Bauer Facility layout Dr. Everette S. Gardner .ppt

Bauer Facility Layout showing how exit paths are setup

1. Facility Layout
Dr. Everette S. Gardner, Jr.

2. Facility Layout 2
Machine shop process layout
Receiving Grin-
Mills ders
Raw matl. Large number
of
storage Assem- low volume
bly products
Drills
Planers
Finished
Inspec-goods
Lathes Automatics tion storage
Part A
Part B

3. Facility Layout 3
Product layout
Raw matl. Fabrication
Rec-storage line-part B
eiving Fabrication Planer
line-part A
Finished Lathe
goods Drill
storage Mill
Mill
Drill
Grinder
Mill
Assembly line Automatic
Small number
of
high volume
products

4. Facility Layout 4
Possible solutions to the process
layout problem
6 Department problem has 6! or 720 possible solutions:
A B C
D E F
I.E., there are 720 different arrangements of the 6 departments
on the 6 locations on the grid.

5. Facility Layout 5
Possible solutions to the process
layout problem (cont.)
Problem complexity grows exponentially:
Nbr. depts. Solutions
10 3,628,800
15 1.31 x 10^12
20 2.43 x 10^18
50 3.04 x 10^64

6. Facility Layout 6
Solutions considered by Craft
•N! solutions to problem with N depts.
•Craft considers only
N(N-1)pairs of exchanges,
2 starting with each
dept.

7. Facility Layout 7
Craft initial layout of furniture plant
A B C
D E
F G
I H
J
TOTAL COST= $2524.68

8. Facility Layout 8
Craft final layout
A E C IG F B H J D
TOTAL COST = $766.68

9. Facility Layout 9
Synopsis of assembly line balancing
1.Set up a precedence table.
2.Compute required cycle time:
C = (production time) / (required output in units)
3.Compute minimum cycle time:
CMIN = time for longest task
4.Compute minimum number of stations:
SMIN = (sum of all times) / C

10. Facility Layout 10
Synopsis of assembly line balancing
(cont.)
5.Select rule by which tasks are assigned to work
stations.
Examples:
(1) select tasks with longest operation times first or
(2) select tasks with largest number of following tasks first
6.Assign tasks to the first work station until the sum of
the task times are equal to the cycle time, or no other
tasks are feasible. Repeat for stations 2, 3, … until
tasks are assigned.
7.Evaluate the efficiency of the balance:
E = (sum of all times) / (actual nbr. of stations x C)

11. Facility Layout 11
Line balancing quiz
0.4
0.3 1.1
1.1 0.5 0.7 0.3
1.2 0.4 0.8
Balance this production line to achieve an output of 367 units per
day. Available production time is 8 hrs. less a 40 min. lunch break.
Use the largest number of following tasks rule to select tasks for
work stations. Break ties with the longest operation time.
A
B
C
D
E
F
G
H
I J

12. Facility Layout 12
Multiple solutions in line balancing
6
4
7
3 5
5 5
2
A
B
C
D
E
F
G
H

13. Facility Layout 13
Multiple solutions in line balancing
(cont.)
84
25
3
1 2 3 4 5 6 7
Stations
Number of solutions

14. Facility Layout 14
Volvo layouts
Rotating
round table
with definite
cycle time --
facilitates teamwork

15. Facility Layout 15
Volvo layouts (cont.)
Horseshoe
conveyor
sections to
enable worker
communications

16. Facility Layout 16
Volvo layouts (cont.)
Interim storage
Storage areas to separate
line into definite
supervisory groups
Supervisor Supervisor
B A

17. Facility Layout 17
Volvo layouts (cont.)
Machines grouped
in banks of 3
so workers can
exchange jobs and
assist each other
in set-up

18. Facility Layout 18
Volvo continued
Connections of subassembly islands feed parts/components to
end-assembly islands—each island functions as a separate team
E
S
S
S
E
E
S
S
S