 5
A x x x
MACHINES

B x x x
C x x x
D x x
E x x x
 PARTS PARTS
1 2 3 4 5 1 2 3 4 5
A x x x A x x x
MACHINES

MACHINES
B x x x STEP 1 D x x
C x x x B x x x
D x x C x x x
E x x x E x x x

STEP 2

PARTS
1 3 2 4 5 Exceptional
Part
A x x x

MACHINES
D x x
B x x x
C x x x
E x x x
PRODUCTION FLOW ANALYSIS PARTS

INCIDENCE
MATRIX
MACHINES
STEP 1 :CREATE THE FREQUENCY TABLE
Machine Parts frequency PARTS
1 2
2 8
3 5
4 7
5 13
6 19
7 3
8 19
9 10
10 7
11 6
12 5
13 2
14 4
15 7
16 7
STEP 2 :FORMING NUCLEUS 1
Machine Parts frequency
1 2
2 8 Identify the machine with the smallest non-zero frequency.
3 5
4 7 Start by looking at the parts that need to be manufactured on that
5 13
machine
6 19
Using this alter matrix, adjust the frequency matrix.
7 3
8 19
9 10 Machines 37 42
10 7 1 * *
11 6 2 * *
12 5 6 * *
13 2
8 *
14 4
9 * *
15 7
16 * *
16 7
STEP 3 :ADJUST THE FREQUENCY MATRIX
Machine Parts
frequency
1 2 0
2 8 6
3 5 5
4 7 7
5 13 13
6 19 17
7 3 3
8 19 18
Machines 37 42
9 10 8
10 7 7
1 * *
11 6 6 2 * *
12 5 5 6 * *
13 2 2 8 *
14 4 4 9 * *
15 7 7 16 * *
16 7 5
STEP 3 :MODULE 2
Machine Parts
frequency
1 2 0
2 8 6 Machines 3 24
3 5 5 13 * *
4 7 7 8 * *
5 13 13 11 * *
6 19 17 12 *
7 3 3
8 19 18
Part 24 visits an extra machine
9 10 8
10 7 7 M/c 24 may not be a subset of M/C 3.
11 6 6
12 5 5 Create an additional column in the frequency
13 2 2 table.
14 4 4
15 7 7
16 7 5
STEP 3 :MODULE 2
Machine Parts
frequency
1 2 0
2 8 6 Machines 3 24
3 5 5 13 * *
4 7 7 8 * *
5 13 13 11 * *
6 19 17 12 *
7 3 3
8 19 18 16
9 10 8
10 7 7
11 6 6 4
12 5 5 4
13 2 2 0
14 4 4
15 7 7
16 7 5
Continue this process till all the frequency
becomes 0.

A maximum of 16 modules can be created or

less than 16 if all the frequencies hit zero
early.

Create a Module Table, that shows machines

allotted to the components.

Check for the fourth iteration.

 Modules Machines Components
Every component will appear in only one
module 1 1 2 6 8 9 16 37 42
2 13 8 11 12 3 24
But M/C can appear multiple times 3 7 6 8 10 1 13 25
4 10 6 8 12 26 31 39
After it becomes a nucleus, it will not appear 5 11 4 5 8 12 9 20 27 30
later. 6 12 8 11 22
7 12 2 6 8 9 16 3 2 6 17 36
8 3 6 16 7 34 36
9 16 2 9 6 8 10 8 32 38
10 2896 28 40
11 9 4
12 4 5 12 6 8 5 14 19 21 23 29
13 6 5 8 15 8 33 43
14 15 5 8 41
15 85 15
16 5 516
 Module merger
Modules Machines Components

Merge the modules if Machines in a particular 1 1 2 6 8 9 16 37 42

module are a subset of another module 2 13 8 11 12 3 24
3 7 6 8 10 1 13 25
4 10 6 8 12 26 31 39
Modules Machines Components 5 11 4 5 8 12 9 20 27 30

1 1 2 6 8 9 16 4 28 40 10 8 32 38 37 6 12 8 11 22
42 7 12 2 6 8 9 16 2 6 17 36
2 8 11 13 12 11 22 3 24 3

3 7 6 8 10 12 26 31 39 1 13 25 8 3 6 16 7 34 36

4 4 5 8 11 12 9 20 27 30 9 16 2 9 6 8 10 8 32 38

5 2 6 8 9 14 16 3 7 34 36 2 6 17 35 10 2896 28 40

6 4 5 15 6 8 16 15 41 8 33 43 5 14 11 9 4
19 21 23 29 12 4 5 12 6 8 5 14 19 21 23
29
13 6 5 8 15 8 33 43
14 15 5 8 41
15 85 15
16 5 5 16