Facility Layout_PGDM.PDF - Facility Layout PGDM(2017-19 Term I Operations Management – I(OPM 101 Session 13 14 Prof Kalyana C Chejarla Layout

Facility Layout_PGDM.PDF - Facility Layout PGDM(2017-19...

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Facility Layout PGDM (2017-19): Term I Operations Management – I (OPM 101) Session # 13 & 14 Prof Kalyana C Chejarla 8/23/2017
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Layout Decisions Facility layout: the process of determining placement of departments, workgroups within departments, workstations, machines, and stoc holding points within a facility This process requires the following inputs: Specification of the objectives used to evaluate the design Estimates of product or service demand Processing requirements Space requirements for the elements Space availability within the facility Prof Kalyana C Chejarla 8/23/2017 Source: Chase
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Layout Design Performance implications Product Line Total Distance Travelled (in meters) Number of items Manufactured* Average Distance per item Product A 375,655 1080 347.83 Product B 415,125 757 548.38 Product C 288,710 301 959.17 Product D 297,110 405 733.60 * The total distance travelled includes only those of the items manufactured on the shop floor of items that finally get assembled into the final product includes many bought out items in a these. Prof Kalyana C Chejarla 8/23/2017 Source: Mahadeva
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Layout Design Performance Measures Performance Measure Basis for measurement Distance travelled by jobs in the shop floor Kg - Metres of job movement for each product Space utilization index Minimum space required to actual space utilised Material Handling costs Rupees per month Lead time of the processes Hours per average product Investment in work-in-progress Rupees per month Inter-departmental moves Number and quantum of inter- departmental moves Utilisation of the resources Percent to total capacity Ease of production control Number of job cards and control documents generated; Size of the progress chasing staf Number of ownership changes Number of times the responsibility for the job changes hands Prof Kalyana C Chejarla 8/23/2017 Source: Mahadeva
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Basic Production Layout Formats Workcenter (job-shop or functional layout) Similar equipment are grouped together. Assembly line (flow-shop layout) Work processes are arranged according to the steps by which the product is made. Manufacturing cell Dissimilar machines are grouped to work on similar products. Project layout Product remains at one location. Prof Kalyana C Chejarla 8/23/2017 Source: Chase
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Volume – Variety – Flow Implications for layout planning Variety Very low variety Medium Variety High Variety One off execution Flow attributes Stream lined flow Multiple flow paths Dis-organised flow Jumbled flow Volume attributes High Volume Mid-volume Low volume One piece Examples of operating systems Process industry; Mass Product/ Service provider Batch Manufacturing firms Job shops; Customized Product/ Service Provider Project Shops Types of layout used Assembly Line Layout; Product Layout Manufacturing Cell / Group Technology Layout Work-Center / Job Shop / Functional Process Layout Fixed Position/ Project Layout Examples Cafetaria Airlines Hospital Consulting Prof Kalyana C Chejarla 8/23/2017 Source: Mahadeva
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Assembly Lin Project Layou Functional Layout Cellular Layout
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