SCHOOL OF MECHANICAL AND

INDUSTRIAL ENGINEERING

PLANTS LAYOUT DESIGN

4. Systematic Layout Planning
(SLP)

Yared Lemma
[Link]@[Link]

A.Y. 2016-2017

4-1
 OUTLINE
 Introduction
 Information Gathering
 Flow and Activity Analysis
 Relationship Diagram
 Space Requirements and Availability
 Designing the Layout

4-2
SYSTEMATIC LAYOUT PLANNING (SLP)
 The most popular approach used in
designing plant layout.

 The procedure has been applied to

production, transportation, storage,
supporting services, and office activities,
among others.
4-3
 CONT’D
 Information gathering
 Flow analysis + Activity analysis
 Relationship diagram
 Space consideration + Relationship diagram
 Space relationship diagram
 Modifying consideration + Practical limitation
 A number of alternative layouts are designed
and evaluated
4-4
4-5
 OUTLINE
 Introduction
 Information Gathering
 Flow and Activity Analysis
 Relationship Diagram
 Space Requirements and Availability
 Designing the Layout

4-6
 INFORMATION GATHERING
 Information is required pertaining to the
product, process, and schedule.

 Data regarding product design decisions

can affect the layout significantly.

 The product design decisions can directly

or indirectly affect the layout. 4-7
 CONT’D
 Basic product design data can be obtained form
photographs of the product, exploded drawings,
engineering drawings of individual parts, parts
lists, bill of materials and assembly charts.

4-8
CONT’D

4-9
CONT’D

4 - 10
 CONT’D
Company open-close valve Prepared by Jhon Mc Francies
company
Product gate valve Date October 31, 19xx
Part Part Drawing No. Unit Materials Size Make Buy
No. Name No.
0105 Nut 2005 1 Brass Buy
0204 Washer 2003 1 Aluminum 0.8”odx0.22”idx0.01” thick Buy
0303 Handle 1010 1 Zinc, die casting 2.0”x0.6” Make
0501 Cap 1008 1 Brass, hex bar stock 0.75”x0.40” Make
0601 Packing 2001 1 Rubber 0.58”odx0.25”idx0.25” Buy
0702 Ferrule 1007 1 Brass, tube 0.4”x0.2” Make
0802 Stem 1000 1 Brass, rod 3.0”x0.375” Make
0901 Bushing 1004 1 Bronze 1.1”x1.5” Make
1001 Gasket 2007 1 Rubber 1.4”odx1.17”idx0.025” Buy
1101 Gate 1006 1 Bronze 1.2”x0.96”x0.55” Make
1305 Body 1002 1 Bronze 1.4”x1.9”x2.125” Make
1402 Box 2011 1 Cardboard 2.125”x2.125”x4.25” Buy
1503 Staple 2012 4 Aluminum Buy
1603 Label 2013 1 Adhesive backed paper 2.0”x1.0” Buy 4 - 11
Company open-close valve company Prepared by Jhon Mc
Francies

Product gate valve Date October 31, 19xx

Level Part No. Part Name Drawing No. No. Unit Make Buy Comments
0 0010 Pipe valve 0010 1 Make
1 0100 Bottom assembly 0020 1 Make
2 0200 Top assembly 0030 1 Make
4 0105 Nut 2005 1 Buy
3 0204 Washer 2003 1 Buy
2 0303 Handle 1010 1 Make
3 0403 Paint - 0.010 oz. Buy
4 0501 Cap 1008 1 Make
5 0601 Packing 2001 1 Buy
3 0702 Ferrule 1007 1 Make
1 0802 Stem 1000 1 Make
2 0901 Bushing 1004 1 Make
3 1001 Gasket 2007 1 Buy
2 1101 Gate 1006 1 Make
2 1201 Grease - 0.001 oz. Buy
3 1305 Body 1002 1 Make
6 1402 Box 2011 1 Buy
4 - 12
CONT’D

4 - 13
 CONT’D
♦ The assembly chart is an analog model of the
operations and inspections required in
assembling a product.

