Operations Management

FACILITY LAYOUT

KRISHNA MURARI
 FACILITY LAYOUT
A layout is the physical configuration of
departments, workstations, and equipments in
the conversion process. it is arrangement of
physical resources used to create the product.
Success of operations depends on the physical
layouts of the facilities. Flow of raw material.
Productivity and human relationship are all
affected by the arrangements of the conversion
facilities.
Plant layout involves:
i) planning and arranging facilities in new plant
ii) improvements in existing layout to introduce
new methods.
 FACILITY LAYOUT
Layout decisions have long term consequences on
cost and companies ability to serve the customers.
Major objectives of layout
i) Providing enough production capacity
ii) Reducing material handling costs
iii) Easy supervisions
iv) Improvement in productivity
v) Efficient utilisation labour
vi) Increase in morale of the employees
vii) Reducing accidents and hazards to personnel
viii) Reducing congestion
ix) utilizing the space efficiently and effectively.
 FACTORS AFFECTING LAYOUT
1. Material – materials need storage. Layout
should cater to storage and transportation of
materials.
2. Product – Layout should suit to the nature of
product and its method of production. i.e. aircraft
manufacturing and car manufacturing layouts
will be different. Sales also affects the layout.
3. Machinery – Size of machinery based on
product, its volume and labour, affects the
layout.
4. labour – Movement of workers, facilities for
workers like canteen, toilet, restroom etc affects
the layout.
 FACTORS AFFECTING LAYOUT
5. Location – Type of building depends on the
soil condition. Location decides the
transportation and layout plan has to take care of
this aspect.
6. Managerial policies – top management decides
the layout objectives
7. Type of industry
 CRITERIA FOR GOOD LAYOUT
1. Flexibility
2. Maximum coordination
3. Maximum visibility
4. Maximum accessibility
5. Minimum distance
6. Minimum handling
7. Minimum discomfort- proper light,
ventilation etc.
8. Inherent safety
9. Efficient process flow
10. Identification –provision of space to
workers.
 TYPES OF LAYOUTS
The layouts are differentiated by the types
of workflow they entail , and workflow in
turn is dictated by the nature of product.
Basic layouts are :
1. Process layout
2. Product layout
3. Grouping technology layout
4. Fixed position layout
5. Hybrid layout
 Process layout
These are appropriate for intermittent operations
where work flow is not consistent for all output.
Variable workflow occurs when variety of
products or variation of single product are
produced.
This is also called as functional layout or job-
shop layout.
In this layout similar equipments are grouped
and located at one place like lathe, drilling
machines etc.
Workers should be highly skilled. Intensive job
instructions should be given to them and
technical supervision is required. These layout
are quick to change and adapt to the unique
batches of the products.
 Process layout
Advantages
i) Greater Flexibility
ii) Better and more efficient supervision possible
through specialization
iii) Breakdowns can be taken care by shifting the
job to another machine
iv) Capacity of different product line can be
expanded easily.
v) Better utilisation of men and machine
Disadvantages
1) More work in progress
2) More floor space
3) More distances traveled by the product.
 Product layout
It is appropriate for producing one
standardized product, usually in large
volume.
It is also called as flow –shop layout or
straight line layouts.
The machines are arranged according to the
progressive steps by which the product is
made.
Examples: Chemical, paper, rubber,
refineries, cement industry.
 Product layout
Advantages:
i) Mechanization of materials is possible and
material handling cost can be reduced.
ii) It requires less floor area.
iii) It facilitates better production control
iv) Production bottlenecks are avoided.
Disadvantages
i) Expansion of production line is difficult
ii) There is difficulty in supervising
iii) Breakdown of equipment disrupts the
production.
 Product layout in Machining Piston of a
automobile

Casting
ROUGH TURING CAM TURNING LATHE
LATHE

PINHOLE BORING
GROOVING MACHINE
MACHINE

CIRCLIP GROOVING INSPECTION PACKING

MACHINE
 Grouping Technology Layout
Grouping technology or cellular
manufacturing layout is made for a single
part family i.e. parts with common
characteristics. In this layout dissimilar
machines are grouped into cells and each
cell functions like product layout.
It reduces material handling cost and
simplifies machine changeovers. It
reduces in-process inventory and
automate the production. But reduces
flexibility.
 CARAVAN, BATON and MIXED CELLS
BATON CELLS CARAVAN CELLS MIXED CELLS

