Facility and Work Design

FACILITY AND
WORK DESIGN
CBME 1
FACILITY LAYOUT • refers to specific arrangement of physical facilities.
OBJECTIVES OF • Minimizes delay in material handling & customer

movement
FACILITY • Maintain flexibility
LAYOUT • Use labor and space effectively

• Promote high employee morale and customer satisfaction
STUDIES • Minimize energy use and environmental impact
Product layout
FOUR
MAJOR Process layout
LAYOUT
PATTERN Cellular layout
S
Fixed –position layout
PRODUCT LAYOUT
• an arrangement based on the sequence of
operations that is performed during the
manufacturing of a good or delivery of a service
• are used to achieve a smooth and rapid flow of large
volumes of goods or customers through a system.
• This is made possible by highly standardized goods or
services that allow highly standardized, repetitive
processing.
• The work is divided into a series of standardized
tasks, permitting specialization of equipment and
division of labor.
PRODUCT • DISADVANTAGES
• A breakdown of one piece of
LAYOUT Advantages equipment can cause the entire
• Higher output rates process to shut down.
• Lower work in process • In addition, because the lay out is
determined by the good or service, a
inventories change in product or introduction of
• Less materials handling new products may require major
changes in the layout ;thus , flexibility
• Higher labor and equipment can be limited.
utilization • Expensive to change.
• Simple planning and control • They also usually require more costly,
systems specialized equipment.
• The jobs in a product layout, such as
those on a mass –production line, may
provide little job satisfaction. This is
primarily because of the high level of
division of labor often required, which
usually results in monotony.
PROCESS • Also known as functional layout that are designed
to process items or provide services that involve a
LAYOUT variety of processing requirements.
• Job shops are an example of facilities that use
process layouts because they typically handle a
wide variety of customized orders.
• Because equipment in a process layout is arranged
by type rather than by processing sequence, the
system is much less vulnerable to shutdown caused
by mechanical failure or absenteeism.
ADVANTAG DISADVANTAG
ES ES
• Process layouts provide more flexibility Low equipment utilization
• Generally require a lower investment in
equipment
• If a piece of equipment fails, it generally High materials-handling costs
does not affect the entire system.
• The diversity of jobs inherent in a process
More complicated planning and control
layout can lead to increased worker
systems
satisfaction.
Higher worker skill requirements.

CELLULAR
LAYOUT
• the design is not according to the
functional characteristics of equipment,
but rather is based on self –contained
groups of equipment needed for
producing a particular set goods or
services.
• Cellular layouts facilitate the processing
of families of parts with similar
processing requirements. The procedure
of classifying parts into such families is
called group technology.
CELLULAR
LAYOUT
• is a type of layout in which workstations are grouped
into what is referred to as a cell.
• Groupings are determined by the operations needed
to perform work for a set of similar items, or part
families, that require similar processing.
• The cells become, in effect, miniature versions of
product layouts. The cells may have no conveyorized
movement of parts between machines, or they may
have a flow line connected by a conveyor (automatic
transfer).
• All parts follow the same route, although minor
variations (e.g., skipping an operation) are possible.
FIXED POSITION LAYOUT
• are used in large construction projects (buildings, power plants, dams), shipbuilding, and
production of large aircraft and space mission rockets.
• In those instances, attention is focused on timing of material and equipment deliveries so as
not to clog up the work site and to avoid having to relocate materials and equipment around
the work site.
• Lack of storage space can present significant problems, for example, at construction sites in
crowded urban locations.
• Because of the many diverse activities carried out on large projects and because of the wide
range of skills required, special efforts are needed to coordinate the activities, and the span of
control can be quite narrow.
• For these reasons, the administrative burden is often much higher than it would be under
either of the other layout types.
FACILITY LAYOUT IN A
SERVICE ORGANIZATION
•Service organizations use product , process,
cellular, and fixed –position layouts to
organize different types of work. For
example, in a lab area, however, where lenses
are manufactured , a cellular layout is used.
•In service organizations, the basic trade –off
between product and process layouts
concerns the degree of specialization versus
flexibility. Services must consider the volume
of demand, range of the types of service ,
skills of emnployees, and cost. Those that
need the ability to provide a wide variety of
services to customers with different
requirements usually use a process layout.
Designing Product Layouts
• Product layout in flow shops generally consist of a fixed sequence of workstations. Workstations are
generally separated by buffers to store work waiting for processing, and are often linked by gravity
conveyors to allow easy transfer of work.
• Such product layouts, however, can suffer from two sources of delay; flow –blocking delay and
lack of work delay.
• Flow-blocking delay occurs when a work center completes a unit but cannot release it because the
in-process storage at the next stage is full. The worker must remain idle until storage space becomes
available.
• Lack-of work-delay occurs whenever one stage completes work and no units from the previous
stage are awaiting processing. Lack of- work delay is often described as starving the immediate
successor workstations. Such delays cause bottlenecks limiting the throughout of the entire process.
It is important to identify any bottlenecks if process improvements are to be made.
Assembly –Line Balancing
• An important type of product layout is an assembly line.
• An assembly line is a product layout dedicated to combining the components of a good
and service that has been created previously. Assembly lines were pioneered by henry ford
and are vital to economic prosperity and are the backbone of many indutries such as
automobiles and appliances; their efficiencies lower cost and make service operations such
as processing laundry , insurance policies, mail, and financial transactions.
• The sequence of tasks required to assemble a product is generally dictated by its physical
design.
• Clearly, you cannot put the cap on a ballpoint pen until the ink has been inserted.
However, for many assemblies that consist of a large number of tasks, there are many
ways to group tasks together into individual workstations while still ensuring the proper
sequence of work.
• Assembly-line balancing is a technique to
group tasks among workstation so that
each workstation has-in the ideal case- the
same amount of work.
• Assembly line balancing focuses on
organizing work efficiently in flow shops.
• An important concepts in assembly –line
balancing is the cycle time.
• Cycle time is the interval between
successive outputs coming off the
assembly line.

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FACILITY AND

OBJECTIVES OF • Minimizes delay in material handling & customer

LAYOUT • Use labor and space effectively

Higher worker skill requirements.

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