3. Job and Batch production - use large machines and materials handling equipment but the equipment is normally general purpose. Re-layout may take place more ofte= n than mechanized assembly lines because the need for relayout increases over time= as product life cycles become shorter, shorter production runs become necessary and flexibility & move ability are needed. Ex. Filter production=

4. Labor intensive services - Relayout may or may not be a a com= mon occurrence. Often it is becau= se it is made necessary by the competitive pressure to improve service.

Layout Types:

1. Process - arrange facilities in process groups based on proce= ss being performed. Ex. Hospital and a&nbs= p; Carpet mill

Facilitates:

a. tool & maintenance support

b. utility hook-ups

c. control of fumes & heat etc.

d. mutual support of workers

e. cross training & talent development

Ex. Job Shops

2. Product Layout - laying out facilities along product flow lin= es with the customer (next process) next to the provider. Ex. Production/Assembly line.=

* old concept

3. Cellular layout - workstations arranged in cells that process families of parts or products that follow similar flow paths. Underlying concept is group techno= logy and product family—you analyze products and based on similarities in = how they are made, parts included, you group them into families. You may in fact tweak the product designs to make them a “tighter” family. A family in group technology, is n= ot like marketing concept of a product family. A family in the context of group technology is based on similarities in processing requirements. Basis for justification for creati= ng cells (combined volume of product family makes it easier to justify setting= up a cell, when the individual product volumes might not. Generally attempt to standardize p= arts, use coding system to differentiate parts (color maybe or bar codes-if using computer) that go in different products.&n= bsp; Basically a "mini" product layout.

Examples: C Cell, U Cell, Rabbit Chase C= ell

4. Fixed position layout - product itself is fixed and facilities come to it. Ex: Building a bridge or home

5. Mixed or Hybrid types: combination of any of the above, a= nd in fact, cellular is a hybrid. Mention FMS (flexible manufacturing system—millitron machine)

In layout planning we must carefully consider people - employees and customers (remember Socio-Technical Systems Theory)

We have for years approached layout in a mechanical way and it has only been in recent years that we started to place proper emphasis on the human factor.<= o:p>

An idea from J.I.T. =3D put the customer in close proximity to the maker—= ;can reduce distance traveled, reduce need for materials handling equipment, and= can reduce WIP. (Next process is = the customer)

This is reflected in the J.I.T. philosophy that process layouts should be broken= up and replaced with islands of repetitive (continuous) manufacturing. This is the idea behind Cellular Layout—see discussion above.

Important Fact= ors Influencing Layout:

1. Volume of Production (Influences cost)

2. Weight of item being produced

3. Nature of service being provided

4. Cost of building to house operation

5. Product mix to share facility

6. Fragility of a product or component

7. Quality

8. People factor

9. Potential hazards

Question: Where do you put support services?=

Does it really matter?

What about standardized Layout?

Same effective & efficient layout used for all locations. (Jiffy lube, groce= ry stores, convenience stores, department stores, auto-parts stores, etc.)

Layout Plannin= g: Steps= and Possible tools.

&= nbsp;

Step 1.&nbs= p; Analyze product resource flows (may be one-may be many we usually lo= ok for dominant flows)

Possible Tools=

Flow diagram

From-To charts (where from where to matr= ix)

Step 2.&nbs= p; Identify and include nonflow factors where significant (noise level/toxic fumes/etc.)

Possible Tools=

Activity-relationship (REL) chart <= /o:p>

combined REL chart

Step 3.&nbs= p; Assess data and arrange work areas (rough layout)<= /p>

Possible Tools=

Activity arrangement Diagram<= /span>

Step 4.&nbs= p; Determine space arrangement plan (space requirements for rough layou= t)

Possible Tools=

Space relationship diagram

Step 5.&nbs= p; Fit space arrangement in to available space. (Several alternatives m= ay be developed from which we will choose one.)

Possible Tools=

Floor plan

Detailed layout models=

Compu= terized tools like CRAFT

*one layout principle is to layout according to the dominant flow.

Goal: Get production or resources into, through, and out of each workstation in minimum time and at reasonable cost= .

Faster through means lower cost (WIP etc= .) and better service to customer (reduced lead-time)

Materials handling considerations:

The best materials handling is the least materials handling. Equipment costs money and distance traveled adds to time and costs.

Fixed path (conveyors etc.)

Inflexible, suitable for large volume, normally in continuous flow.

Variable path (hyster)

Flexible, normally handles lots (iffy), used mostly when flow of mtl. is variable.

*Compare costs vs. benefits for situation at hand to make a rational choice.

Automatic systems: Automatic storage retrieval system= s are becoming commonplace.