Layout and flow by sir taj mohammad tamkeen
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The document discusses different types of layouts for operations including fixed position, process, cell, and product layouts. It explains the advantages of a good layout including higher utilization of space, equipment, and people as well as improved flow and employee morale. Key aspects of each layout type are defined such as how in a fixed position layout the resources move to the product. The document also covers considerations for product layout design like calculating cycle time and allocating activities to stages. Safety, flow, use of space, and other factors are important to consider for an efficient and well-designed layout.
Layout and flow by sir taj mohammad tamkeen
- 2. • The layout of an operation is concerned with the physical location of its transforming resources, that is deciding where to put the facilities, machines, equipment and staff in the operation. Advantages of a good layout ◦ Higher utilization of space, equipments & people ◦ Improved flow of information, materials or people ◦ Improved employee morale and safer working conditions ◦ Improved customer interaction
- 3. Fixed position layout Process layout Cell layout Product layout
- 4. 1) In a fixed position layout, the transformed resource does not move between its transforming resources. Equipment, machinery, plant and people who do the processing move as necessary because the product or customer is either Too large to move(fixed position (e.g., a hospital operating room where doctors, nurses, and medical equipment are brought to the patient)
- 5. 1) In a process layout, similar processes or processes with similar needs are located together because: i. It is convenient to group them together or ii. The utilization of the transforming resource is improved
- 6. An example of a process layout in a library showing the path of just one customer Entrance Exit On-line and CD-ROM access room Loan books in subject order Enquiries Store room Counter staff Copying areaCompanyreports To journal sack Current journals Reserve collection Reference section Study desks
- 7. 3.Cell layout 1) In a cell layout, the transformed resources entering the operation move into a cell in which all the transforming resources it requires in located. 2) After being processed in the cell, the transformed resource may move to a different cell in the operation or it may be a finished product or service. 3) Each cell may be arranged in either a process or product layout. 4) The cell type layout attempts to bring order to the complex flow seen in a process layout.
- 8. The ground floor plan of a department store showing the sports goods shop-within-a-shop retail ‘cell’ Sports shop Menswear Women’s clothes Luggage and gifts Confectionery, newspaper, magazines and stationery Books and videos Footwear Perfume & jewellery Elevators Entrance
- 9. Product layouts are found in flow shops (repetitive assembly and process or continuous flow industries). Flow shops produce high-volume, highly standardized products that require highly standardized, repetitive processes. In a product layout, resources are arranged sequentially, based on the routing of the products.
- 10. © Wiley 2010 10 In Out
- 11. Here are the characteristic differences between a process and product layout. © Wiley 2010 11
- 12. A restaurant complex with all four basic layout types Fixed-position layout service restaurant Cell layout buffet Line layout cafeteria Cool room Freezer Vegetable prep Grill Preparation Oven Process layout kitchen Main course buffet Starter buffet Desert buffet Service line
- 13. Product layout design 1) Product type layout is designed based on a technique called line balancing. The technique consist of the following steps: 1) Calculating the required cycle time. 2) Calculating the number of stages. 3) Producing a precedence diagram. 4) Finally allocating activities to the stages.
- 14. Cycle time: It is the time between completed products emerging from the process. Example: Suppose the regional back-office operation of a large bank is designing an operation which will process its mortgage applications. The number of applications to be processed is 160 per week and the time available to process the applications is 40 hours per week. Cycle time = 40 = 1/4 hours = 15 minutes 160 1 product every 15 minutes
- 15. Number of stages Required no. of stages = total work content required cycle time Where the total work content is the total quantity of work involved in producing the product given in time. Example: Suppose that the bank in the previous example calculated that the average total work content of processing a mortgage application is 60 minutes. The number of stages needed to produce a processed application every 15 minutes can be calculated Required no. of stages = 60 minutes = 4 stages 15 minutes If you get a fraction round it up to the higher whole number.
- 16. Precedence diagram This is a diagram representing the ordering of the elements which comprise the total work content of the product or service. Two rules when constructing the diagram: 1. The circles which represent the elements are drawn as far to the left as possible. 2. None of the arrows which shows the precedence of the elements should be vertical. a b c d e f g h i 0.12 mins 0.30 mins 0.36 mins 0.25 mins 0.05 mins 0.17 mins 0.10 mins 0.08 mins 0.25 mins
- 17. Allocating activities to the stages The general approach is to allocate elements from the precedence ( priority) diagram to the first stage, starting from the left, until the work allocated to the stage is as close to, but less than, the cycle time. When the stage is full of work without exceeding the cycle time, move to the next stage. Two rules help to decide which activities to allocate to a stage: 1. Choose the largest that will fit into the time remaining at the stage 2. Choose the element with the most ‘followers’.
- 18. Layout is important to be well designed from every aspect Layout design should be made with a high managerial efficient skill Layout can reduce the costs and damages
- 19. Inherent safety - all processes which might constitute a danger to either staff or customers should not be accessible to the unauthorised Length of flow - the flow of materials, information or customers should be appropriate for the operation. This usually means minimising the distance travelled by transformed resources.
- 20. Clarity of flow - all flow of materials and customers should be well signposted, clear and evident to customers and staff alike Staff conditions - staff should be located away from noisy or unpleasant parts of the operation. Management coordination - Supervision and communication should be assisted by the location of staff and communication devices
- 21. Accessibility - all machines and facilities should be accessible for proper cleaning and maintenance. Use of space - all layouts should use space appropriately; this usually means minimising the space used.
- 22. Thank you for your attention