- More open work areas with fewer walls, partitions, or other obstacles
- Smaller and more compact factory layouts
- Less space provided for storage of inventories throughout the layout
- Two Categories of Software Tools
- Computer aided design (CAD)
- Allows 3-D, full-color views of facility design
- Allows virtual walk-throughs
- Ex. – ArchiCAD, AutoSketch, AutoCAD
- Computer simulation
- Can simulate proposed system layout in operation and measure its performance
- Ex. – ProModel, VisFactory, SIMPROCESS
Planning Manufacturing Facility Layouts - Process and Warehouse Layouts
- Product Layouts
- Cellular Manufacturing Layouts
Planning Manufacturing Facility Layouts - Process Layouts
- Primary focus is on the efficient flow of materials
- The wide variety of potential product routings through the facility can be evaluated using computer simulation
- Warehouse Layouts
- Primary focus is the fast storage and retrieval of inventory items
- Decisions about aisle size/placement and location of each inventory item can be evaluated using computer simulation
Planning Manufacturing Facility Layouts - Product Layouts
- Primary focus is on the analysis of production lines
- The goal of the production line analysis is to:
- Determine how many workstations to have
- Determine which tasks to assign to which workstation
- Minimize the number of workers & machines used
- Provide the required amount of capacity
- Line balancing is a key part of the analysis
Planning Product Layouts - Line Balancing Procedure
- 1. Determine the tasks involved in completing 1 unit
- 2. Determine the order in which tasks must be done
- 3. Draw a precedence diagram
- 4. Estimate task times
- 5. Calculate the cycle time
- 6. Calculate the minimum number of workstations
- 7. Use a heuristic to assign tasks to workstations
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