Chapter 10: Facility Layout C-215

ALDEP

(automated layout design program)computer software packages can be used as decision-support tools in making the layout decision. called decision-support tools because they use different heuristics to develop a solution

CRAFT

(computerized relative allocation of facilities technique) called decision-support tools because they use different heuristics to develop a solutioncomputer software packages can be used as decision-support tools in making the layout decision.

Product layouts have the following characteristic

Resources are specialized. Product layouts use specialized resources designed to produce large quantities of a product.2. Facilities are capital intensive.Product layouts make heavy use of automation, which is specifically designed to increase production.3. Processing rates are faster.Processing rates are fast, as all resources are arranged in sequence for efficient production.4. Material handling costs are lower.Due to the arrangement of work centers in close proximity to one another, material handling costs are significantly lower than for process layouts.5. Space requirements for inventory storage are lower.Product layouts have much faster processing rates and less need for inventory storage.6. Flexibility is low relative to the market.Because all facilities and resources are specialized, product layouts are locked into producing one type of product. They cannot easily add or delete products from the existing product line.

Characteristics of Process Layouts

Resources used are general purpose. The resources in a process layout need to be capable of producing many different products.2. Facilities are less capital intensive.Process layouts have less automation, which is typically devoted to the production of one product.3. Facilities are more labor intensive.Process layouts typically rely on higher-skilled workers who can perform different functions.4. Resources have greater flexibility.Process layouts need to have the ability to easily add or delete products from their existing product line, depending on market demands.5. Processing rates are slower.Process layouts produce many different products, and there is greater movement between workstations. Consequently, it takes longer to produce a product.6. Material handling costs are higher.It costs more to move goods from one process to another.7. Scheduling resources is more challenging.Scheduling equipment and machines is particularly important in this environment. If it is not done properly, long waiting lines can form in front of some work centers while others remain idle.8. Space requirements are higher.This type of layout needs more space due to higher inventory storage needs.

three steps in designing process layouts

Step 1 Gather information.Step 2 Develop a block plan or schematic of the layout.Step 3 Develop a detailed layout.

Gather information

Step 1 in a process plan Several kinds of information are needed. Identify Space Needed The first piece of information to be collected is the amount of space needed for each of the organization's key resources. Step 2 Identify Available Space The available space of a facility is best seen by using a block plan, a schematic that shows the placement of departments in a facility. Using a block plan, we can visualize the available space and evaluate whether we can meet space needs Identify Closeness Measures Recall that the main criterion in deciding the location of departments relative to one another is the importance of proximity between them. At this stage we need a measure of the importance of having any pair of departments in close proximity to one another. There are two simple tools that can be used for this purpose: a from-to matrix and a REL chart

Develop a Detailed Layout

The last step in designing a process layout is the development of a detailed layout design. At this stage the block plan is translated into a more realistic schematic. We begin to consider exact sizes and shapes of departments and work centers. We also focus on specific work elements, such as desks, cabinets, and machines, as well as aisles, stairways, and corridors. Operations managers can use a variety of tools in this final stage; they include drawings, three-dimensional models, and computer graphics software.

group technology (GT) or cell layouts

Type of hybrid layouthat create groups of products based on similar processing requirements. hey are created whenever possible in order to combine the strengths of each type of layout. One of the most popular types of hybrid layouts is _____p. 396

systematic layout planning (SLP)

Using a relationship chart to develop acceptable layouts is part of a classic layout technique called _______

Identify Closeness Measures

a schematic that shows the placement of departments in a facility. Using a block plan, we can visualize the available space and evaluate whether we

warehouse layout

a special case of process layout. where multiple floors, and consideration for things like height for assigning storage locations,

From-to-matrix

a table that shows the number of trips or units of product moved between any pair of department

relationship chart. A REL chart

a tool that reflects opinions of managers with regard to the importance of having any two departments close together.

Hybrid Layouts

combine aspects of both process and product layouts. This is the case in facilities where part of the operation is performed using an intermittent processing system and another part is performed using a continuous processing system.

Product Layouts

layouts that arrange resources in a straight-line fashion to promote efficient production. They are called product layouts because all resources are arranged to meet the production needs of the product. This type of layout is used by companies that have repetitive processing systems and produce one or a few standardized products in large volume. Examples of product layouts are seen on assembly lines, in cafeterias, or even at a car wash. In product layouts the material moves continuously and uniformly through a series of workstations until the product is completed. The challenge in designing product layouts is to arrange workstations in sequence and designate the jobs that will be performed by each station in order to produce the product in the most efficient way possible. Operations managers must decide exactly what tasks will be performed by every workstation in the sequence. They need to consider the logical order in which jobs should be done. For example, at a car wash you cannot perform drying before you have performed washing. Managers also need to consider how fast production occurs and how many units can be processed through the system. The faster production occurs, the more units that can be processed through the system.

Process Layouts

layouts that group resources based on similar processes or functions. This type of layout is seen in companies with intermittent processing systems. You would see a process layout in environments in which a large variety of items are produced in a low volume. Since many different items are produced, each with unique processing requirements, it is not possible to dedicate an entire facility to each item. It is more efficient to group resources based on their function. The products are then moved from one resource to another, based on their unique needs.

Afixed-position layout

when the product is large and cannot be moved due to its size. All the resources for producing the product—including equipment, labor, tools, and all other resources—have to be brought to the site where the product is located.