layout amp material handling systems Prepared by Şevkinaz Gümüşoğlu using different references about POM Facılıty Layout Defıned Facility layout can be defined as the process by which the placement of departments workgroups within departments workstations ID: 329274
Download Presentation The PPT/PDF document "Facilities" is the property of its rightful owner. Permission is granted to download and print the materials on this web site for personal, non-commercial use only, and to display it on your personal computer provided you do not modify the materials and that you retain all copyright notices contained in the materials. By downloading content from our website, you accept the terms of this agreement.
Slide1
Facilities layout& material handling systems
Prepared by
Şevkinaz
Gümüşoğlu
using different references about POMSlide2Slide3
Facılıty Layout
Defıned
Facility layout
can be defined as the process by which the placement of departments, workgroups within departments, workstations, machines, and stock-holding points within a facility are determined
This process requires the following inputs:
Specification of objectives of the system in terms of output and flexibility
Estimation of product or service demand on the system
Processing requirements in terms of number of operations and amount of flow between departments and work centers
Space requirements for the elements in the layout
Space availability within the facility itselfSlide4
Layout decisions are concerned with the arrangement of production, support, customer service and other facilities. Layout can be costly investments, but they effect material (non production cost) handling, capital equipment utilization, inventory storage levels, worker productivity, and even group communications and employee morale. A good layout will be enable materials, people, and information to flow in a safe and efficient manner. For this reason two of the major criteria for selecting and designing a layout
are
;
1. Materials-handling cost
2.worker effectiveness. Slide5
Material- handing cost has often been considered the most important criteria of a layout. Cost are minimized by using belts and conveyors to automate product flows belts and keeping the flow distances as short as possible. Sequential processing activities are usually located in adjacent areas. In service systems such as subways, customer are frequently the material that moves through the system. So the customer service time becomes a relevant variable.Workers effectiveness
is an increasingly important criterion in facilities today. Good layouts provide workers with a satisfying job and permit them to work effectively at the highest skill level for which they are being paid. This applies just as much to a office layout (where an engineers might spend unnecessary time delivering memos) as it does to a factory layout (where a machinist might have to walk long distances for tools). Good communications systems and well-placed supporting activity locations are critical to the success of any facility. Slide6
Changes in
environmental
or other legal
requirements
Changes in volume of
output or mix of
products
Changes in methods
and equipment
Morale problems
The Need for Layout Desıgn Slide7
Layout relationshıps; Product Design Process Design
Layout
Design
SCHEDULE DESİGNSlide8
Types of LayoutBasic types of layouts areProcess (functional) layouts
Product
(line) layouts
Fixed position
layouts
Cellular
Layout
There are many combinations of these. Flexible production systems are line layouts that use micro processor and robots to gain some of the advantages of functional layouts.
The type of layout is generally determined by the following:
Type of product:
This concerns whether the product is a good or a service, the product design and quality standards and whether the product is produced for stock or for order.
Type of production process: This relates to the technology used, the type of materials, handled, and for the means of providing the services.Volume of production: Volume affects the present facility design and capacity utilization, plus provisions for expansion or change.Slide9
Job shop
Batch
Assembly line
Continuous
flo
w
Mass
Customization
Jobbing
Production
Layout
Structures
are
related
with process typesSlide10
Facility layout are influenced by the level of automation and cost of manufacturing equipment. Many numerically controlled (CNC) machines and industrial robots perform simple tasks such as drilling holes or welding joints. However, as the number of task performed by automated machinery increases, the machines can become quite large and expensive. In these situations the equipment and configuration significantly influence the layout and product flo
o
r
. The more advanced systems gaining acceptance in U.S. firms today cellular manufacturing which is building-block step toward flexible manufacturing system.
*Manufacturing cells
also enable a firm to operate with less work-in-process inventory. Slide11
Process Layout:
Interdepartmental Flow
Given
The flow (number of moves) to and from all departments
The cost of moving from one department to another
The existing or planned physical layout of the plant
Determine
The “best” locations for each department, where best means maximizing flow, which minimizing costs Slide12
Process Layout –
Position of equipment is dominant considerationSlide13
Process LayoutProcess layouts group the people and equipment performing similar functions, such as x-raying, typing or electroplating. They lend themselves to low volumes of customized jobs and use a variety of general purpose equipment.