Operators are Operator and Products move

fixed but product from station
products move move from to station and
from station to operators move
station to station station between stations
 Fixed Position Layout

When due to size , shape and other

characteristic constraints, the products
can not be moved, the machine and
operators move around the product.
Example -construction of a building,
assembly of an aircraft or ship.
Less investment is required in this layout
and less transport cost as bulky materials
are not moved.
 Hybrid Layout

No single layout like process, product of

fixed position layout is used in strict
meaning, a combination of these layouts
are used. This is called a hybrid or
combined layout.
For example, in process layout, one
section may use product layout like parts
may follow process layout and assembly
as product layout. (Used in aircraft
manufacturing)
DEVELOPING A PROCESS LAYOUT

Various models like mathematical models,

computer models and physical models are
used. Mathematical models helps in
analyzing and conceptualizing while
compute models provide quick
approximation. Physical model visualizes
the layout.
 Graphic and Schematic Analysis

Templates or two dimensional cutouts of

the equipments drawn to scales are used.
These are moved about by trial and error
within a scaled model of the walls and
columns of the facilities. Computers can
visualize and display layout and the
electronic templates can be manipulated
with a keyboard.
 Computer Models or CRAFT
Many computer based layout models have been
developed and come under category of CAD. CRAFT
(computerized relative allocation of facilities
technique) is one such program which can handle
upto 40 work centers. The model considers various
type of layouts and different material handling
methods that a firm can use among the work
centers.
The analyst provides initial layout, a matrix
identifying the number of loads moved among work
centers and matrix identifying the cost of
transportation. After calculating the initial
effectiveness, the CRAFT exchanges the location of
pairs or triplets of work centers and by many
iteration and evaluation final solutions printed out.
 Load Distance Model

A facility using a process oriented

layout produces diversified products in
variable work flows and handles a
relatively large amount of material.
Since transport adds no value to the
product, managers seek layout that
minimizes unnecessary flow among the
work centers.
Load distance model minimizes flow by
considering the number of loads
moved and the distance between each
pair of the work centers.
 Load Distance Model
In this model we minimize the Cost C as
given below:
n n
C= ∑ ∑ Lij Dij K
i=1 j=1
Where n = number of work center
L ij = No. of loads moved between
work centers I and j
Dij = distance between the work
centers
K =Cost to move one load one
distance unit.
 Load Distance Model

Initial cost is calculated using the above

following formula
And then this is modified to reduce cost and
process is repeated till there is no further
scope to reduce the cost.
Limitation – due to additional complexities
like electrical wiring, the work centers need
AC, variety of materials handled, different in
sizes of work centers etc, optimal layout can
not be arrived and if number of work centers
is very large it is difficult to use this
technique.
DEVELOPING A PRODUCT LAYOUT
Organsiations which produces a large
volume of single product benefit from a
product layout. Henry Ford revolutionized the
US economy by mass producing the
automobiles.
The design for developing a product layout is
partly established when each part of the
product is designed and the different steps
required to make it are determined. The
volume of production determines the most
economical process and the process
technology defines the sequence of steps
which are performed in production. Finally
the equipments are placed along a line in
that sequence.
 DEVELOPING A PRODUCT LAYOUT

Some Possible Line Arrangements :

Straight line
1
Step 2 3 4 5

GRIND PAINT
MILL WELD
CUT

U-SHAPED

L- SHAPED
DEVELOPING A PRODUCT LAYOUT

Some Possible Line Arrangements :

SERPENTINE SHAPE
OR CONVOLUTED
DEVELOPING A PRODUCT LAYOUT

Some Possible Line Arrangements :

