Layout Planning Models

Layout Planning Models
Chapter VIII Layout Planning Models BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

PERANCANGAN TATA LETAK FASILITAS
Layout till This Point Coordinating facilities planning with other organizational units Facility requirements a product design, process design, schedule design Activity relationships and space requirements Personnel requirements BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Basic Layout Types Fixed product layouts the workstations are brought to the material Product layouts based on the processing sequence Group layout; Product family layout high degree of intradepartmental flow Process layout high degree of interdepartmental flow BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Basic Layout Types BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Basic Layout Types Product Layout Layout that uses standardized processing operations to achieve smooth, rapid, high-volume flow Linear arrangement of workstations to produce a specific product Process Layout Layout that can handle varied processing requirements Centers/machines grouped by process they perform Fixed Position Layout Layout in which the product or project remains stationary; workers, materials, and equipment are moved as needed Used in projects where the product cannot be moved BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Hybrid Layouts Cellular layouts group machines into machining cells Flexible manufacturing systems automated machining & material handling systems Mixed-model assembly lines produce variety of models on one line BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Layout Formats Group Technology Layout Just-in-Time Layouts Assembly-lines or Group Technology formats Fixed Position Layout e.g. Shipbuilding BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Manufacturing Process Layout
Milling Department Lathe Department Drilling Department L L M M D D D D M M D D D D L L L L G G G P G G G P L L Grinding Department Painting Department L L A A A Receiving and Shipping Assembly BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Service Process Layout
Women’s Lingerie Shoes House- wares Dresses Cosmetics & Jewelry Children’s Department Sportswear Entry & Seasonal Men’s BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Product Layout IN OUT BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

A U-Shaped Production Line
1 2 3 4 5 6 7 8 9 10 IN OUT Workers BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Cellular Layout Cellular Manufacturing Layout in which machines are grouped into a cell that can process items that have similar processing requirements Group Technology The grouping into part families of items with similar design or manufacturing characteristics BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Group Technology One Worker, Multiple Machines Machine 2 Machine 3 Machine 1 Materials in Finished goods out Machine 4 Machine 5 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Group Technology Parts Families BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Receiving and shipping
Group Technology Lathing Milling Drilling D D L L M M D D L L M M Grinding L L M M G G Assembly L L G G A A Receiving and shipping A A G G BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Group Technology Lathing Milling Drilling D D L L M M D D L L M M Grinding L L M M G G Assembly L L G G A A Receiving and shipping A A G G (a) Jumbled flows in a job shop without GT cells BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Group Technology Drilling D Grinding G Milling M Assembly A Lathing Receiving and shipping L (a) Jumbled flows in a job shop without GT cells BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Group Technology Cell 3 L M G Cell 1 Cell 2 Assembly area A D Shipping Receiving (b) Line flows in a job shop with three GT cells BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Layout Procedures Construction type develop a new layout “from scratch” Improvement type generate layout alternatives based on an existing layout BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Apple’s Plant Layout Procedure
Procure the basic data Analyze the basic data Design the procedure process Plan the material flow pattern Consider the general material handling plan Calculate equipment requirements Plan individual workstations Select specific material handling equipment Coordinate groups of related operations Design activity interrelationships BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Apple’s Plant Layout Procedure
Determine storage requirements Plan service and auxiliary activities Determine space requirements Allocate activities to total space Consider building types Construct master layout Evaluate, adjust, and check the layout with the appropriate persons Obtain approvals Install the layout Follow up on implementation of the layout BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Reed’s Plant Layout Procedure
Analyze the product or products to be produced Determine the process required to manufacture the product Prepare layout planning charts Determine workstations Analyze storage area requirements Establish minimum aisle widths Establish office requirements Consider personnel facilities and services Survey plant services Provide for future expansion BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Layout Planning Chart Flow process, including operations, transportation, storage, and inspections Standard times for each operation Machine selection and balance Manpower selection and balance Material handling requirements BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Muther’s Systematic Layout Planning (SLP) Procedure BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Relationship Diagram BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Space Relationship Diagram

Alternative Block Layout

Algorithmic Approaches
The relative placement of departments on the basis of their “closeness ratings” or “material flow intensities” is one that can be reduced to an algorithmic process. Algorithm classification Type of input data qualitative “flow” data (relationship chart) quantitative flow matrix (from-to chart); numerical values of closing rating ~ mostly used both qualitative and quantitative (BLOCPLAN, used one at a time) BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Algorithm Classification
Objective function “distance-based”: Minimizing the sum of flows times distances (from-to chart) – QAP: “adjacency-based”: maximizing an adjacency score (relationship chart) BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Normalized adjacency score (efficiency rating) Normalized adjacency score for an X relationship BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Layout representation discrete (grid size<->computational burden) continuous (rectangular building and department shapes) department cannot be split Any grid assigned to a department must be “reachable” form any other such grid enclosed void (atrium) BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Layout improvement start with an initial layout improve through incremental changes Layout construction develop a layout from scratch given dimension (basic assumption in the book) “green field”: site plan BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Relationship Diagramming for New Layouts
Step 1. Select the first department to enter the layout - select the department with the greatest # of “A” Step 2. Select the second department to enter the layout – have an “A” with the 1st department Step 3. Select the third department to enter the layout - AA, AE, AI, A*, EE, EI, E*, II, I* Step 4. Determine the fourth department to enter the layout - AAA, AAE, AAI, AA*, AEE, AEI Step n. Department n is placed according to the rules described in Steps 3 and 4 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Pairwise Exchange Method for Layout Improvement
Minimize the total cost of transporting materials among all departments in a facility Rectilinear distance, from centroid to centroid BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Example Four departments with equal size Material flow matrix Distance matrix BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Pairwise Exchange Method
Remark does not guarantee to yield the optimal solution: local optimality may cycle back to one alternative symmetric layout may occur can be accomplished only if the department pair considered are of equal size or if they share a common border BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Graph Based Construction Methods ( GBCM )

