Product-Oriented Floor Plan Analysis:

 10,000





 12,000



 20,000 10,000

.000



10,000

13,000

10,000

12,000

Next, we change the shape of the parts to suit the system in the workshop until the requirements are met.

5,000

 Load - distance analysis.

Operation chain analysis and block diagram analysis do not select the optimal layout, they only give us one good layout. In case there are many layout options to choose from, the above method is not effective, then people use load-distance analysis.

This is a very useful method in comparing several satisfactory layouts, to select an optimal layout based on the lowest movement of raw materials or products in a period.

Example 5.3: Suppose the production layout department is hesitating between the two best layout options below. Not knowing which option is better, they perform the method of calculating the load - distance of the two layout options based on knowing the average production quantity of each type of product in the period (month) and the transportation distance between the production departments as given below.

 The layout department knows two good layout options:

Layout A
8	4	10	2	5
3	7	1	9	6

Maybe you are interested!

Layout B
7	1	9	6	3
4	10	2	5	8

 Know the transportation distance between production departments.

Movement

between parts

About	way	(m)	Movement between parts	About	way	(m)
Layout A	Layout B			Layout A	Arrange		B
1-5	30	30		3-9	30	20
1-7	10	10		4-5	30	30
1-9	10	10		4-7	10	10
1-10	10	10		4-10	10	10
2-5	10	10		5-6	10	10
2-6	20	20		6-9	10	10
2-10	10	10		7-8	20	50
3-6	40	10		8-10	20	30

 Know the manufacturing method and average quantity of each type of product produced during the period.

Product

parts chain

Number of products manufactured

Product

parts chain

Number of products manufactured

product

manufacture

in the month

product

manufacture

in the month

1-5-4-10

2-6-3-9

2-10-1-9

1,000

2,000

3,000

1-7-8-10

2-5-6-9

1-7-4-10

1,000

2,000

4,000

Solution:

 First, calculate the shipping distance for each product from the start of the

until product completion for each layout.

Product

parts chain

manufacture

Distance/product rating (dm)

Layout A

Layout B

ABCDE

1-5-4-10

2-6-3-9

2-10-1-9

1-7-8-10

2-5-6-9

1-7-4-10

30+30+10=70

20+40+30=90

10+10+10=30

10+20+20=50

10+10+10=30

30+30+10=70

20+10+20=50

10+10+10=30

10+50+30=90

10+10+10=30

 Next, we take the transportation distance and multiply it by the average monthly production volume to know the load distance of each product, then calculate the total load - distance of each layout. The layout with the smallest total load - distance is the better layout.

Product

Number of products manufactured in the month	Distance/sp (dm)		Distance/month (dm)
Number of products manufactured in the month	Layout A	Layout B	Layout A	Layout B
ABCDE F	1,000 2,000 3,000 1,000 2,000 4,000	70 90 30 50 30 30	70 50 30 90 30 30	70,000 180,000 90,000 50,000 60,000 120,000	70,000 100,000 90,000 90,000 60,000 120,000
Total				570,000	530,000

Through the calculation table, we see that layout B gives good results, with the total distance of product movement during the month through the machinery and equipment being the smallest.

In recent years, many computer programs have been developed to develop and analyze process-oriented layouts. Some programs use proximity ratios to maximize the total relationship for different parts to fit on the factory floor. Others are written to minimize the transportation cost over a period of time.

In general, these programs help us save time and effort in solving large and complex problems. However, the results are only initial layouts, sometimes we need to edit, check the logic as well as the equipment must be adjusted to fit by hand.

2.2.2 Product-oriented floor plan analysis:

Process analysis is the central objective of product-oriented layout. Factors such as product design and market demand for the product ultimately determine the technological process and production capacity. In addition, the number of workers, manual or automatic machines and other tools needed for production are also determined.

Production line balancing: Is to analyze the production line, dividing the work performed into each production area, each production area is responsible for a task.

similar tasks, grouping these homogeneous production areas into production centers. The goal of production line analysis is to determine how many production areas are required and what tasks are assigned to each area. Thus, the number of workers and machinery is minimized while still ensuring the required volume of products produced.

Now the production area has completed its assignment. Finish and start a new production area.

Tea

Level

Is this usage 100%?

Yes

Is all the work assigned?

