Facility Layout Dr Everette S Gardner Jr Facility

Facility Layout Dr. Everette S. Gardner, Jr. Facility Layout

Machine shop process layout Receiving Grinders Mills Raw Large number of low volume products matl. storage Assembly Drills Planers Lathes Automatics Part A Part B Inspection Finished goods storage Facility Layout 2

Product layout Receiving Raw matl. storage Fabrication line-part A Finished goods storage Fabrication line-part B Planer Lathe Drill Mill Drill Small number of high volume products Grinder Mill Assembly line Automatic Facility Layout 3

Possible solutions to the process layout problem 6 Department problem has 6! or 720 possible solutions: A B C D E F I. E. , there are 720 different arrangements of the 6 departments on the 6 locations on the grid. Facility Layout 4

Possible solutions to the process layout problem (cont. ) Problem complexity grows exponentially: Nbr. depts. 10 15 20 50 Solutions 3, 628, 800 1. 31 x 10^12 2. 43 x 10^18 3. 04 x 10^64 Facility Layout 5

Solutions considered by Craft • N! solutions to problem with N depts. • Craft considers only N(N-1) 2 pairs of exchanges, starting with each dept. Facility Layout 6

Craft initial layout of furniture plant A B C D E F G I H J TOTAL COST = $2524. 68 Facility Layout 7

Craft final layout A E C I G F B H J D TOTAL COST = $766. 68 Facility Layout 8

Synopsis of assembly line balancing 1. Set up a precedence table. 2. Compute required cycle time: C = (production time) / (required output in units) 3. Compute minimum cycle time: CMIN = time for longest task 4. Compute minimum number of stations: SMIN = (sum of all times) / C Facility Layout 9

Synopsis of assembly line balancing (cont. ) 5. Select rule by which tasks are assigned to work stations. Examples: (1) select tasks with longest operation times first or (2) select tasks with largest number of following tasks first 6. Assign tasks to the first work station until the sum of the task times are equal to the cycle time, or no other tasks are feasible. Repeat for stations 2, 3, … until tasks are assigned. 7. Evaluate the efficiency of the balance: E = (sum of all times) / (actual nbr. of stations x C) Facility Layout 10

Line balancing quiz 0. 4 B 1. 1 A 0. 5 0. 3 1. 1 E G C 1. 2 0. 4 0. 8 D F H 0. 7 0. 3 I J Balance this production line to achieve an output of 367 units per day. Available production time is 8 hrs. less a 40 min. lunch break. Use the largest number of following tasks rule to select tasks for work stations. Break ties with the longest operation time. Facility Layout 11

Multiple solutions in line balancing 6 B 7 3 A 4 F 5 C H 5 5 D G 2 E Facility Layout 12

Multiple solutions in line balancing (cont. ) Number of solutions 84 25 3 1 2 3 4 5 6 7 Stations Facility Layout 13

Volvo layouts Rotating round table with definite cycle time -facilitates teamwork Facility Layout 14

Volvo layouts (cont. ) Horseshoe conveyor sections to enable worker communications Facility Layout 15

Volvo layouts (cont. ) Interim storage areas to separate line into definite supervisory groups Storage Supervisor B Supervisor A Facility Layout 16

Volvo layouts (cont. ) Machines grouped in banks of 3 so workers can exchange jobs and assist each other in set-up Facility Layout 17

Volvo continued E S S Connections of subassembly islands feed parts/components to end-assembly islands—each island functions as a separate team Facility Layout 18