Perancangan Tata Letak Dengan Metode Grafik
Merupakan metode perancangan layout dengan menggunakan adjacency graph (grafik kedekatan)untuk memperoleh bobot terbesar Berdasarkan from-to-chart (keterkaitan aktivitas) Node :menyatakan departemen/aktivitas Arc : menghubungkan departemen Angka : menyatakan tingkat kedekatan (closeness) Bobot terbesar = jumlah nilai busur-busur BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Contoh metode grafik Dep 1 2 3 4 5 60 100 50 40 65 30 80 10 Diketahui From-to-chart BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Alternatif block layout
4 3 5 2 1 80 60 65 40 100 Alternatif block layout 3 4 2 5 1 80 65 10 50 60 (b) (a) BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Bobot layout (a) Bobot layout (b) Busur Bobot 1 - 2 1 - 4 1 - 5 2 - 4 3 - 4 3 - 5 4 - 5 60 50 65 80 10 1 - 3 2 - 3 100 40 265 terpilih 345 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Grafik kedekatan terakhir

Langkah-langkah metode grafik
Pilih pasangan departemen yang mempunyai bobot terbesar, dari contoh (block layout b) terpilih dept 1 dan 3. Hubungkan node 1 dan 3 1 3 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Langkah 2 Pilih departemen ke 3 yang akan masuk dalam grafik , dengan menjumlah bobot departemen yang belum terpilih dengan departemen a dan 3 Pilih pasangan yang mempunyai nilai terbesar BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

1 - 3 2 4 5 60+40=100 50+80 =130 0 + 0 = 0 - Terpilih 1 3 4 50 100 80 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Langkah 3 Memilih departemen yang belum terpilih dalam grafik Jumlahkan bobot departemen yang belum terpilih dengan dept 1,3 dan 4 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

1 – 3 - 4 2 5 =160 = 10 Terpilih - 1 3 4 50 100 80 2 65 40 60 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Langkah 4 Karena tinggal departemen 5 yang belum masuk grafik, maka ditentukan bidang yang akan menjadi tempat departemen 5 Bidang segitiga yang terbentuk: 1 – 2 – 3 1 – 2 – 4 1 – 3 – 4 2 – 3 – 4 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

1-2-3 1-2-4 1-3-4 2-3-4 5 0+30+0=30 = 40 terpilih 0+0+10= 10 = 40 1 3 4 50 100 80 2 65 40 60 5 10 30 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Bobot layout (b) Busur Bobot 1 - 2 1 – 3 1 – 4 1 - 5 2 - 3 2 - 4 2 - 5 3 – 4 4 - 5 60 100 50 40 65 30 80 10 435 Langkah 5 Menyusun ulang block layout berdasarkan grafik kedekatan BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Contoh BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

penyelesaian Bobot terbesar adalah dept A dan B A B BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Perhitungan bobot dept A dan B dengan dept yang lain BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

B BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

A – B - C D E F G 10+0+1=11 6+6+0 =12 6+0+2 = 8 0+9+7 = 16 - Terpilih BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

B C 7 9 4 G 6 1 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

A-B-C A-B-G A-C-G B-C-G D E F 10+0+1=11 6+6+0=12 6+0+2=8 10+0+6= 16 6+0+0=6 10+1+6=17 6+2+0=8 0+1+6= 7 0+2+0=2 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

B C 8 13 5 G 7 9 D 1 10 6 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Computer-Aided Layout Techniques

Evaluation and Interchange in CRAFT
Interchanges are only possible if Depts. are the same size; or Adjacent (a necessary but not sufficient condition) Estimate the potential saving for an interchange For evaluation only the centroids are swapped (error?) Select the best among all possible interchanges Actually perform the interchange Path-dependent heuristic (locally optimal) Try different initial solutions or exchange options the error in estimated cost may go either direction BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Dummy Departments May be used to Fill building irregularities Represent obstacles or unusable areas in the facility (fixed location) Represent extra space in the facility Aid in evaluating aisle locations in the final layout BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Example 6.1 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

The Impact of Change Plant layout situations Changes in the design of existing product, the introduction of new products Changes in the processing sequence for existing products Changes in production quantities and schedules - the need for capacity changes Changes in production strategies BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Flexibility Can be achieved by utilizing modular office equipment, workstations, and material handling equipment installing general purpose production equipment utilizing a grid-based utility and services system using modular construction BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Flexible Layout BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

Layout Planning Models

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