Work flow is typically intermittent and guided by individual work orders.
This
f
igure
s
illustrates a process layout.Slide14
Process Layout (Job Shop)
F
E
D
A
B
C
Product 1
Product 2
Product
3
Product 1
Product 2
Product 3Slide15
Different
products on customers flow through the facility along different path.
Similar equipment processed or similar skills are grouped together by department (or work center).
Process layouts tend to rely heavily on the planning and professional skills of employees at all level. Slide16
Some of Advantages of functional(process) layouts Flexible systems for custom work.
Less costly general-purpose equipment
Enhances
job satisfaction (more diversity and challenge)
Some of Disadvantages of
process
(
functional
)
layouts
Costly materials handling
High-cost skilled labor
Higher supervision cost Per employee
Low equipment utilizationMore complex production control (for instance, scheduling, inventory, control) These layout problems fall into two basic categoriesThose involving quantitative decision criteriaThose involving qualitative criteria.Slide17
Quantıtatıve CrıterıaVarious types of process layout problem can be formulated with quantitative criteria. These include the minimization of material-handling costs in factories and warehouses and the minimization of employee or customer traveling time in service operations. A choice of criteria, of course, always requires a decision on the objectives of the operations for example;
Is it more important to minimize doctor or patient traveling time in a hospital, or should the sum of both times be minimized?
Many quantitative-criteria problems concerning the location of facilities can be expressed in the flowing form
:
T
ij
: trips between department I and department j
C
ij
: cost Per unit distance Per trip traveled
D
ij
: distance from I to j
C: Total costN: number of department.Slide18
Example: A facility that will be used to produce a single product has three departments (A,B,C) that must be housed in the configuration shown in figure. The interdepartmental work centers are given in Table. In addition two trial-and-error optional layouts are shown. Assume that the cost to transport this product is $1 Per load food. Between center distances;10ft&&15ft
.
50(15)($1)=750
40(10)($1)=400
90(10)($1)=900
$2050Slide19
Qualıtatıve CrıterıaLayout problems involving qualitative criteria occur when relationships between in qualitative terms. In some cases, these qualitative criteria may be more readily available or more appropriate than quantitative criteria.
The qualitative location problem has been studied in depth by
Muther
(1962) who has proposed a method of formulation and solution called SLP (systematic Layout Planning).
According to
Muther’s
approach, the desirability of locating a given department next to any other department is rated by one of the following terms: Absolutely necessary, Especially important, important, Ordinary closeness okay, Unimportant, undesirable.
These qualitative ratings may be based on safety considerations, customer convenience, or approximate flows between departments.Slide20
For example, it might be desirable to locate the baby food department near the milk department in a supermarket for convenience of shopping. In these example it is shown for a typical supermarket. The solution is not necessarily an optimal solution but simply a good solution chosen for purposes of illustration. Qualitative layout problems are frequently encountered in the service industries, where customers interact with the facilities.
Several computerized approaches are available for developing and analyzing process layouts. Computerized Relative Allocation of Facilities Technique CRAFT (Soft ware) packages program attempts to minimize material-handling costs by calculating cost a exchanging department. ALDEP and CORELAP programs attempt to maximize a nearness rating within the facility dimension constraints. None of the methods guarantees optimality.Slide21
For example;Slide22
solution for example:Slide23
The other Example of Systematıc Layout Plannıng &
Solution
:
Importance of Closeness
Value
A
E
I
O
U
X
Closeness
Line
code
Numerical
weightsAbsolutely necessary
Especially importantImportantOrdinary closeness OKUnimportantUndesirable
16842080Slide24
SUPERMERKET
Example
of
Systematıc
Layout
Plannıng
:
Relatıng
Reasons and Importance
From
1. Credit department
2. Toy department
3. Wine department
4. Camera department
5. Candy department6I--U4A
--U--U1I1,6A--U
1X1XTo2345Area(sq. ft.)100400300100100Closeness ratingReason for rating
LetterNumberSlide25
Example of Systematıc Layout Plannıng:
Inıtıal Relatıonshıp Dıagram
1
2
4
3
5
U
U
E
A
I
The number of lines here represent paths required to be taken in transactions between the departments. The more lines, the more the interaction between departments.