Sub- Assy C

Sub- Assy D
Sub- Assy B
Sub- Assy A

Main Assembly line

DEVELOPING A PRODUCT LAYOUT

Modeling The Product Layout

Defining the layout problem:
Fundamental problem – determining number
of workstations and assigning task to these
work stations to get desired output.
Main Concerns are : Capacity, Sequencing
and efficiency.
Good design meet the following criteria:
1. They produce the desired output
2. They are feasible.
3. They are efficient
DEVELOPING A PRODUCT LAYOUT
Table 1: assembly line layout for Al window
Work Presiding Task assigned Predecessors Task time/
station WS unit
(WS)
1 - A: assy frame work None 70
2. 1 B: installation rubber A 80
mould
3. 2 C: install frame latch A 40
D: install handle A 20

4. 3 E: Install handle A 40
F: install glass pane B,C 30
5. 4 G: Cover Frame C 50
screws
6. 5 H: Pack D,E,F,G 50
 DEVELOPING A PRODUCT LAYOUT
Capacity Adequacy : No. of units a layout
allows depends on the station whose tasks
take longest time.
From Table 1. :
Station 2 takes 80 sec. while Station 3 takes 60
sec (40+20). When every unit pass through
station 2, it takes 80 sec. This is bottleneck
operation. A finish window will flow at end of
the line at every 80 sec. This time is called
cycle time.
Available time = 8hrs/shift=28,800 sec.
Maximum daily out put =28,800/80= 360 units
If required out put is 320 units, this can serve.
There is capacity adequacy. But if required
output is 361 unit ?????
 DEVELOPING A PRODUCT LAYOUT
Line Efficiency :
Layout has 6 stations. Each has one worker.
Each worker works for 8 hrs. 320 units are to
be made.
For 320 units requirement, cycle time allowed is
= time available/ no. of unit required
= 28,800/320 = 90 sec.
Idle time = 20 at station1 + 10 at station 2+ 30 at
station 3+ 20 at station 4+ 40 at station 5 + 40 at
station 6 = total 160 sec. sec per unit
Total time at 6 stations = 90 x 6 = 540 sec.
Time utilized = 540-160 = 380 sec.
Efficiency = (380/ 540) x 100 = 70.4 %
 Line Balancing
How can the cost of idleness be reduced?
By reassigning the tasks. So that more available
employee time is used. If every station used up an
equal amount of task time, no time would be idle
time.
The method of equalizing stations in this way is
called line balancing. Steps are:
1. Define tasks
2. Identify precedence requirements
3. Calculate minimum no. of workstations reqd.
4. Apply an assignment heuristic to assign task to
each work center
5. Evaluate effectiveness and efficiency
6. Seek further improvement
 Line Balancing
In above problem:
Theoretical minimum no. of workstation = time
required per unit / time allowed per unit
= 380 /90 = 4.22 stations
= 5 station as whole stations are possible.
Initial layout uses 6 stations.
Task Assignment
Longest –operation – time (LOT) heuristic is
applied.
The steps are :
LOT 1: assign first task that takes the most time to
the first station. Maintain precedence
requirements.
 Line Balancing
LOT 2 : After assigning a task, determine how much
time that station has left to contribute
LOT 3: If the station can contribute more time,
assign a task requiring as much time as possible.
Maintain precedence relationship.
Task with time are B(80), A(70),G(50), H(50), C(40),
E(40), F(30), and D(20)
By LOT1 , B is first task but it has to follow A,
hence A is chosen as station1. It has 20 sec extra
From available time 90 sec (LOT2). Task D can be
assigned with time 20 sec (LOT3).
Again, With LOT1, station 2, B takes longest time,
meets precedence requirements (A), it is assigned
station 2. Left time 10 sec. (LOT 2) No task takes
10 sec. Hence no extra addition of work.
Line Balancing

Work Presidin Task assigned Predecessor Task time/

station g WS s unit
(WS)
1 - A: assy frame work None 70
2. 1 B: installation rubber A 80
mould
3. 2 C: install frame latch A 40
D: install handle A 20
4. 3 E: Install handle A 40
F: install glass pane B,C 30
5. 4 G: Cover Frame C 50
screws
6. 5 H: Pack D,E,F,G 50
 Line Balancing
To station 3, we can assign C or E as choice of G
and H will violate precedence requirements. We
assign C with operation time 40 sec. Left out time
50 sec. E or G with operation time 50 sec. can be
assigned. As G is preceded by C, G is assigned.
At station 4, E or F can come by precedence
requirement, but operation time is more for E (40
Sec) (LOT1) hence E will be assigned. Now left
over time is 50 sec. hence F (30 sec) will be added
to this work station.
At station 5, left out task H will come.
Hence, revised, window assy will be as given in
table 2,
Line Balancing

