Chapter 10 Facility layout

Question 1

facility layout (layout planning) :

Answer 1

Deciding the best physical arrangement of all resources that consume space within a facility

Question 2

Intermittent processing systems:

Answer 2

low volume of many different products

Question 3

Repetitive processing systems:

Answer 3

high volume of a few standardized products

Question 4

The 4 types of layouts:

Answer 4

Process layouts, product layout, hybrid layout, fixed-position layout

Question 5

process layouts:

Answer 5

Group similar resources together based on

similar processes/functions

Question 6

product layouts:

Answer 6

Designed to produce a specific product efficiently

Question 7

hybrid layouts:

Answer 7

Combine aspects of both process and product layouts

Question 8

fixed-position layouts:

Answer 8

Product is too large to move, and all resources must be brought to production site; e.g., shipbuilding

Question 9

unique characteristics for process layouts are:

Answer 9

o resources used are general-purpose
o facilities are less capital intensive
o facilities are more labor intensive
o resources have greater flexibility
o processing rates are slower
o material handling costs are higher
o scheduling resources flow is more challenging
o space requirements are higher

Question 10

unique characteristics of product layouts are:

Answer 10

o resources are specialized
o facilities are capital intensive
o processing rates are faster
o material handling costs are lower
o space requirements for inventory storage are lower
o flexibility is low relative to the market

Question 11

characteristics of hybrid layouts are:

Answer 11

• Combine elements of both product and process layouts
o Maintain some of the efficiencies of product layouts
o Maintain some of the flexibility of process layouts
• Group technology or cell layouts
o Identify parts of the process layout operation that can be
standardized and produce them in a product layout format
example: grocery stores

Question 12

characteristics of fixed-position layout are:

Answer 12

• Used when product is large
• Product is difficult or impossible to move, i.e., very large or fixed
• All resources must be brought to the site
• Scheduling of crews and resources is a challenge

Question 13

Steps in Design Process layout are:

Answer 13

1. Gather information
2. Develop a block plan
3. Develop detailed layout

Question 14

Steps in Design Process layout, Gathering information:

Answer 14

Identify space needed, space available, closeness measures

from-to matrix, REL, SLP

Question 15

From-to matrix

Answer 15

A table that shows the number of trips or units of product moved between any pair of departments

Question 16

REL chart:

Answer 16

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

Question 17

Steps in Design Process layout, Develop Block plan:

Answer 17

Use trial-and-error or decision support tools (load–distance model,
ALDEP, CRAFT)

Question 18

Rectilinear distance: (used with load-distance model)

Answer 18

The shortest distance between two points measured by using only north–south and east–west movements.

Question 19

ALDEP

Answer 19

automated layout design program

Question 20

CRAFT

Answer 20

computerized relative allocation of facilities technique

Computer software packages for designing process layouts

Question 21

Steps in Design Process layout, develop a detailed layout:

Answer 21

• Consider exact sizes/shapes of departments and work centers
including aisles and stairways
• Tools like drawings, three-dimensional models, and computer graphics software are available to facilitate this process

Question 22

Special Cases of Process Layouts: Warehouse

Layouts

Answer 22

• Warehouse layout considerations
o Primary decision is where to locate each department relative to the dock.
• Storage areas of equal sizes
o Assign departments to locations in order to minimize the number of trips to the
dock.
• Storage areas of unequal sizes
o Step 1: Take the ratio of the number of trips relative to the storage area required.
o Step 2: Use the ratios from Step 1 to make assignments. Assign the department with the highest ratio closest to the dock. Next, assign the department with the second-highest ratio second closest to the dock. Continue in this manner until all departments have been assigned.

Question 23

Special Cases of Process Layouts: Office

Layouts

Answer 23

• Office layout considerations
o Almost half of U.S. workforce works in an office environment.
o Human interaction and communication are the primary factors in designing office layouts.
o Layouts need to account for physical environment and psychological needs of the organization.
o Key trade-off is between proximity and privacy.
o Open concept offices promote understanding and trust.
o Flexible layouts incorporating “office landscaping” help to solve the privacy issue in open office environments.

Question 24

Designing product layouts:

Answer 24

• Designing product layouts requires consideration of:
o Sequence of tasks to be performed by each workstation
o Logical order
o Speed considerations – line balancing

Question 25

Steps in Designing product layouts:

Answer 25

Step 1: Identify tasks and their immediate predecessors.
Step 2: Determine output rate.
Step 3: Determine cycle time.
Step 4: Compute the theoretical minimum number of stations.
Step 5: Assign tasks to workstations (balance the line).
Step 6: Compute efficiency, idle time, and balance delay.

Question 26

Steps in Designing product layouts, Step 1: Identify tasks and their immediate predecessors.

Answer 26

can list out the tasks or use a diagram

Question 27

Steps in Designing product layouts, Step 2: Determine output rate.

Answer 27

Output rate is the number of units to be produced over a specific period of time.
The goal is to design a product layout that can produce the desired number of units with the fewest work centers and a balance of workload.

Question 28

Steps in Designing product layouts, Step 3: Determine cycle time:

Answer 28

The amount of time each workstation is allowed to complete its tasks
Limited by the bottleneck task (the longest task)
Minimum cycle time = bottleneck
Maximum cycle time = sum of the task times

Question 29

Steps in Designing product layouts, Step 4: Compute the theoretical minimum number of stations:

Answer 29

TM = number of stations needed to achieve 100% efficiency (every
second is used)
Always round up (no partial workstations)
Serves as a lower boundary for our analysis

Question 30

Steps in Designing product layouts, Step 5: Assign tasks to workstations (balance the line) :

Answer 30

o Start at the first station and choose the longest eligible task following precedence relationships.
o Continue adding the longest eligible task that fits without going over the desired cycle time.
o When no additional tasks can be added within the desired cycle time, begin assigning tasks to the next workstation until finished.

Question 31

Steps in Designing product layouts, Step 6: Compute efficiency, idle time, and balance delay:

Answer 31

Efficiency (%) is the ratio of total productive time divided by
total time.
Balance delay (%) is the amount by which the line falls short of 100%.
example: Balance delay (%) = 100% − 91.7% = 8.3%

Question 32

other product layout considerations, Shape of the line (S, U, O, L):

Answer 32

Share resources, enhance communication and visibility, impact
location of loading and unloading

Question 33

other product layout considerations, Paced versus unpaced lines:

Answer 33

Paced lines use an automatically enforced cycle time

Unpaced lines have more autonomy; product may be removed from assembly line

Question 34

other product layout considerations, Number of product models produced:

Answer 34

Single-model lines – one version of a product

Mixed-model lines – many versions of a product