FACILITY LAYOUT

It is the integrating phase of the design of productive

systems.

It is the physical expression of the technological choices,

the capacity requirements, the process, job design, the material handling, and the communication systems that interconnect the processes.

Product, Process, and Schedule Design

The facilities planning process listed below :

Define the products to be manufactured and/

or assembled. Specify the required manufacturing and/ or assembly processes and related activities. Determine the interrelationships among all activities. Determine space requirements for all activities
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Product, Process, and Schedule Design

5.) Generate alternative facilities plans. 6.) Evaluate alternative facilities plans. 7.) Select the preferred facilities plan. 8.) Implement the facilities plan. 9.) Maintain and adapt the facilities plan. 10.) Update the products to be manufactured and/ or assembled and redefine the objective of facility.
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The questions to be answered before alternative facility plans can be generated are as follows 1) What is to be produced ? 2) How are the products to be produced ? 3) When are the products to be produced ? 4) How much of each product will be
produced ? 5) For how long will the products be produced ? 6) Where the products to be produced ?

Relationship among product, process and schedule design and facilities planning
P r Product design o d u c t Facilities design

Process design

Schedule design

Product Design
Product design involves both the

determination of which products to be produced and

The detailed design of individual product

Process design
Define the elemental operations Identify the alternative process for each
operation Analyze alternative processes Standardize processes Evaluate alternative processes Select the processes

Schedule Design
Marketing information

Table: Minimum market information required for facilities planning st year 2nd year 3rd year 4th year Product/ 1
Service A
B C

volume 5000
8000 3500

volume 5000
7500 3500

volume 8000
3000 3500

volume 10,000
0 4000

2000

3000

8000
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Information to be obtained from marketing Who are the consumers of the product ?

Valuable information that should be obtained from marketing and used by a facilities planner

Where are the consumers located ? What is the trend in

Facilities planning issues impacted by the information 1.) Packaging 2.)Susceptibility to product changes 1.) Method of shipping 2.) Warehousing system design 1.) Space allocation 10

Layout is affected by :
Centralized or decentralized storage of
WIP ,tooling, and supplies,

Fixed path or variable path handling Unit load size Degree of automation Type and level of inventory and control of
materials
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Volume-variety layout classification

High Product layout Group technology layout Fixed location layout Process layout

Medium Volume

Low

Low

Variety

Medium

High
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Product layout
Lathe S T O R E Drill Grind Drill A S S E M B L Y Drill

Press

Bend

Drill

Mill Lathe

Drill

Mill

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Fixed location layout

Lathe S T O R E Press Grind W A R E H O U S E Weld Paint Assembly

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Process layout
Lathe
Lathe

Lathe
Lathe

Drill Drill

Weld Paint

Weld
Paint W A R E H O U S E

S T O R E

Mill

Mill

Grind

Assembly

Mill

Mill

Grind

Assembly

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Group Technology

ROTATIONAL ROTATIONAL COMPONENT COMPONENT

CAD & CAM

Group Technology

PRISMATIC COMPONENT

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Family of components :

COMPONENT

DESIGN FAMILIES (Similarity in Design) CAD

PRODUCTION FAMILIES (Similarity in Manufacturing Requirements) CAM

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Group technology layout

Grind

Part family-1 Part family -2

Lathe

Drill

Broach

Lathe

Drill

Broach

Grind

Part family - 3

Lathe

Drill

grind

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Layout design procedures

Manual methods

Computerized methods
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Manual methods

Travel chart Systematic layout planning

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Computerized methods

Three methods are used :

1. Computerized relative allocation of

facilities technique (CRAFT), 2. Automated layout design program (ALDEP) 3. Computerized relationship layout planning (CORELAP)

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Computerized relative allocation of facilities technique (CRAFT),

Features of CRAFT
Attempts to minimize transportation cost,
where transportation cost = flow x distance x unit cost

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CRAFT input requirements:

1) 2) 3) 4) 5) 6)
Initial layout Flow data Cost per unit distance Total number of departments Fixed departments and their location Area of department

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The procedures adopted for using CRAFT

1) Determine departmental centroids 2) Calculate rectilinear distance between

centroids 3) Calculate the transportation cost for the layout 4) Consider department exchanges of either equal area departments or of departments sharing a common border
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The procedures adopted for using CRAFT

5.) Determine transportation cost of each departmental interchange 6.) Select and implement the departmental interchange that offers the greatest reduction in transportation cost 7.) Repeat the procedure for the new layout until no interchange is able to reduce the transportation cost.
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Problem on layout
Consider the following layout problem with
unit cost matrix. Use CRAFT algorithm to obtain layout. The initial layout is in figure 1 and flow matrix is in Table 1.

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Initial layout
7 7

C
7

Figure - 1

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Table 1: Flow matrix

Departm A ent A B C D 20 10 100 20 10 5
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B 30

C 25 15

D 45 20 10

Centroids of all departments in the initial layout

(XA,YA)= 3.5,10.5 (XB,YB)= 10.5,10.5 (XC,YC)= 10.5,3.5 (XD,YD)= 3.5,3.5

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Table: Distance Matrix

Departm ent A B C A 0 7 14 B 7 0 7 C 14 7 0 D 7 14 7

14

0
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Table: Total cost Matrix (Total cost=flow x distance x unit cost)

Depart ment A B
C

A
0

Cost
875

210

350

315

140
140

0
140

105
0

280
70

525
350

700

140

35

875
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 Total cost = 2625

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Table : Departmental interchanges

Department pair A-B A-C A-D B-C B-D C-D Reason Common border and Equal area Equal area Common border and Equal area Common border and Equal area Equal area Common border and Equal area

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