Proceess Layout
Transcript of Proceess Layout
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D D
D D
G G
G G
G G
M M
M M
M M
A A
A A
L
L L
L L
L L
L
Process LayoutChapter 7Chapter 7
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Implement
changes6
Redesign Process(Revise layout)
5
Redesigning a Process
Through Layout Revision
Docum
entprocess3
Definescope
2
Evaluate
performance4
Figure 7.1Figure 7.1
I
dentifyopportunity1
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StrategicIssues
Facilitating the flow ofmaterials
Increasing the efficient utilization of
labor and equipment
Reducing hazards to workers Improving employee morale
Improving communication
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Layout Types
FoundryMilling
machines
LathesGrinding
Painting Drills
Office
Welding
Forging
(a) Layout of a job shop(a) Layout of a job shopFigure 7.3Figure 7.3
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Frdelarmed en funktionell verkstad:
flexibel, anpassningsbar till varierandeproduktionsfrhllande, ltt att styra om produktionen till
att tillverka nya produkter
lg strningsknslighet, om en maskin gr snder kanman arbeta i en annan
genom specialisering erhlls personal medspecialistkunnande
hgt maskinutnyttjande kan stadkommas
Flexible-Flow layout (funktionell verkstad)
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Nackdelarmed en funktionell verkstad:
hg kapitalbindning, mycket produkter iarbete och stora mellanlager
lnga oskra genomloppstider
svra planerings, lednings ochadministrationsproblem
ofta lnga transportvgar
genom specialisering, kan den enskildeoperatren bli lst till sin maskin
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Layout Types
(b) Layout of a production line(b) Layout of a production line
Figure 7.3Figure 7.3
Station 1 Station 2 Station 3 Station 4
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Frdelarmed linjetillverkning:
kort genomloppstid
mindre kapitalbindning
mindre transporter
arbetet lttare att planera och administrera n i en
funktionell verkstad (nr installationen r klar)
Line-Flow layout (linjetillverkning)
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Group Technology
Machine
1
Machine
2Machine
3
Machine
4Machine
5
Materials in
Finished
goods out
Figure 7.4Figure 7.4
One Worker, Multiple MachinesOne Worker, Multiple Machines
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Group Technology
Figure 7.5Figure 7.5
Drilling
D D
D D
Grinding
G G
G G
G G
Milling
M M
M M
M M
Assembly
A A
A A
Lathing
Receiving and
shipping
L
L L
L L
L L
L
(a) Jumbled flows in a job shop withoutGT cells(a) Jumbled flows in a job shop withoutGT cells
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Group Technology
(b) Line flows in a job shop with three GT cells(b) Line flows in a job shop with three GT cells
Cell 3
L M G G
Cell 1 Cell 2
Assembly
area
A A
L M DL
L M ShippingD
Receiving
G
Figure 7.5Figure 7.5
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Designing Process Layouts Step 1: GatherInformation
Space Requirements by Center
Available Space
Closeness Factors
Other Considerations
Step 2: Develop a Block Plan
Step 3: Design a Detailed Layout
Aids for Process Layout Decisions
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Department Area Needed (ft2)
1. Administration 3,500
2. Social services 2,600
3. Institutions 2,400
4. Accounting 1,600
5. Education 1,500
6. Internal audit 3,400
Total 15,000
100'
150'
Office of Budget
Managem
ent
3 6 4
1 2 5
Figure 7.6Figure 7.6
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Office of Budget
Managem
entTrips between Departments
Department 1 2 3 4 5 6
1. Administration
2. Social services
3. Institutions
4. Accounting
5. Education
6. Internal audit
3 6 5 6 10
8 1 1
3 9
2
1
100'
150'
3 6 4
1 2 5
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Office of Budget
Managem
enty Departments 1 and 6 close together
y Departments 3 and 5 close together
y Departments 2 and 3 close together
Figure 7.7Figure 7.7
100'
150'
1 5
6
100'
150'
3 6 4
1 2 5
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Office of Budget
Managem
enty Departments 1 and 6 close together
y Departments 3 and 5 close together
y Departments 2 and 3 close together
Figure 7.7Figure 7.7
100'
150'
1 5
6 3
100'
150'
3 6 4