♦ Assembly chart shows graphically which parts

must go into(or be assembled to) other parts.

♦ The assembly chart is the basis for the layout of

the assembly department or assembly lines.
4 - 14
 CONT’D
♦ Process design decisions determine whether a
part will be purchased or produced, how the
production of parts will be achieved, what
equipment will be used, and how long it will take
to perform the operation.

♦ Such information is typically summarized on an

operation sheet or route sheet.
4 - 15
 CONT’D
Company open-close valve company Prepared by Jhon Mc Francies _ _

Product gate valve Date October 31, 19xx _

Part name Bushing Part Number 0901 _

Material Bronze casting Production Quantity 1500 _

Op. No. Op. Description Machine type Tooling an d supplies Setup time (hrs) Op. time
05 Cast: using green sand mold with 50 bushings per Bench mold T- shaped dry sand core for 0.50 2.00
mold; pour, cool, cut off gates and risers Band saw each bushing

06 Clean: grind, as needed to remove flashing, and Bench or pedestal grinder; A-24-M-8-V type grinding 0.25 0.75
tumble tabling barrel wheel

07 Drill hole:3/16”x1/2” Turret lathe 3/16” drill 0.50 2.5o

08 Bore hole: 7/16”x1/4” Turret lathe 7/16” bore - 2.75
09 Turn: small end to 5/8” large end to 3/2” and then Turret lathe Round-nose turning tool, cut- - 10.50
large end to 5/4” off tool and right-hand facing
tool

10 Thread: small and large ends (5/8”-16 UNC-2A Turret lathe Stationary, self-opening die - 9.25
and 5/4”-16 UNC-2A threads) heads for 5/8” and 5/4”

Total 1.25 27.75

Comments: Operations 7 through 10 are performed on the same turret lathe, using one setup. The operating times given include rechecking the work piece. The operations
are performed as follows: chuck large end; drill, bore, turn, thread, and cutoff small end to length; chuck small end, grip hexagonal surface; turn large end to 1.50” over
0.375” length, cutoff to length, turn large end to 1.25” over 0.25” length, retaining 1.50” diameter over 1.25” length.
4 - 16
 CONT’D
♦ The operation process chart is often used to
supplement the route sheet; in a sense, it is a
pictorial representation of the route sheet.

♦ Its an expansion of the assembly process chart in

that it includes all operations and inspections
performed on the product.

♦ The basis for the layout of a manufacturing plant.

4 - 17
4 - 18
 CONT’D
♦ A precedence diagram establishes the
prerequisite assembly steps that must be
completed before performing a given assembly
step.

4 - 19
 CONT’D

♦ Schedule design decisions tell us how much to

produce and when to produce.

♦ Production schedules are given using an analog

model called Gantt chart.

4 - 20
CONT’D

4 - 21
 CONT’D
♦ Most information sources available portray
yesterdays and, possibly today’s data.

♦ We are interested in tomorrow's data, since we are

developing a solution to be used tomorrow.

♦ Data sources emphasizes the interrelationships

among product, process, schedule, and layout
design.
4 - 22
 CONT’D
♦ The effective arrangement of personnel and
equipments depends on accurate information
regarding product, process, and schedule
requirements.

♦ When such requirements change rapidly, it is

important for the layout to accommodate changes
in requirements.
4 - 23
 OUTLINE
 Introduction
 Information Gathering
 Flow and Activity Analysis
 Relationship Diagram
 Space Requirements and Availability
 Designing the Layout

4 - 24
 FLOW
FLOW AND
AND ACTIVITY
ACTIVITY ANALYSIS
ANALYSIS

 Flow analysis concentrates on some

quantitative measures of movement
between departments or activities.

 Activity analysis is concerned with the non-

quantitative factors that influence the
location of departments or activities.
4 - 25
 CONT’D

♦ Basic data have been obtained concerning the

process, product and schedule, the layout analyst
is in position to analyze the flow of materials,
equipment, and personnel.

