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1
Objectives of Facility Layout
labor
Eliminate
bottlenecks
Facilitate
organization structure
manufacturing process
visual control
Minimize
manufacturing cycle time or customer flow time
investment
Provide
convenience, safety and comfort of the employees
Selection 10 Evaluation
Layout Types
Product layout
Process or Functional layout
Project or Fixed-position layout
Cellular Manufacturing
Group Technology
6
Product Layout
Facility
organized around product
Design minimizes line imbalance
Delay between work stations
Types:Fabrication line; assembly line
Examples
Autoassembly line
Paper manufacturing.
7
Product Type Layout
W
A
S a
s r
t s
o Drill e
Press Bend e h
r
a m o
g b u
se
e l
y
Mill Drill
Milling
Assembly
Grinding
& Test
Drilling Plating
Process Layout - work travels
to dedicated process centers
10
Project or Fixed-Position
Design is for stationary project
Workers & equipment come to site
Complicating factors
Limitedspace at site
Changing material needs
Examples
Shipbuilding
Highway construction
11
Fixed-Position Layout
12
Fixed Position Layout
16
Cellular Manufacturing
Typical
objectives of cellular
manufacturing:
To shorten manufacturing lead times
To reduce WIP
To improve quality
17
Cellular Layouts
Machines
Enter
Worker 2
Worker
Worker 1 3
Exit
W
S a
t re
o Mill Assembly Weld Paint h
r o
a u
g se
e
Press Lathe Drill Press Assembly
24
parts shown are
different in size,
shape, and material,
but quite similar in
terms of
manufacturing
All parts are
machined from
cylindrical stock by
turning; some parts
require drilling and/or
milling
Part Families
Dissimilar parts requiring similar machining operations (hole drilling, surface milling
©
1- Visual Inspection Method
Parts classification and Coding
©
Parts classification and Coding
Hybrid structure
Hierarchical structure
Also known as a monocode
The interpretation of each successive symbol is
dependent on the preceding symbols.
Chain type structure or Polycode
Solution
• Length-to-diameter ratio: L/D = 1.5 Digit 1 = 1
• External shape: both ends stepped with screw thread on one end Digit 2 = 5
High
Product Planning
Department
Product Layout
Medium Product Family
Volume
Planning
Department
Fixed Location Layout Process Layout
Group Technology Layout
Fixed Materials Process Planning
Low Location Planning Department
Department
FMS operations:
1. Processing operations
2. Assembly operations
Activity Relationship Chart
A- absolutely necessary
E- especially important
I - important
O - ordinarily important
U- unimportant
X- undesirable
Closeness Rating: multiple
criteria
45
Legend
5 8 7
A Rating
E Rating
10 9 6
I Rating
O Rating
4 2 3
U Rating
X Rating
Fig 6 Activity relationship 1
diagram
Assembly Line Balancing
General Procedure
1. Determine cycle time - The time between
production of successive units. (May be
measured in seconds, minutes, etc.)
Task times
Efficiency =
(Actual number
* (Cycle time)
of work stations)
9-48
Assembly Line Balancing
Heuristics
Most following tasks.
Choose task with largest number of following
tasks.
c d e
0.7 min. 0.5 min. 0.2 min.
Line Balancing
Immediate
Task Time Predecessor
A 0.2 min. -
B 0.6 min. A,C Suppose we want to
C 0.5 min. - produce 450 units/day
D 0.3 min. -
E 1.0 min. B,D and 8 hours are available
F 0.2 min. D each day.
G 0.9 min. E,F
3.7 min.
cycle time 480 minu tes / day 1.0667 minu tes / unit
450 units / day
N 3.7 minu tes 3.47 ... or 4 workstatio ns
1.0667 minu tes
9-51