IENG 471 Facilities Planning Dr. Frank Joseph Matejcik

1. IENG 471 Facilities Planning Dr. Frank Joseph Matejcik 10/3: Chapter Six LAYOUT PLANNING MODELS AND DESIGN ALGORITHMS South Dakota School of Mines and Technology, Rapid City

2. 6.1 Introduction • Block layout as opposed to detailed layout • Handling best is less • Material handling or layout first? Both

3. 6.1 Introduction • following affect layout • 1. Centralized versus decentralized storage of work-in-process (WIP), tooling, and supplies • 2. Fixed-path versus variable-path handling • 3. The handling unit planned for the systems • 4. The degree of automation used in handling • 5. The type of level of inventory control, physical control, and computer control of materials

4. 6.2 Basic Layout Types (4 types) • Product large, stable demand for a standardized product like an engine block, often a production line • Fixed materials location low sporadic demand awkward to move, aircraft fuselage • Product family (group technology) medium demand for a medium number of similar components. Similar components form groups.

5. 6.2 Basic Layout Types (4 types) • Process planning combination of workstations containing “similar” processes are metal cutting departments, gear cutting departments, and hobbing departments • The difficulty in defining process departments is in the interpretation of the word “similar.”

6. 6.2 Basic Layout Types

7. 6.2 Basic Layout Types

8. 6.2 Basic Layout Types

9. 6.2 Basic Layout Types

10. 6.3 Layout Procedures • Apple's Plant Layout Procedure • 1. Procure the basic data. • 2. Analyze the basic data. • 3. Design the productive process. • 4. Plan the material flow pattern. • 5. Consider the general material handling plan. • 6. Calculate equipment requirements. • 7. Plan individual workstations. • 8. Select specific material handling equipment

11. 6.3 Layout Procedures • Apple's Plant Layout Procedure • 9. Coordinate groups of related operations. • 10. Design activity interrelationships. • 11. Determine storage requirements. • 12. Plan service and auxiliary activities. • 13. Determine space requirements. • 14. Allocate activities to total space. • 15. Consider building types. • 16. Construct master layout.

12. 6.3 Layout Procedures • Apple's Plant Layout Procedure • 17. Evaluate, adjust, and check the layout with the appropriate persons. • 18. Obtain approvals. • 19. Install the layout. • 20. Follow up on implementation of the layout.

13. 6.3 Layout Procedures • Reed's Plant Layout Procedure • 1. Analyze the product or products to be produced. • 2. Determine the process required to manufacture the product. • 3. Prepare layout planning charts. • 4. Determine workstations. • 5. Analyze storage area requirements.

14. 6.3 Layout Procedures • Reed's Plant Layout Procedure • 6. Establish minimum aisle widths. • 7. Establish office requirements. • 8. Consider personnel facilities and services. • 9. Survey plant services. • 10.Provide for future expansion. • Most important part is the Layout planning chart (Figure 6.2)

15. 6.3 Layout Procedures Muther

16. 6.3 Layout Procedures Muther

17. 6.3 Layout Procedures Muther

18. 6.3 Layout Procedures Muther

19. 6.3 Layout Procedures Muther

20. Layout Planning Chart • Most important phase (Reed) • Incorporates • Flow process • Standard times for each operation • Machine selection and balance • Manpower selection and balance • Material handling requirements

21. Layout Procedures • Construction Type • Improvement Types • Algorithms • Relationship diagramming • Pairwise exchange method • Graph-based construction method

22. Facility Layout Once we have determined a new location for our facility, we wish to design an optimal configuration for the layout of departments. Suppose we have the following:

23. Relationship Chart 4 =Very Important 2 = Useful 3 = Important 1 = Not very useful

24. 1 Nodal Representation Idea: Start with most valuable department first and begin building other departments around it. Departments in order 1 - 2 - 6 - 7 - 3 -4 - 5 Ties are broken arbitrarily. Add Production

25. 1 2 Nodal Rep. (cont) Department 2, Warehouse, is next most important so we add it next. It has a relationship value of 4 with production. Continue adding Departments in order of importance.

26. 1 2 6 Nodal Rep. (cont.) Add 6, support

27. 7 1 2 6 Nodal Rep. (cont.) Add 7, shipping

28. 7 4 1 2 6 Nodal Rep. (cont.) Add 4, toolroom

29. 7 4 1 2 3 6 Nodal Rep. (cont.) Add 3, office

30. 7 4 1 2 5 3 6 Nodal Rep. (cont.) Add , 5 Food Service

31. 7 4 1 2 5 3 6 Nodal Rep. (cont.) Nodal Clean-up

32. Block Calculations Idea: Add Blocks pretty much in same manner as nodal representation

33. 7 7 4 1 2 4 1 2 5 3 3 6 5 6 Nodal to Block Representation

34. 7 7 4 4 1 2 1 2 3 3 5 6 5 6 Nodal to Block Representation Initial Layout

35. 7 4 1 2 3 6 5 Layout Evaluation Idea: Compute the rectilinear distance between departments and multiply by the relationship chart; e.g. Distance = 3

36. Layout Evaluation

37. Evaluation (cont.) Total Effectiveness = 108 Idea: Try new layout and search for lower effectiveness score

38. 6.4 Algorithmic Approaches • Human judgment is still required • Generally need computer implementation • Outgrowth of university research • Commercial packages • emphasize layout evaluation or • presentation (CAD Tools)

39. Algorithmic Classification • Use from to chart and/or relationship chart • Problems become increasingly difficult as size increases. Limited approaches may be used. • Multiple Objective functions are used

40. Algorithmic ClassificationMultiple Objectives • cij cost of unit flow/unit distance • dij distance, fij flow, xij adjacent 1, else 0 • distance based objective • adjacency based objective • relatively efficiency

41. Discrete or continuous layout

42. Pairwise Exchange

43. Pairwise Exchange

44. Pairwise Exchange

45. Pairwise Exchange

46. Graph-based Method

47. Graph-based Method

48. Graph-based Method

49. Graph-based Method

50. Graph-based Method