What is a process layout?

A process layout is used for factories or service facilities dealing with a variety of products that follow different pathways through the facility.

How is the systematic layout planning method used?

The systematic layout planning method, or closeness ratings, determines which departments should be placed near or apart based on specific criteria.

Who created the systematic layout planning method?

The systematic layout planning method was created by Richard Luthor.

What do closeness ratings determine?

Closeness ratings determine which departments absolutely must, should, or cannot be next to each other.

What happens if departments that shouldn't be near each other are placed together?

Unsafe or inefficient conditions may arise, such as health risks or workflow bottlenecks, making it crucial to separate certain departments.

What visual diagram is used to plan facility layouts?

A stick diagram is used to help visualize the placement and relationships between departments in a facility layout.

What are 'A', 'E', and 'X' in closeness ratings?

'A' indicates departments that must be next to each other, 'E' is preferable but not critical, and 'X' means they must not be next to each other.

Why is department 6 significant in this example?

Department 6 appears most often in the criteria list, influencing its placement to prioritize its relationships with others.

What is the purpose of folding the stick diagram?

Folding the stick diagram helps visualize and adjust the spatial arrangement of departments to fit within the available facility space.

Can corner placements count as departments being close to each other?

Yes, departments that share a corner can be considered close in the context of layout planning.

Closeness Ratings

00:11:28

https://www.youtube.com/watch?v=pMVCnimPd5k

Summary

TLDRIn this instructional video on facility layout planning, the focus is on using the process layout approach, a method particularly suited for dealing with varied products and processes. This necessitates determining the optimal location of various departments within a building. The core strategy introduced is the systematic layout planning method, also known as closeness ratings, invented by Richard Luthor. This approach involves evaluating which departments need to be positioned next to one another, which should ideally be close, and which must remain separated. This determination is made based on several criteria such as safety requirements, shared equipment, or workflow dependencies; for instance, separating toxic paint areas from customer service zones in a body shop. The video illustrates a practical example of constructing closeness ratings through visual diagrams, identifying A's, E's, and X's that represent different proximity needs. It explains step-by-step how to translate these diagrams into spatial layouts that adhere to the planning criteria, using stick diagrams to depict and rearrange departmental relationships within a given space.

Takeaways

🏢 Process layouts are crucial for facilities with varied processing needs.
🗺️ Systematic layout planning helps in optimizing space and workflow.
⚠️ Safety is a key criteria in determining closeness ratings.
📊 Closeness ratings are important for department placement decisions.
🛠️ Departments must be planned based on specific 'A', 'E', 'X' criteria.
🔄 Stick diagrams assist in visualizing spatial relationships between departments.
👷 Efficient layouts prevent unsafe conditions and improve workflow.
🔀 The diagram must be folded to fit within the available facility space.
🔍 Reviewing and adjusting based on X's ensures proper separation of departments.
📐 Corner adjacency can be used to fulfill proximity requirements.

Timeline

00:00:00 - 00:05:00
The discussion focuses on process layouts in facilities, emphasizing that not all work processes will follow the same path through a facility. The systematic layout planning method, developed by Richard Luthor, utilizes closeness ratings to determine which departments must be near or far from each other. Different closeness ratings criteria such as 'A', 'E', and 'X' indicate essential proximity, importance of proximity, and the necessity to avoid proximity, respectively. The process involves identifying these ratings and using them to plan facility layout, focusing on safety and effectiveness of operational processes.
00:05:00 - 00:11:28
The explanation in this section further illustrates how to apply these closeness ratings to actual facility planning. It outlines the process of identifying department pairings according to the ratings 'A', 'E', and 'X', focusing on safety and operational efficiency. Once ratings are assigned, planners must place departments with 'X' ratings on the edges to prevent unwanted proximity. The uses of a stick diagram are detailed to visually guide the placement of departments in a manner that respects all proximity requirements. The goal is to adjust and fit the diagram into the facility layout while honoring all assigned closeness ratings.