Note here again, Depts. (1) and (2) are linked together, and Depts. (2) and (5) are linked together by multiple lines or required transactions.Slide26
Example of Systematıc Layout Plannıng:
Inıtıal and Fınal Layouts
1
2
4
3
5
Initial Layout
Ignoring space and
building constraints
2
5
1
4
3
50 ft
20 ftFinal LayoutAdjusted by squarefootage and buildingsizeNote in the Final Layout that Depts. (1) and (5) are not both placed directly next to Dept. (2).Slide27
http://www.youtube.com/watch?v=2gbmatgagdg&feature=player_detailpagehttp://www.youtube.com/watch?v=uF4l1Imnc0c&feature=player_detailpage
http://www.youtube.com/watch?v=gpp6CvCgtNY&feature=player_detailpage
http://www.youtube.com/watch?v=7ezjHnOATQs&feature=player_detailpageSlide28
http://www.youtube.com/watch?v=Cdm2t952jYg&feature=player_detailpagephttp://www.youtube.com/watch?v=i6H7nfHjHtY&feature=player_detailpage
http://www.youtube.com/watch?v=Cdm2t952jYg&feature=player_detailpage
http://www.youtube.com/watch?v=i6H7nfHjHtY&feature=player_detailpageoutube.com/watch?v=PusvVnC_4Uc&feature=player_detailpageSlide29
Product Layout – Flow of product is dominant
consideration
Adam Smith: Division of Labor
Whitney:Interchangeable parts
Ranked Positional Weight, COMSOAL Slide30
Product Layout (Lıne layout)Product layouts group the workers and equipment according to the sequence of operations performed on the product or customer. They lend themselves to the use of (assembly line) conveyors and automated equipment to produce large volumes of relatively few items (for instance, refrigerators and freezers).
Work flow is typically continuous and guided by standardized instructions
.
Product layout are used in both discrete manufacturing and in process industry plants.
It is important to distinguish process layouts from process industries.Slide31Slide32
AdvantagesHigh utilization of people and equipmentLow material-handling costLow-cost unskilled labor
Less work-in-process inventory
Disadvantages
Inflexible system (unless designed for flexibility)
High-cost specialized equipment
Interdependent operations
Dull, monotonous jobs (unless products are customized or system is flexible)
expensive machine investment.Slide33
Layout analysis has focused primarily upon these two concerns:Process layout attempt to minimize material-handling costs by arranging departmental sizes and locations according to the volume and flow rate of products.Product layout attempt to maximize worker effectiveness by grouping sequential work activities in to work stations that field a high utilization of labor and equipment with a minimum of idle time
.
Line balancing
is the apportionment of sequential work activities in to work stations in order to gain a high utilization of labor and equipment and therefore minimize idle time in product layouts.
Compatible work activities are combined in to approximately equal time groupings that do not violate precedence relationships. The length of work time that a component is available at each work station is the cycle time, CT.Slide34Slide35Slide36Slide37
0.62 0.39 0.27 0.14/0.56 0.35 0.28 Slide38
Fıxed Posıtıon Layout
Question: What are our primary considerations for a fixed position layout?
Answer: Arranging materials and equipment concentrically around the production point in their order of use. Slide39
Fıxed-Posıtıon LayoutsThey are arrangements where labor, materials, and equipment are brought to the work side.
They apply to construction, farming, mining, and other activities that must be completed in a particular place. Project activities can take advantage of network techniques (CPM and RERT) for planning and control
.