Work Eligible Task assigned PredecessorsTask time/

station Tasks unit
(WS)
1 A A None 70
D D A 20
2. B,C,E B A 80

3. C,E C A 40
E,F,G G C 50
4. E,F E A 40
F F B,C 30
5. H H D,E,F,G 50

Efficiency = total time / cycle x no. of work centers

= 380/ 5 x 90 = 84.44% (more than 70.4 % initial efficiency )
Line Balancing

Many other heuristics, like selecting the

tasks having most successors can also
be used.
Several computerized heuristics are
available.
Different heuristics give different layout,
managers use different heuristics before
arriving at the final conclusion.
Also some times, by task sharing, idle
time is utilized.
Mixed Model line balancing
When more than one products are produced
Mixed Model line balancing is used.
Mixed model lines involve multiple lot size,
lot sequencing, different setup times for
each lot, different workstation sizes along
the line and task variations. This makes it
very difficult to design a layout. In this
design objectives are reducing idle time
and increasing the efficiency.
Optimal solution is not find inspite of using
various techniques.
 DEVELOPING A CELLULAR
MANUFACTURINGLAYOUT
Steps:
1. Parts that follow a common sequence of
steps are grouped into a family.
Computerized parts classifications and
coding system are used,
2. Dominant flow patterns of parts-families
are identified as a basis for location or
relocation.
3. Machine and processes are physically
grouped into cells.
 DEVELOPING A CELLULAR
MANUFACTURINGLAYOUT
Major problems in developing a cellular
manufacturing layout are
i) Developing and classification a coding
scheme fro items of different shape,
sizes, materials etc
ii) Grouping parts in families to form cell
groups on the basis of processing
requirements and routings
iii) creating physical layouts for
positioning cells relative to each other.
 JAPANESE APPROACHES AND TRENDS
IN MANUFACTURING LAYOUTS

Japanese layouts are compact as apace is

premium in Japan. Hence movement is less and
space utilisation is more.
Japanese layouts are used for flexibility and
adaptability for various products. in comparison to
US layouts form high worker and machine
utilisation.
 Service facility Layouts
Service facilities exist to bring together customer
and organisation's services.
Features like easy entrance, well organized parking
lots, well marked entries and exits, powered doors,
escalators and lobbies for customers, create a
convenience to customer and increase the
business.
The layouts depend on degree of customer
contacts. One case, it may be designed around the
customer and other around the technology,
process materials and production efficiency.
Example Banks designed around customer and
hospitals around the technology.
 Service facility Layouts
Some are balanced between the two like restaurant.
Retail Service Layout
Due to rise in land prices, objective of the retail
layout is to maximize returns per unit area. Super
markets try to maximize the product exposure,
bank try to provide comfort ambiance to customer.
Service escape – physical surroundings – consists
of ambiance, spatial layout and functionality and
signs, symbols and artifacts.
 Service facility Layouts
Ambiance- all physical attributes of a place : noise
level, lightening , temperature, colour, style of
fixtures etc. These have significant effect on
customers and workers. It determines the
perception of the customer.
Spatial Layout and Functionality –
Grouping of merchandises and well designed
circular paths are important features.
Grouping of merchandise is done based on
customers perception of related items. Circular
paths are made so that products can be visible to
the customer.
 Service facility Layouts
Sign, Symbols and artifacts
These are more visible parts of service facilities.
These provide directions, uniqueness, advertising
of brand, differentiation of services etc.
Example: In big super markets, different items at
different floors are kept and sign and symbols are
used to guide the customers.
Decisions regarding these elements are taken
based on type of the service. Low customer
involvement proper information is provided by
signs like in fast food restaurant.