1. Layout Strategy

12. Emergency Room Layout Surgery Radiology E.R. beds Pharmacy Billing/exit E.R.Triage room E.R. Admissions Patient B - erratic pacemaker Patient A - broken leg Hallway

14. Cost of Process-Oriented Layout

15. Interdepartmental Flow of Parts 1 2 3 4 5 6 1 2 3 4 5 6 50 100 0 0 20 30 50 10 0 20 0 100 50 0 0

16. Number of Weekly Loads 100 50 30 10 20 50 20 100 50 1 2 3 4 5 6

17. Possible Layout 1 Assembly Department (1) Painting Department (2) Machine Shop Department (3) Receiving Department (4) Shipping Department (5) Testing Department (6) Room 1 Room 2 Room 3 Room 4 Room 5 Room 6 60’ 40’

18. Number of Weekly Loads 100 50 30 10 20 50 20 100 50 1 2 3 4 5 6

19. Possible Layout 2 Painting Department (2) Assembly Department (1) Machine Shop Department (3) Receiving Department (4) Shipping Department (5) Testing Department (6) Room 1 Room 2 Room 3 Room 4 Room 5 Room 6 60’ 40’

21. Out-Patient Hospital Example CRAFT 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 Total cost: 20,100 Est. Cost Reduction .00 Iteration 0 Total cost: 14,390 Est. Cost Reduction 70. Iteration 3 Legend: A = xray/MRI rooms B = laboratories C = admissions D = exam rooms E = operating rooms F = recovery rooms D E E E E E D D D B B B A A A A F F F F F D D D C C D D D D D B A A A A F F F A A A F F E B B B D D D D A A A A A E E D C C E E D D D B D D D D

23. Improving Layouts by Moving to the Work Cell Concept

25. Work Cell Advantages Inventory Floor space Direct labor costs Equipment utilization Employee participation Quality

26. Work Cell Floor Plan Office Tool Room Work Cell Saws Drills

28. Work Cells, etc. Work Cell A temporary assembly-line-oriented arrangement of machines and personnel in what is ordinarily a process-oriented facility Example: job shop with rearranged machinery and personnel to produce 30 unique control panels Focused Work Center A permanent assembly-line-oriented arrangement of machines and personnel in what is ordinarily a process-oriented 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

31. Office Layout Floor Plan Accounting Manager Brand X Finance Fin. Acct.

34. Retail/Service Layout – Grid Design Office Carts Check- out Grocery Store Meat Bread Milk Produce Frozen Foods

35. Retail/Service Layout - Free-Flow Design Feature Display Table Trans. Counter Apparel Store

39. Warehouse Layout Floor Plan Zones Conveyor Truck Order Picker

48. An Assembly Line Layout

49. Assembly Line Types

50. Repetitive Layout 1 3 2 4 5 Work Office Belt Conveyor Work Station Note: 5 tasks or operations; 3 work stations Work Station Station

55. Assembly Line Balancing Equations Cycle time = Production time available Demand per day Minimum number of work stations  Task times Cycle time Efficiency = =  Task times * (Cycle time) (Actual number of work stations)

57. Line Balancing Example #1 30 E, H I 70 D, G H 100 F G 50 - F 30 B, D E 40 C D 30 - C 80 A B 60 - A Seconds Predecessor Task

59. Line Balancing Example #2 30 E, H I 70 D, G H 100 F G 50 - F 30 B, D E 40 C D 30 - C 80 A B 60 - A Seconds Predecessor Task