4 - 26
 CONT’D
Factor that affect the flow pattern given by Apple:
1. External transportation facilities
2. Number of parts in product
3. Number of operations on each part
4. Sequence of operations on each part
5. Number of subassemblies
6. Number of units to be produced
7. Necessary flow between work areas
8. Amount and shape of space available
4 - 27
 CONT’D
9. Influence of process
[Link] of flow pattern
[Link] versus process type of layout
[Link] of service areas
[Link] department location
[Link] requirement of departments
[Link] storage
[Link] flexibility
[Link] building
4 - 28
 CONT’D
Types of Flow Patterns

♦ Flow patterns can be classified either horizontal or

vertical.

♦ There are at least five basic types of horizontal

flow patterns.

4 - 29
CONT’D

4 - 30
 CONT’D

♦ Vertical flow pattern exist both in single-story and

multistory buildings. Utilization of overhead space
has focused great attention on the design of
vertical flow pattern.

4 - 31
CONT’D

4 - 32
 CONT’D
Types of layout

♦ The choice of layout type is the factor affecting

the flow pattern.

♦ There are four general types of layout categories:

1. Product layout
2. Process layout
3. Fixed position and,
4. Combination layout
4 - 33
 CONT’D
Flow analysis approach

♦ Flow process chart

♦ Multiproduct process chart

♦ Flow diagram

♦ From-to-chart

4 - 34
 CONT’D

Flow process chart

4 - 35
 CONT’D

Multiproduct process chart

4 - 36
 CONT’D

Flow diagram

4 - 37
 CONT’D

From-to-chart 4 - 38
 OUTLINE
 Introduction
 Information Gathering
 Flow and Activity Analysis
 Relationship Diagram
 Space Requirements and Availability
 Designing the Layout

4 - 39
 ACTIVITY
ACTIVITY RELATIONSHIP
RELATIONSHIP ANALYSIS
ANALYSIS

• Flow analysis tends to relate various activities on

some quantitative basis.

• Typically, the relationship is expressed as a

function of transport cost or material handling
cost.

• There might be other qualitative aspects of layout

design that might be important. 4 - 40
 CONT’D
Relationship chart

• A relationship chart is a triangular matrix whose

A: Absolutely

necessary
elements represent the relationships among plant
E: Especially
layout departments.
important

• Letter codes areI: Important

also used to represent desirable
or undesirable O: Ordinary
levels closeness
of closeness between
OK
departments.
U: Unimportant 4 - 41
 CONT’D
• The activity relationship chart (REL chart) was
developed to facilitate the consideration of
qualitative factors – analytically!

• The REL chart replaces the numbers in the Travel

chart by a qualitative closeness rating.

• All pairs of relationships are evaluated, and a

closeness rating (A, E, I, O, U, and X) is assigned to
4 - 42
 CONT’D

• With the exception of U rating, the reason for the

assigned rating is indicated using a numeric code.

• Closeness ratings represent an ordered preference

for “closeness”.

4 - 43
 CONT’D

• Specifically, A and X ratings are considered to be

most important ratings.

• Hence, any layout must satisfy A and X ratings.

• Thus, A and X > E > I > O > U , where > means

“more important or higher ranking than.”

4 - 44
 CONT’D
Rule of thumb:
• Very few A and X relationships should be
assigned. (no more than 5% of the closeness
ratings to be an A and X).
• No more than 10% should be an E.
• No more than 15% to be an I.
• No more than 20% to be an O.
• Which means that about 50% of the relationships
should be U.
4 - 45
 CONT’D
• Block plans, or block layouts are developed first
by determining the sizes, shapes and relative
locations of departments or other designated
activities.

• Next, detailed layouts are designed for each

department.

• Thus different REL charts are needed for designing

4 - 46
 CONT’D

• The process of constructing an activity

relationship chart can be complicated by the

presence of multiple relationships that will

influence the design of the layout.

4 - 47
CONT’D

4 - 48
 CONT’D
• The relationship chart and the numerically
weighted ratings, assigned to the closeness
values, are the basis for the order and placement
in which departments enter the layout.