1 2 5
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Office of Budget
Managem
enty Departments 1 and 6 close together
y Departments 3 and 5 close together
y Departments 2 and 3 close together
Figure 7.7Figure 7.7
100'
150'
1 5
6 32
4
100'
150'
3 6 4
1 2 5
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Office of Budget
Managem
ent
100'
150'
3 6 4
1 2 5
y Departments 1 and 6 close together
y Departments 3 and 5 close together
y Departments 2 and 3 close together
Figure 7.7Figure 7.7
100'
150'
1 5
6 32
4
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Distance Measures
Euclidian DistanceEuclidian Distance
Rectilinear DistanceRectilinear Distance
ddABAB = (= (xxAAxxBB))22 + (+ (yyAA yyBB))
22
ddABAB = |= |xxAAxxBB| + || + |yyAA yyBB||
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Office of Budget
Managem
ent
100'
150'
3 6 4
1 2 5
Load Distance Analysis
Current Plan Proposed Plan
Dept Closeness Distance Distance
Pair Factor, w d wd Score d wdScore
1,2 3 1 3 2 6
1,3 6 1 6 3 18
1,4 5 3 15 1 51,5 6 2 12 2 12
1,6 10 2 20 1 10
2,3 8 2 16 1 8
2,4 1 2 2 1 1
2,5 1 1 1 2 2
3,4 3 2 6 2 6
3,5 9 3 27 1 9
4,5 2 1 2 1 2
5,6 1 2 2 3 3
ld= 112 ld= 82Example 7.2
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Office of Budget
Managem
ent
100'
150'
3 6 4
1 2 5
Figure 7.8Figure 7.8
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Office of Budget
Managem
ent
100'
150'
3 6 4
1 2 5
Figure 7.9Figure 7.9
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Out-and-Back Warehouse
Figure 7.10Figure 7.10
Dock Aisle
Storage area
Storage area
3 5 5 6 4 2 7
1 5 5 4 4 2 7
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Zone Systems
Figure 7.11Figure 7.11
Click to add title
Zones Zones Control
station Shipping
doors
Tractor
trailer
Tractor
trailer
Overflow
Feeder
linesFeeder
lines
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Designing Product Layouts Line Balancing
Precedence Diagram
Desired Output rate Cycle Time
Theoretical Minimum
Idle Time, Efficiency, and Balance Delay
Finding a Solution
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Line Balancing
Green Grass, Inc.Green Grass, Inc.
Big BroadcasterBig Broadcaster
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Line Balancing Big BroadcasterBig Broadcaster
AA Bolt leg frame to hopperBolt leg frame to hopper 4040 NoneNone
BB Insert impeller shaftInsert impeller shaft 3030 AA
CC Attach axleAttach axle 5050 AA
DD Attach agitatorAttach agitator 4040 BB
EE Attach drive wheelAttach drive wheel 66 BB
FF Attach free wheelAttach free wheel 2525 CC
GG Mount lowerpostMount lowerpost 1515 CC
HH Attach contro
ls
Attach contro
ls 2020
D, E
D, EII Mount nameplateMount nameplate 1818 F, GF, G
TotalTotal 244244
WorkWork TimeTime ImmediateImmediateElementElement DescriptionDescription (sec)(sec) Predecessor(s)Predecessor(s)
4040
3030
B
A
Example 7.3Example 7.3
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Line Balancing Big BroadcasterBig Broadcaster
AA Bolt leg frame to hopperBolt leg frame to hopper 4040 NoneNone
BB Insert impeller shaftInsert impeller shaft 3030 AA
CC Attach axleAttach axle 5050 AA
DD Attach agitatorAttach agitator 4040 BB
EE Attach drive wheelAttach drive wheel 66 BB
FF Attach free wheelAttach free wheel 2525 CC
GG Mount lowerpostMount lowerpost 1515 CC
HH Attach controlsAttach controls 2020 D, ED, E
II Mount nameplateMount nameplate 1818 F, GF, G
TotalTotal 244244
WorkWork TimeTime ImmediateImmediateElementElement DescriptionDescription (sec)(sec) Predecessor(s)Predecessor(s)
4040
66
2020
5050
1515
1818
E3030
2525
4040H
I
D
B
F
C
A
G
Example 7.3Example 7.3
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Line Balancing Big BroadcasterBig Broadcaster
Example 7.4Example 7.4
4040
66
2020
5050
1515
1818
E3030
2525
4040H
I
D
B
F
C
A
G
Desired output rate = 2400/week
Plant operates 40 hours/week
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Line Balancing Big BroadcasterBig Broadcaster
4040
66
2020
5050
1515
1818
E3030
2525
4040H
I
D
B
F
C
A
G
Desired output rate = 2400/week
Plant operates 40 hours/week
r= 2400/40 = 60 units/hour
Example 7.4Example 7.4
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Line Balancing Big BroadcasterBig Broadcaster
4040
66
2020
5050
1515
1818
E3030
2525
4040H
I
D
B
F
C
A
G
