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Facility Layout and Design Concepts

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Flexible manufacturing system (FMS)

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Combines high flexibility with high efficiency by using automated machines and a central control system, expensive but can reduce setup times and work in process.

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Cross-docking

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Products are received through an inbound dock and immediately transferred across the dock to the outbound transportation dock, which reduces storage and handling costs but requires tight scheduling.

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Fixed-position layout

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Used when products are too large or heavy to move, which minimizes product movement but can complicate resource planning and scheduling.

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Material handling

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Involves the movement of materials within a facility, which impacts efficiency, product flow, and worker safety, and should be optimized to reduce costs.

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Process-oriented layout

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Facilitates the processing of a variety of products or services with intermittent workflow, improving flexibility but potentially increasing transportation costs.

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Cellular layout

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Groups different machines into cells that process a family of parts with similar shapes or processing requirements, reducing lead time and work in process.

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Just-In-Time (JIT) layout

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Reduces waste by keeping inventory levels low and uses small, decentralised workstations, which requires robust planning and is vulnerable to disruptions.

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Ergonomics

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Considers the interaction between people and systems in the work environment, improving safety, comfort, and productivity but requiring careful design and investment.

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Product-oriented layout

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Supports the production of a few standardized products at high volumes, which enhances efficiency but reduces flexibility.

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SMED (Single-Minute Exchange of Dies)

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Aims to reduce equipment setup times to less than 10 minutes, which increases operational efficiency and flexibility but requires initial investment and training.

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Throughput

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The rate at which a facility produces goods relative to the capacity, affecting profitability and efficiency, and can be used to measure performance.

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Six Sigma

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A set of techniques and tools for process improvement, aiming at reducing variability and defects to enhance quality and efficiency, necessitating cultural change and ongoing training.

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