Rain

Stop

End of assignment for old production area, start of new production area.

 Continue adding work by assigning the next unassigned work in the priority chart to this production area, calculating the utilization for the production area.

In production line balancing, work is assigned to production areas so that there is as little idle time as possible. This means that work at each production area is as close to the cycle time as possible but does not exceed that time.

Starting from the left side of the priority diagram

 Start a new production area by assigning the next job in the priority chart to the new production area, calculating the utilization for this production area.

Figure 5.3: Implementation process of incremental usage method

Steps to balance the chain:

 Identify the tasks that must be performed to complete a particular product.

 Determine the order of work to be performed.

 Draw a work sequence diagram (circles represent work, arrows show the order of work).

 Estimate work time.

 Cycle time calculation ( T ck ).

T  T sx  Production time in period

ck d

The production process in the period

 Calculate the minimum number of production areas.

S kv

T tg

T ck

Time to complete the demolition

Time of use

 Efficiency of use (machinery, equipment or labor)

Effective 

Output power (uS kvs xmin ) x 100 Output power (S kvs xthèûtăc )

Researchers often use linear methods or various mathematical models to solve the problem of balancing a production line. However, these are not useful when solving a large problem. Other methods based on simple principles are used to find very good but not optimal solutions. These are the incremental utility method and the longest operation time method.

 Incremental usage method:

Figure 5.3 shows the sequence for performing work assignment using the incremental usage method represented by the general block diagram as on the previous page.

This method simply assigns additional tasks to production areas, in a prescribed order of work, until utilization reaches 100% or begins to decline. This process is repeated until all work is assigned to production areas.

Example 5.4: A pesticide production workshop determines the market demand to be 4,160 bottles of medicine/day. Knowing the time to prepare machinery, equipment, raw materials,

materials, production tools,... takes an average of 64 minutes/day. To complete a bottle of medicine, the factory needs to go through 15 production stages as shown on the following page.

Job

Work completed

before

Job completion time (seconds)

ABCDEFGHIJKLMN



A,B

 C,DE

 GF,H



I,J



LK,MN

Add

152

Requirements:  Develop a process for processing and packaging plant protection drugs.

 Calculate cycle time and minimum number of production areas

 Balancing the production line using the incremental utilization method

 Calculate the efficiency of using machinery and equipment.

Solution:

First, we base on the sequence of performing the tasks to complete the processing stages, we build the diagram as follows.

 Cycle time (production rate): is the time interval between the previous product and the next product being completed.

T T sx   8x60  64  x60 6 pcs/bottle

ck d

4,160

 Calculate the minimum number of production areas (minimum number of workers or machinery and equipment needed for production).

S kvsx

T tg .d

Production

T tg

T ck

152 25.3 kvsx

 Balancing the production line using the incremental utilization method.

First, we assign tasks to each production center (production station), which must strictly follow the order of the tasks (C must come after A, after B; E must come after C, after D; ...). The tasks are combined in order until the utilization of the production center is 100%, or when we observe a decrease in it compared to the previous assignment. At this point, we open a new production center and start the sequence again.

Production station (1)

Work (2)	Minutes/machine (3)	Number of working KVSX (4)=[(3)/time cycle time]	Production area number necessary practice (5)	KVSX utilization rate (%) [(4)/(5)]x100
1	A	10	1.67	2	83.3
1	A,B	10+15=25	4.16	5	83.3
1	A,B,C	10+15+10=35	5.83	6	97.2
1	A,B,C,D	10+15+10+6=41	6.83	7	97.6
1	A,B,C,D,E	10+15+10+6+8=49	8.17	9	90.7
2	E	8	1.33	2	66.7
2	E,F	8+6=14	2.33	3	77.8
2	E,F,G	8+6+10=24	4.00	4	100.0
3	H	5	0.83	1	83.3
3	H,I	5+7=12	2.00	2	100.0
4	J	8	1.33	2	66.7
4	J,K	8+12=20	3.33	4	83.3
4	J,K,L	8+12+10=30	5.00	5	100.0
5	M	15	2.50	3	83.3
5	M,N	15+20=35	5.83	6	97.2
5	M,N,O	15+20+10=45	7.50	8	93.8
				26

Summary of work assignment to production area on the line as follows:

Production station

1	2	3	4	5
Work in the production station	A,B,C,D	E,F,G	H,I	J,K,L		M,N,O
Actual number of production areas	7	4	2	5	8	Total: 26

Thus, to complete the production volume of 4,160 bottles of medicine in 1 day, we need 5 work stations, depending on each station, the number of production areas (number of workers or machinery and equipment) is needed.

