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Facilities - PowerPoint Presentation

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Facilities - PPT Presentation

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

process layout layouts product layout process product layouts equipment amp work cost department time www watch player feature flow youtube manufacturing facility

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Slide1

Facilities layout& material handling systems

Prepared by

Şevkinaz

Gümüşoğlu

using different references about POMSlide2
Slide3

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.Slide31
Slide32

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.Slide34
Slide35
Slide36
Slide37

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!!!