FACILITIES DESIGN/

FACILITY LAY OUT

OBJECTIVES

Explain the importance of facility

design
Describe the basic processing

types
List some reasons for redesign of
layouts
FACILITY LAYOUT

Lay out refers to the

configuration of departments,
work centers and equipment, with
particular emphasis on movement
of work (customers or materials)
through the system.
AREAS OF INTEREST:
Transportation
Receiving
Storage
Production
Assembly
Packaging and packing
Material handling
Personnel services
 Auxiliary production services- (giving
assistance or support)
 Warehousing
 Shipping
 Offices
 External Facilities
 Buildings
 Grounds
 Location
 Safety
 Scrap
IMPORTANCE OF LAY OUT DECISIONS

 1. they
require substantial investments of
money and effort
 2. they involve long-term commitments,
which makes mistakes difficult to
overcome
 3. they have a significant impact on the
cost and efficiency of operations.
THE WORK OF DESIGNING A
FACILITY USUALLY STARTS
WITH AN ANALYSIS
The product to be made or service
to be performed
Consideration of the overall flow
of material or activity
IMPORTANCE OF FACILITIES
DESIGN
 An efficient plan for the flow of materials
is a primary requisite for economical
production
 The material flow pattern becomes the
basis for an effective arrangement of
physical facilities
 Material handling – converts the static
flow pattern into a dynamic reality ,
providing means by which material is
caused or permitted to flow
Effective arrangement of facilities
around the material flow pattern
should result in efficient operation of
the various related processes.
Efficient operation of the processes
should result in minimum production
cost
Minimum production cost should
result in maximum profit.
OBJECTIVES OF FACILITIES
DESIGN
Facilitate
the manufacturing process
Minimize material handling
Maintain flexibility of arrangement
and operation
Maintain high turn over of work in
process
Hold down investment in
equipment
Make economical use of building
cube
Promote effective utilization of
man power
Provide for employee
convenience, safety, and comfort
in doing the work.
FACILITATING THE MANUFACTURING
PROCESS
 Some specific suggestions are;
 1. Arrange machines, equipment, and
work areas so that material is caused to
move smoothly along in as straight a line
as is possible.
 2. Eliminate all delays possible
3. Plan the flow so that the work
passing through an area can be easily
identified and counted, with the
possibility of becoming mixed with
other parts or batches in adjacent
areas.
4.Maintain quality of work by
planning for the maintenance of
conditions that are conducive to
quality.
PROMOTING EFFECTIVE USE OF
MANPOWER
Suggestions such as the following should
lead to increased labor utilization;
o 1. Reduce manual handling of materials to

a minimum
o 2. Minimizing walking
o 3. Balance machine cycles
o 4. Provide for effective supervision
TYPES OF FACILITY LAY OUT
 Process/ Functional Lay out
 Product Lay out

 Hybrid Lay out

 Fixed Lay out

 BATCH REDUCTION OR ELIMINATION

Process/ Functional Layout

Material

Punch Grinders
Presses Shipping
Receiving Warehouse
Warehouse
Finished Goods

Lathes
Drill Presses Inspection

Ship
PROCESS LAY OUT
 Groups work stations or departments according
to functions
ex. All drilling equipment is located in one area of a
machine shop , or all budget apparel is displayed in one
area of a department store.
 The process lay out is most common when the
same operation must intermittently produce
many different products or serve many different
customers.
 Demand levels are too low or unpredictable
ADVANTAGES OF PROCESS LAY OUT
Itis more flexible
Equipment utilization is high
Employee supervision can be
specialized
 DISADVANTAGES OF PROCESS LAY OUT

 Processing rates tend to be slower

 Productive time is lost in changing from one
product or service to another.
 More space and capital are tied up in inventory

 The time lags between job starts and end points

are relatively long
 Materials handling tends to be costly
CONT…

 Diversityin routings and jumbled flows

necessitate the use of variable path
devices, such as carts rather than
conveyors.
PRODUCT LAY OUT
 Arranges work stations or departments in a
linear path.
 It is often called production or assembly line

 Disadvantages;
Product lay outs often rely heavily on
specialized, capital-intensive resources.
These lay outs are therefore riskier for

products or services with short or uncertain

lives.
 BATCH REDUCTION OR ELIMINATION

Product Layout
Finished
Grinders Inspection Goods & Customer
4 5 Shipping
6

Materials
Punch Drill Press
Lathes Warehouse
Presses 1
2
3
 ADVANTAGES

Fasterprocessing rates
Lower inventories
Less unproductive time lost to
changeover
 HYBRID LAY OUT

 Combines elements of both a product and process focus.