 T B i c u d e r e d e r e s e d u c t i o n g machinery and equipment ( M s d ) J

M 

S kv mim

25.3 x100 97.3%

area

 Longest working time method.

In this method, jobs are added to a production area in the following order. If there is a choice between two or more jobs, the job with the longest working time is selected and assigned first. This is effective for quickly assigning difficult jobs to production areas.

Example 5.5: Continuing with Example 5.4 , suppose the unit redefines the production demand of this workshop to be 832 bottles of medicine/day (instead of 4,160 bottles). Balance the production line in this case.

Solution:

 First, we calculate the cycle time.

T T sx   8x60  64  x6030 pcs/bottle

ck d

832

 Minimum number of production areas.

S kv

T tg

T ck

152 5.07 square meters

 Assign work to production areas.

Area

manufacture

The works job	Working time new	Total time perform	Time left over Production area
(1)	(2)	(3)	(4)	[30''-(4)]
1	A	10	10	20
1	A,B	15	25	5
2	C	10	10	20
2	CD	6	16	14
2	C,D,E	8	24	6
2	C,D,E,F	6	30	0
3	G	10	10	20
3	G,H	5	15	15
3	TAKE NOTE	7	22	8
3	G,H,I,J	8	30	0
4	K	12	12	18
4	K,L	10	22	8
5	M	15	15	15
6	N	20	20	10
6	N,O	10	30	0

Summarize the assignment of jobs to production areas on the production line.

Production area

1	2	3	4	5	6
Work to be done	A,B	C,D,E,F	G,H,I,J	K,L	M	N,O
Time left (seconds)	5	0	0	8	15	0

 Calculate the usage of machinery, equipment or labor.

M S kvmin x100 5.07 x100 84.5%

kctt

 The conditions for using the longest working time method are:

T ck

T cv(max) ,

That is, the cycle time must be greater than or equal to the maximum time required to perform the work in the product manufacturing workflow. According to the above problem, T ck = 30 seconds, the work that consumes the maximum time is work N which takes 20 seconds.

III. SERVICE LAYOUT:

3.1 Types of service floor layout:

Service premises layout depends on the nature of the service and the way businesses coordinate and transport their services: airlines, banks, retailers, hospitals, restaurants, insurance, transportation, entertainment, telecommunications.... In addition, service premises layout also depends on the specialized machinery for each type of service.

The difference between service businesses and manufacturing businesses is the encounter between customers and the services they provide. This encounter may be intense because the customer is actually part of the production process, as in a hospital, where the service is actually built on the customer. Or it may be less intense in a retail store, where customers select, pay for, and take away physical goods. But in either case, the service floor plan has a profound effect.

The general principle is to arrange so that customers can easily enter, exit and move between parts of the premises. In addition, it is also necessary to allocate appropriate areas for corridors, waiting rooms...

There are two poles in the arrangement of service premises. For example, in multi-banks, one pole is public services, where machines and equipment must be arranged around customers, making them most convenient (waiting room, parking lot, cashier window...). The other pole is internal services with service machines arranged mainly according to financial transaction work (updating accounts, making reports...).

Most layouts revolve around these two poles. For example , restaurants are designed to emphasize customer acceptance and personal convenience rather than food preparation and cooking.

3.2 Analysis of service floor layout:

In most types of services, people try to arrange so that the total distance of the customer's movement is as short as possible, in addition to arranging convenient service machines. In addition, it is necessary to pay attention to the arrangement of waiting rooms and queues so that they are comfortable.

For many services, the reasons why a department is located next to another department are complex. In this case, people often use proximity ratios to reflect the desire for a department to be next to another department. Then, using trial and error, chain of operations analysis or block diagram analysis, use proximity ratios to build a good floor plan.

Example 5.6: Suppose a store sells food products and plans to arrange 6 groups of products (A, B, C, D, E, F) according to the degree of close relationship between the groups of products as follows:

Intimacy ratio

Meaning

Intimacy ratio

Meaning

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