Layout And Flow

Question 1

What is layout?

Answer 1

1. How its transforming resources are positioned relative to each other
2. how it’s various tasks are allocated to these transforming resources
   = the flow of transformed resources

Question 2

What is fixed position layout?

Answer 2

• transforms resources do not move between transforming resources
• the recipient of the processing is stationary
  Ex; open heart surgery, construction site, high class service restaurant

Question 3

What is functional layout?

Answer 3

• similar resources or processes are located together
• as products, information or customers flow through the operations, they will take a route according to their needs
  Ex; IKEA, hospital, super market

Question 4

What is cell layout?

Answer 4

• when transformed resources entering the operation are pre selected to move to one part of the operation in which all transforming resources are located
• lunch section, maternity unit at a hospital and some computer component manufacturer

Question 5

What is product layout?

Answer 5

• locating the transforming resources entirely for the convenience of the transformed resources
• sequence of activities that are required matches the sequence in which processes have been located
• cafeteria self service

Question 6

What are mixed layouts?

Answer 6

• combined elements of some or all of the basic layout types or use the lure basic layout types in different parts of the operation

Question 7

What are the advantages and disadvantages with fixed position layout?

Answer 7

Advantages:

• very high product and mix flexibility
• product and customer are not moved
• high variety of tasks for staff

Disadvantages:

• very high unit costs
• scheduling spaces and activities can be difficult

Question 8

What are the advantages and disadvantages with process layout?

Answer 8

Advantages:

• high product and mix flexibility
• relatively robust in case of disruptions
• easy to supervise

Disadvantages:

• low utilization
• can have very high WIP
• complex flow

Question 9

What are the advantages and disadvantages with cell layout?

Answer 9

Advantages:

• low unit costs for high volume
• opportunities for specialization of equipment

Disadvantages:

• can have low mix flexibility
• not very robust to disruption
• work can be very repetitive

Question 10

What are the steps in choosing layout?

Answer 10

Decision 1 (volume and variety): process type: 
Ex; project, jobbing, batch, mass, continuous processes or professional, service shops and mass customization 

Decision 2 (strategic performance objectives): basic layout type:
Ex; fixed position, process, cell, and product layout 

Decision 3: detailed design of layout: the physical position of all transforming resources (flow of the operations ransomed resources)

Question 11

What different design techniques are needed for the layout types?

Answer 11

1. Fixed position: resource location analysis
2. Functional: flow charts and relationship charts (need information on area required by each work centre, load and direction of flow between each work centre, distance between work centers)
3. Cell: flow analysis (need information on extent and nature of the cells, which resources to allocate to each cell)
4. Product/line: assembly line balancing techniques (Info on cycle time, number of stages, task time variation, work time allocation, balancing techniques)

Question 12

What are the advantages of long thin arrangements?

Answer 12

1. Controlled flow of materials or customers
2. Simple material handling
3. Lower capital requirements (every stage does not need the same expensive equipment)
4. More efficient operation: higher proportion of productive work, due to lack of In Between tasks

Question 13

What are the advantages of the short fat arrangement?

Answer 13

1. Higher mix flexibility: each stage of line can specialize in different types of the range of products or services
2. Higher volume flexibility: does not need rebalancing like thin lines, can be closed down or started up as required
3. Higher robustness: if one breaks down the others are not affected by it
4. Less monotonous work: less repeat of same task