 Arranges some portions of the facility as a process lay
out and others as a product lay out.
 Other hybrid lay outs ;

 FMS – flexible manufacturing systems

 GT – Group technology

 OWMM – one worker ; multiple machines

 Each of these technologies help achieve repeatability

even when product volumes are too low to justify
dedicating a single line to one product.
 GROUP LAYOUT
(CELLULAR LAYOUT)

• combination of 1 & 2
• trade-off interdepartment mtl
handling w/ intra-department
M.H.

Each cell produces one or a few

families of parts.
 GROUP TECHNOLOGY

 This manufacturing technique groups parts or

products with similar characteristics into families
and sets aside groups of machines for their
production.
 Families may be based on size, shape ,
manufacturing or routing requirements or demand.
 The goal is to find a set of products with similar
processing requirements and minimize machine
changeover or set up. (ex. Bolts might be assigned to
the same family because they all require the same
basic processing steps regardless of the size and
shape.
 INFORMATION FOR GROUPING PARTS INTO
FAMILIES
 Visual inspection of the different parts
made
 Examining the final product designs and
process design specifications
 Organize the machine tools needed to
perform the basic processes into separate
areas called cell.
FIG.10.3
BENEFITS OF GT
Less set up time
Lower work-in-process inventory
Less materials handling
Reduced cycle time
Increased opportunities for
automation
ONE WORKER, MULTIPLE MACHINE
(OWMM)
 A process in which a worker operates
several different machines simultaneously
to achieve a line flow.
 There are several different machines in
the line
ONE WORKER, MULTIPLE MACHINE

 Reduces inventory as well as labor

requirements
 Inventory is cut because materials do not pile
up in queues but move directly into the next
operation.
 The addition of several low-cost automated
devices can maximize the number of machines
included in OWMM: automatic tool changers,
loaders and un loaders, start and stop devices,
and fail-safe devices that detect defective parts
or products.
 FLEXIBLE MANUFACTURING SYSTEMS

 Is a configuration of computer-controlled ,
semi-independent work stations where
materials are automatically handled and
machine loaded. Like NC (numerically
controlled) machines and industrial robots.
 FMS is a type of flexible automation and
is part of CIM.
KEY COMPONENTS OF FMS;
 Several computer-controlled work
stations, such as CNC (computerized
numerically controlled ) machines or
robots, that perform a series of operations
 A computer-controlled transport system
for moving materials and parts from one
machine to another and in and out of the
system
 Loading and unloading stations
 FLEXIBLE MANUFACTURING SYSTEM

 Workers bring raw materials for a part family to

the loading points, where the FMS takes over.
Under the direction of the central computer ,
transporters begin delivering the materials to
various work stations, where they pass through a
specific sequence of operations unique to each
part. The route is determined by the central
computer.
 The goal is to synchronize activities to maximize
the system’s utilization.
FIXED –POSITION LAY OUT

 The product is fixed in place; workers, along

with their tools and equipment, come to the
product to work on it.
 This type of lay out makes sense when the
product is particularly massive or difficult to
move
 It minimizes the number of times that the
product must be moved and often is the only
feasible solution.
COMMON REASONS FOR REDESIGN OF LAY
OUTS:

 Inefficientoperations (e.g. high cost, bottlenecks)

 Accidents or safety hazards.

 Changes in the design of products or services.

 Introduction of new products or services.

 Changes in the volume of output or mix outputs.

 Changes in methods or equipment

 Changes in environment or other legal requirements.

 Morale problems (e.g. lack of face-to-face- contact