We
can
use
some
computer
packages
programs like;PRİMAVERA, MICROSOFT PROJECT, ASTA TILOSSlide40
Assembly Line Cells
Group Technology
&
Celular LayoutSlide41
http://www.youtube.com/watch?v=wBPY34jCmos&feature=player_detailpagehttp://www.youtube.com/watch?v=iY0oBGo0-W4&feature=player_detailpage
http://www.youtube.com/watch?v=DkNVhtOCcrE&feature=player_detailpageSlide42
Cellular ProductionLayout in which machines are grouped into a cell that can process items that have similar processing requirementsGroup TechnologyThe grouping into part families of items with similar design or manufacturing characteristicsManufacturing Cells Manufacturing cells are smaller groups of machines that are arranged according to a similarity in the operations performed. A close grouping of equipment for performing a sequence of operations on multiple units of a component or family of similar components or products is called manufacturing a cell.
Cellular LayoutsSlide43
Benefıts of Group TechnologyChangeover setup time reduced for tooling and equipmentAutomation may be possible
Operator may be specially trained with improved expertise
Quality of output improved
In-process inventory reduced
Productivity improved
Lead time reduced
Improved human relationsSlide44
Departmental (Batch Process) Specialization
Saw
Saw
Lathe
Press
Press
Grinder
Lathe
Lathe
Saw
Press
Heat Treat
Grinder
We
can say in
stead
of;
Batch/Lot
ThınkıngSlide45
Press
Lathe
Grinder
Grinder
A
2
B
Saw
Heat Treat
Lathe
Saw
Lathe
Press
Lathe
1
Group Technology Cells
We
must use;Sıngle-Pıece
Flow ThınkıngSlide46
© Wiley 2007
Process Flows before the Use of GT CellsSlide47
© Wiley 2007
Process Flows after the Use of GT CellsSlide48
Use of cellular manufacturing-affords advantages beyond reduction of the distances that parts must be moved between machines. Since movement reduces and is there fore not expensive parts do not have to be moved in large batches to spread the cost of a move over a number of units. Frequently parts are processed one by one through the steps of production, making the throughput time short and the work-in-process inventory low. Cells are typically connected with material handling equipment so that these cost are reduced. The use of cells in repetitive manufacturing plants greatly enhances just-in-time production methods. In companies that hove a large variety of parts, group technology is often helpful in selecting appropriate families of pants that can be run in cell. Figure-3 is represented it. They can be expended to words a FMS by adding a supervisory computer and machines.Slide49
LAyOUT & CAPACITY
AND
LOAD
relationships
“TR 6-5 Capacitiy and load” eklenecek!Slide50
DEPENDENT DEMAND EXAMPLESlide51
LOW LEVEL CODE ANALYSISSlide52
ROUGH-CUT CAPACITY PLANNING & Detailed
Capacity
planningSlide53
Warehouse and storage layoutsRetail layoutsOffice layoutsHospital layoutFast Food LayoutHotel and Motel LayoutCar Rental LayoutSPA & Healthcare Layout
Servıc
e
facilities
LayoutsSlide54
8-
54
Designing Physical Surroundings to Affect Employee and Customer Behavior
Ambient Conditions
: background characteristics such as noise level, music, lighting, temperature, and scent.
Spatial Layout and Functionality
: reception area, circulation paths of employees and customers, and focal points.
Signs, Symbols, and Artifacts
: selection, orientation, location, and size of objects.
in
the
Servıces
sectorSlide55
Offıce LayoutsHuman interaction and communication are the primary considerations in office layoutsPeople who need to interact frequently should be close to each other
One key layout tradeoff is between closeness and privacySlide56
Offıce Layouts Open concept offices promote understanding and trust.A few closed rooms are needed for private discussions, such as personnel matters.Moveable walls provide flexibility to change the layout when needed.Slide57
Offıce Layout ExampleHi-tech company – provides equipment and materials for rapid product design and manufacturingOpen office plan
Conference room
Areas for informal meetings
Product showroom for customers
Cyber café and fitness center for employeesSlide58
The Other examples
http://www.authorstream.com/Presentation/Sudiksha-65030-Facility-Layout-Lecture-Notes-Innovations-McDonalds-Supermarket-Retail-Education-ppt-powerpoint/Slide59
Thanks!!!