Hybrid Layout 242x60

Hybrid Layouts

Hybrid Layouts  Hybrid layouts modify and/or combine some aspects of product and process layouts.  Examples:  Group technology & manufacturing cells – used in Just-inTime manufacturing  Grocery stores

 Three hybrid layouts:  Cellular layouts (presented by Maria Roig)  Flexible manufacturing systems Barnes)

(presented by Brian

Hybrid Layouts: Cellular layouts  Cellular layouts group dissimilar machines into work centers (called cells) that process families of parts with similar shapes or requirements.  Combines the flexibility of a process layout with the efficiency of a product layout.

Deg Hybrid Layouts  One of the most popular hybrid layouts uses Group Technology (GT) and a cellular layout  GT has the advantage of bringing the efficiencies of a product layout to a process layout environment

Process Flows before the Use of GT Cells

Process Flows after the Use of GT Cells

Hybrid Layouts: Cellular layouts Characteristics of the process:  Cells are arranged in relation to each other so that material movement is minimized.  Large machines that cannot be split among cells are located near to the cells that use them (point of use)  The layout of machines within each cell resembles a small assembly line.  Adjustments can be used to arrange the machines within the cell.  Computer programs can be used to locate cells.

Hybrid Layouts: Cellular layouts  Example:  Machines are grouped by function into four distinct departments.  Component parts manufactured in the process layout section of the factory are later assembled into a finished product on the assembly line.  The parts follow different flow paths through the shop.  Three representative routings, for parts A, B, and C.  Workers are skilled within a single department and can operate more than one machine at a time.

Hybrid Layouts: Cellular layouts

Original Process Layouts

 Notice:  The distance that each part must travel before completion  the irregularity of the part routings  Amount of “paperwork” needed to direct the flow of each individual part and to confirm that the right operation has been performed

Hybrid Layouts: Cellular layouts  In its current form, there is no apparent pattern to the routings.  PRODUCT FLOW ANALYSIS (PFA) reorders part routing matrices to identify families of parts with similar processing requirements.

Part Routing Matrix

If we reorder the matrix listing which parts have four machines in common, three...

Hybrid Layouts: Cellular layouts

Revised Layout with Three Cells Part Routing Matrix Reordered to Highlight Cells

Hybrid Layouts: Cellular layouts Advantages:  Reduced material handling and transit time  Reduced setup time  Reduced work-in-process inventory  Better use of human resources  multifunctional workers

 Easier to control  Easier to automate

Disadvantages:  Inadequate part families  Poorly balanced cells  Expanded training and scheduling of workers  Increased capital investment

Types of Layout - Example Manufacturing Cell

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Types of Layout - Example Manufacturing Cell

An example of a hybrid layout

Types of Layout - Example Automated Manufacturing Cell

An example of a hybrid layout

Types of Layout - Example Flexible Manufacturing Cell

An example of a hybrid layout

Types of Layout - Example Manufacturing Cell

An example of a hybrid layout

Types of Layout - Example Automated Manufacturing Cell

An example of a hybrid layout

Types of Layout - Example Flexible Manufacturing Cell

An example of a hybrid layout

Types of Layout

Work Cell, Focused Work Center, and Focused Factory Work Cell

Assembly or Production line-oriented arrangement of machines and personnel in what is ordinarily a processoriented facility. Cells can be formed on a temporary basis. Example: job shop with rearranged machinery and personnel to produce 30 unique control s

Focused Work Center

A permanent assembly-line-oriented arrangement of machines and personnel in what is ordinarily a processoriented facility Example: manufacturing of pipe brackets at a shipyard

Focused Factory A permanent facility to produce a product or component in a product-oriented facility Example: a plant to produce window mechanisms for automobiles

Principles of a Good Layout Manufacturing         

Straight-line Flow Pattern when possible Backtracking kept to a Minimum Predictable Production Time Little In-process materials storage Open Floor plans so everyone can see what is going on Bottlenecks under control Workstations close together Minimum of material handling Easy adjustment to changing conditions

New Trends in Manufacturing Layouts  Designed for quality and flexibility  Ability to quickly shift to different product models or to different production rates  Cellular layout within larger process layouts  Automated material handling  U-shaped production lines use to better accomplish flow control  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

Wrap-up

Attaining Lean Production         

Focus on inventory reduction Build systems that help employees Reduce space requirements Develop close relationships with suppliers Educate suppliers Eliminate all but value-added activities Develop the workforce Make jobs more challenging Set sights on perfection!