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09 Facilities Layout - Lesson 09 Facilities Layout the...

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09 - 1 Lesson 09 Facilities Layout the configuration of departments, work centers, and equipment with emphasis on movement of work (product/customers) through the system
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09 - 2 Receiving Production Process Shippin g Storage Work center Work center Storage Work center Work center Storage Facilities Layout
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09 - 3 Layout decisions are important for 3 basic reasons: . Require substantial investments of money and effort . Involve long term commitments which make mistakes difficult to overcome . They have significant impact on cost and efficiency of short term operations The Need For Layout Decisions
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09 - 4 Improve inefficient operations (e.g. bottlenecks) Accidents or safety hazards Minimize material handling costs Utilize space efficiently Utilize labor efficiently Incorporate security measures Morale problems - facilitate communication and interaction between workers, between workers and their supervisors, or between workers and customers The Need For Layout Decisions
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09 - 5 Reduce manufacturing cycle time or customer service time Eliminate waste or redundant movement Promote product and service quality Encourage proper maintenance activities Provide a visual control of operations or activities Facilitate the entry, exit, and placement of material, products, or people Provide flexibility to adapt to changing conditions . Changes in volume or mix of outputs . Changes in methods or equipment . Changes in design of products/services . Introduction of new products/services . Changes in environmental or other legal requirements The Need For Layout Decisions
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09 - 6 Basic Layout Types Product Layouts - uses standardized processing operations to achieve smooth, rapid, high-volume flow . Production /Assembly Line – fixed sequence of production/assembly . U-Shaped Layouts – better utilization of labor Raw materials Finish ed item Material Labor Material Labor Material Labor Material Labor In Out Workers
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09 - 7 Product Layout Advantages/Disadvantages Advantages . High rate of output . Low unit cost – equipment cost spread over many units . Labor specialization reduces training costs & time . High utilization of labor and equipment . Accounting, purchasing & inventory control are more routine Disadvantages . Repetitive jobs with little advancement - morale issues . Poorly skilled workers may have little interest in quality . Inflexible system sometimes susceptible to shutdowns . Quick repairs require spare-parts inventories & maintenance
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09 - 8 Basic Layout Types Process Layouts – can handle varied processing requirements and usually has departments or other functional groupings where similar kinds of activities are performed . Equipment is laid out by type rather than manufacturing sequence . Products/Services move through the system dictated by technical considerations rather than a specified sequence of operations ( e.g. hospitals, banks, machine shops, grocery stores, fast food ) Millin g Assembly Grinding Drilling Plating
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09 - 9 Process Layout Advantages/Disadvantages Advantages . Can handle a variety of processing requirements .
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