• The ratings assigned for A,E,I,O,U and X are used

to calculate the Total Closeness Rating (TCR) for
each department.
4 - 49
 CONT’D
n

TCRi = 
j=1
V( r ij ); i = 1 ... m

Where

TCRj = Total Closeness Rating for department;

V(rij) = Numerical value assigned to the closeness

value for department i and j.

n = Total number of departments.

4 - 50
 CONT’D
• The first department to be placed in the layout is
assigned by taking the department with the
greatest TCR.

• Next, the relationship chart is scanned to see if

there is any department that has an A value with
the department already placed.

4 - 51
 CONT’D

• If no A value exists, a check is made for E value,

and if no E value appears, a check is made for I
value, followed by O value.

• If ties develop, the department having the

greatest TCR is chosen. This process is continually
used until finally all departments are placed in the
layout.
4 - 52
Example
Numerical values
A = 10,000; E = 1,000;
I = 100; O = 10; U = 0; and
X = -10,000

4 - 53
 CONT’D

a b c d

e f g 4 - 54
 CONT’D

i 4 - 55
 CONT’D
REL Diagram

• From REL chart, we construct activity relationship

diagram (REL diagram).

• The purpose is to depict spatially the relationships

of the activities.

• The basic premise is that geographic proximity

can be used to satisfy particular relationships.
4 - 56
 CONT’D

• For example, when the activity relationships

reflect the magnitudes of material flows, pairs of
activities having the greatest pair wise flow are
located next to each other.

• Similarly, pairs of activities having an A rating are

located adjacently.

4 - 57
CONT’D

4 - 58
 OUTLINE
 Introduction
 Information Gathering
 Flow and Activity Analysis
 Relationship Diagram
 Space Requirements and Availability
 Designing the Layout

4 - 59
 SPACE
SPACE REQUIREMENT
REQUIREMENT AND
AND AVAILABILITY
AVAILABILITY

The bases for determining the space requirement:

i. Production rate

ii. Equipment requirement

[Link] requirement

4 - 60
 CONT’D
Commonly used methods of determining space
requirement:

i. Production center method

• Consists of a single machine plus all the

associated equipment and space required for its
operations.

• Work space, maintenance space, and storage

4 - 61
CONT’D

4 - 62
 CONT’D
ii. Roughed-out layout method

• Templates or models are placed on the layout to

obtain an estimate of the general configuration
and space requirements.

iii. Space standards method

• Industry standards can be used to determine the

space requirement.
4 - 63
CONT’D

4 - 64
 OUTLINE
 Introduction
 Information Gathering
 Flow and Activity Analysis
 Relationship Diagram
 Space Requirements and Availability
 Designing the Layout

4 - 65
 DESIGNING THE LAYOUT
Designing the space relationship diagram

• The over all layout is designed by first combining

the space consideration with the REL diagram.

• For each activity, a space template is constructed,

to scale, to represent the size and shape of the
activity.

4 - 66
Example

4 - 67
CONT’D

4 - 68
 CONT’D
• After construction the space relationship diagram,
the space templates are modified and adjusted
and the relative locations of the activities are
shifted as necessary to accommodate practical
limitations and other considerations.

• The block plan is a scaled diagrammatic

representation of the building normally shows the
locations of internal partitions and columns. 4 - 69
4 - 70
 CONT’D
Presenting the layout

• A number of alternative component designs, a

number of alternative overall designs, or a number
of alternative detailed designs should have been
generated.

4 - 71
 CONT’D

There are three methods of visually representing

layouts

• Drawing or sketches

• Two-dimensional iconic models

• Three-dimensional iconic models

4 - 72
CONT’D

4 - 73
 CONT’D
Selection, implementation and follow-up

• Select the design from alternatives which best

meets your objective.

• The design selected must be specified, all

concerned must be sold, and the layout must be
installed, observed, and periodically evaluated in
an operating environment.
4 - 74
 OUTLINE
 Introduction
 Information Gathering
 Flow and Activity Analysis
 Relationship Diagram
 Space Requirements and Availability
 Designing the Layout

4 - 75