Desired output rate = 2400/week
Plant operates 40 hours/week
r= 2400/40 = 60 units/hour
c= 1/60 = 1 minute/unit
= 60 seconds/unit
Example 7.4Example 7.4
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Line Balancing Big BroadcasterBig Broadcaster
cc= 60 seconds/unit= 60 seconds/unit
4040
66
2020
5050
1515
1818
E3030
2525
4040H
I
D
B
F
C
A
G
Desired output rate = 2400/week
Plant operates 40 hours/week
TM= 244 seconds/60 seconds= 4.067 or 5 stations
Example 7.4Example 7.4
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Line Balancing Big BroadcasterBig Broadcaster
cc= 60 seconds/unit= 60 seconds/unit
4040
66
2020
5050
1515
1818
E3030
2525
4040H
I
D
B
F
C
A
G
Desired output rate = 2400/week
Plant operates 40 hours/week
TM= 244 seconds/60 seconds= 4.067 or 5 stations
Efficiency = [244\5(60)]100 = 81.3%
Example 7.4Example 7.4
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Line Balancing Big BroadcasterBig Broadcaster
cc= 60 seconds/unit= 60 seconds/unit
TM= 5 stationsTM= 5 stations
Efficiency = 81.3%Efficiency = 81.3%
4040
66
2020
5050
1515
1818
E3030
2525
4040H
I
D
B
F
C
A
G
Cumm Idle
Station Candidate Choice Time Time
S1 A A 40 20
Example 7.5Example 7.5
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Line Balancing Big BroadcasterBig Broadcaster
cc= 60 seconds/unit= 60 seconds/unit
TM= 5 stationsTM= 5 stations
Efficiency = 81.3%Efficiency = 81.3%
S1
40
66
2020
5050
1515
1818
E3030
2525
4040H
I
D
B
F
C
A
G
Cumm Idle
Station Candidate Choice Time Time
S1 A A 40 20
Example 7.5Example 7.5
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Line Balancing Big BroadcasterBig Broadcaster
cc= 60 seconds/unit= 60 seconds/unit
TM= 5 stationsTM= 5 stations
Efficiency = 81.3%Efficiency = 81.3%
S1
40
66
2020
5050
1515
1818
E3030
2525
4040H
I
D
B
F
C
A
G
Cumm Idle
Station Candidate Choice Time Time
S1 A A 40 20
S2 B,C C 50 10
Example 7.5Example 7.5
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Line Balancing Big BroadcasterBig Broadcaster
cc= 60 seconds/unit= 60 seconds/unit
TM= 5 stationsTM= 5 stations
Efficiency = 81.3%Efficiency = 81.3%
S1
S2
40
66
2020
50
1515
1818
E3030
2525
4040H
I
D
B
F
C
A
G
Cumm Idle
Station Candidate Choice Time Time
S1 A A 40 20
S2 B,C C 50 10
Example 7.5Example 7.5
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Line Balancing Big BroadcasterBig Broadcaster
cc= 60 seconds/unit= 60 seconds/unit
TM= 5 stationsTM= 5 stations
Efficiency = 81.3%Efficiency = 81.3%
S1
S2
40
66
2020
50
1515
1818
E3030
2525
4040H
I
D
B
F
C
A
G
Cumm Idle
Station Candidate Choice Time Time
S1 A A 40 20
S2 B,C C 50 10S3 B,F,G B 30 30
Example 7.5Example 7.5
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Line Balancing Big BroadcasterBig Broadcaster
cc= 60 seconds/unit= 60 seconds/unit
TM= 5 stationsTM= 5 stations
Efficiency = 81.3%Efficiency = 81.3%
S1
S2
40
66
2020
50
1515
1818
E30
2525
4040H
I
D
B
F
C
A
G
Cumm Idle
Station Candidate Choice Time Time
S1 A A 40 20
S2 B,C C 50 10S3 B,F,G B 30 30
Example 7.5Example 7.5
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Line Balancing Big BroadcasterBig Broadcaster
cc= 60 seconds/unit= 60 seconds/unit
TM= 5 stationsTM= 5 stations
Efficiency = 81.3%Efficiency = 81.3%
S1
S2
40
66
2020
50
1515
1818
E30
2525
4040H
I
D
B
F
C
A
G
Cumm Idle
Station Candidate Choice Time Time
S1 A A 40 20
S2 B,C C 50 10S3 B,F,G B 30 30
E,F,G F 55 5
Example 7.5Example 7.5
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Line Balancing Big BroadcasterBig Broadcaster
cc= 60 seconds/unit= 60 seconds/unit
TM= 5 stationsTM= 5 stations
Efficiency = 81.3%Efficiency = 81.3%
S1
S2
S3
40
66
2020
50
1515
1818
E30
25
4040H
I
D
B
F
C
A
G
S1 A A 40 20
S2 B,C C 50 10S3 B,F,G B 30 30
E,F,G F 55 5
Cumm Idle
Station Candidate Choice Time Time
Example 7.5Example 7.5
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Line Balancing Big BroadcasterBig Broadcaster
cc= 60 seconds/unit= 60 seconds/unit
TM= 5 stationsTM= 5 stations
Efficiency = 81.3%Efficiency = 81.3%
S1
S2
S3
S5S4
Figure 7.13Figure 7.13
40
6
20
50
15
18
E30
25
40H
I
D
B
F
C
A
G
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NL8. En produkt bestr av 9 st detal er (D1-D9) vilka monteras ihop enligt strukturen
nedan:
A
D7
E
D4B
C G
D5
DD8
D1
D2
D3
D6
D9
F
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