Mind Map

Video Q&A

What is a process layout?
A process layout is used for factories or service facilities dealing with a variety of products that follow different pathways through the facility.
How is the systematic layout planning method used?
The systematic layout planning method, or closeness ratings, determines which departments should be placed near or apart based on specific criteria.
Who created the systematic layout planning method?
The systematic layout planning method was created by Richard Luthor.
What do closeness ratings determine?
Closeness ratings determine which departments absolutely must, should, or cannot be next to each other.
What happens if departments that shouldn't be near each other are placed together?
Unsafe or inefficient conditions may arise, such as health risks or workflow bottlenecks, making it crucial to separate certain departments.
What visual diagram is used to plan facility layouts?
A stick diagram is used to help visualize the placement and relationships between departments in a facility layout.
What are 'A', 'E', and 'X' in closeness ratings?
'A' indicates departments that must be next to each other, 'E' is preferable but not critical, and 'X' means they must not be next to each other.
Why is department 6 significant in this example?
Department 6 appears most often in the criteria list, influencing its placement to prioritize its relationships with others.
What is the purpose of folding the stick diagram?
Folding the stick diagram helps visualize and adjust the spatial arrangement of departments to fit within the available facility space.
Can corner placements count as departments being close to each other?
Yes, departments that share a corner can be considered close in the context of layout planning.

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Subtitles

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00:00:00
if you have a process layout then when
00:00:03
you are looking at your facilities so
00:00:05
let's say here's your building you need
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to decide what department is going to be
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located where and when it has processed
00:00:15
when you have a process layout you need
00:00:16
to recognize that not all of your work
00:00:19
in process will follow the same process
00:00:22
or a movement through your facility some
00:00:26
of your material might go this way
00:00:29
others might go that way depending on
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what needs to be done so process layouts
00:00:35
are used for services they are used when
00:00:38
there is variety in the products that
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you're producing so each step is not the
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same for each product so you take the
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inventory the work in process to where
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it needs to be for the jobs that need to
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be done well as part of this we need to
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figure out the location of those
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different departments we want to look at
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now is the closeness ratings or
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systematic layout planning method this
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systematic layout planning method or
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closeness ratings
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we're created by a guy named Richard
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Luthor and what they do is they look at
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which departments can and can't be next
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to each other based on preset criteria
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so let's just move it forward here in
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the slides to our discussion on those
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closest ratings and what you see here is
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you see a diagram that shows in this
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case six different departments and you
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see on this diagram we have a ZZZ and
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X's A's are the departments that
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absolutely must be next to each other
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YZ it's important that they're next to
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each other but not critical
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so if given the option we need to put
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them next to each other if we can but if
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we can't they're kind of second priority
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compared to the A's the X's are the
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departments that
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absolutely cannot be near each other so
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maybe is unsafe work conditions for
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these two departments to be near each
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other for example if you're a body shop
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the departments like where your
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customers go to pay cannot be next to
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where you are spraying toxic paint right
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unsafe conditions so you need to keep
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them separated maybe there's separate
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ventilation for example so you may have
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a number of criteria that decides
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whether something absolutely must be
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next another Department so an a is
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important but not critical in E or is
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cannot is be next to each other at all
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it's undesirable in X these may be
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factors such as whether or not they use
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the same equipment do they share some of
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the same personnel we can look at the
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level of workflow between the level of
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communication if some where jobs are
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performed and then of course if there is
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unsafe or unpleasant conditions if
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departments are near each other so what
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we do is we take this diagram that shows
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the A's the ease and the X's and we can
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use it to layout our facility so let's
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suppose at our facility so here's our
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six locations and here's they would how
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they would be laid out what we need to
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do first is identify the pairs of a ease
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and X's let's go back so how do you
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figure out if something as an a well if
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you look here at this box it has an a
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notice that one of the sides of the box
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points the department one and the other
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side of the box points the department to
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so one and two that pair is an A if we
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look at this a here notice that this
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side of the box goes to Department one
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and this one goes to Department three so
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here we have an a4 one and three
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now we have an e here notice that the
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edges of this ebox one goes to two and
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one of the edges goes to Department
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three so Department - and Department
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three are YZ - 3 is an e here we have an
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X one edge of the x box goes the
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Department one's the other edge of the x
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box goes to Department 4 so 1 and 4
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cannot be near each other let's look at
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this X here the edge of this x box goes
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to Department three the other edge goes
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to 4 so 3 & 4 cannot be near each other
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let's go and do the rest of them here's
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a so Department 3 and Department 5 are
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A's when it comes to the a that we see
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here this is Department - and Department
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6 here we have an X and this goes with
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Department 3 and Department 6 and this a
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is Department for and Department 6 and
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the last one here is Department 5 and
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Department 6 RNA notice that some
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departments we have no preference we
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don't care either way and so there is no
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a or E or X for some of these
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combinations so we only need to focus on
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what absolutely must be next to each
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other
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what is important to be near each other
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and what cannot be near each other at
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all
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whatever you put into this X category
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this will these are typically end up
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being in your corners okay the other
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thing we want to look at is which
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department has the most criteria the
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most restrictions so notice as we look
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at these notice that six appears three
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times in the a column and one time in
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the
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x-column so when you start to lay out
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your diagram you should start with the
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six because it appears the most often
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and then you want to start to kind of
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lay out this relationship here so let's
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start with the six is six and two six
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and four six and five those all need to
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be near each other
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notice that the four is also appear in
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the X's so let's put four out here to
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the left and we have a six and A two we
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have a six and the four and the six and
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A five
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okay so here these three branches
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indicate that these four departments
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need to be touching so we've taken care
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of this one and this one and this one
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and we put four out on the left side
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there because it's appearing in the exes
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okay
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so we'll come back to that issue in a
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moment all right let's check out the
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rest of them here we're going to need a
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three and a five let's put a 3 here
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we're going to need a 1 and a 3 notice
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that one is also appearing out here in
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the X's along with the 3 so let's put
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bears at 1 & 3 1 & 3 need to touch one
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in 4 can't so we want them to be far
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away from each other okay
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1 & 2 need to touch so let's click the
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line there so we have 1 & 2 1 & 3 3 & 5
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2 & 6 4 & 6 5 & 6 let's also do our 2
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and our three okay and so as we are
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filling out this diagram here 1 & 4
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cannot be near each other 3 & 4 cannot
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be near each other & 3 & 6 cannot be
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near each other so we're going to do is
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you're going to take this little stick
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diagram here and you're going to fold it
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into the box and we fold it into the box
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we want to think about taking this image
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here and rotating it or
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it until it lays nicely in here so think
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of these little sticks well to fix
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connecting these numbers and you can
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bend them in different directions to
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fold them in so let's put our four here
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in this corner
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because four has things that can't touch
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like the one and we have an issue as
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well that threes cannot be near anything
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so likely we're going to have our ones
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and threes be over here because they
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can't be near the four and the three
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can't be near the six so let's fold this
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in
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by taking this straight line here and
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turning it into that straight line there
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okay so when you do that we then need to
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take the rest of this piece and fold it
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so we have six and two and six and five
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so here's the two and the five they are
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touching so we maintain that piece there
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and then we have our three and our one
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so number five and three need to touch
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three and one and two and one so notice
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if we put three here and one there then
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the two and one are so good the one and
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three are still good the two and three
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are still good and essentially you can
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see that bit of that stick diagram fold
00:10:19
it into the box
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you should always double check your X's
00:10:23
afterwards one and four are nowhere near
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each other three and four are nowhere
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near each other and three and six now to
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be close to something it can be on
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either side or it can be at a corner as
00:10:37
well to count so you see how we have
00:10:40
filled in the department based on which
00:10:44
departments need to be next to each
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other which ones cannot using our
00:10:48
closeness ratings if you double check
00:10:52
this and you find that it does not fit
00:10:54
with X then go back to your stick
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diagram and again try to fold it into
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the box you should look for what can't
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touch each other like once fours and
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threes here and those should be on the
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outside
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side six is also here they're not always
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on the outsides of the box but a good
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majority of them will be because that's
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the only way you're going to get them
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not to interact with other departments