2. FACILITY LAYOUT
• Facility layout is an arrangement of different aspects of manufacturing in an
appropriate manner as to achieve desired production results
OBJECTIVES
Minimize material handling costs
Eliminate bottlenecks
Utilize labor efficiently
Utilize space efficiently
Facilitate communication
Reduce manufacturing cycle
time / customer service time
3. TYPES OF FACILITY LAYOUT
1. Product Layout
2. Process Layout
3. Group Layout
4. Fixed Position Layout
5. Cellular Layout
6. Service Layout
4. PRODUCT LAYOUT
Straight-line layout or layout for serialized manufacture
Arrangement of machines in one line, depending upon the sequence of operations
Materials are fed into first machine and partly finished goods travel automatically and
finished products comes out from the last machine (Output of one machine becoming the
input for the next)
Eg: Sugarcane mill, Paper mill
5.
6. ADVANTAGES
Avoid production bottlenecks
Better production control
Requires less floor area per unit
of production
Reduction in material handling
cost
DISADVANTAGES
Known for its inflexibility
Expensive
Difficulty of supervision
Expansion is so difficult
Any breakdown of equipment
disrupt the whole system
7. PROCESS LAYOUT
Functional layout or Job shop layout or batch production layout
Involves grouping of like machines together in one department
General purpose machines
Eg: Process oriented layout for hospital
8.
9. ADVANTAGES
Reduced investment of
machines
Greater flexibility in production
More efficient supervision
Better utilisation of men and
machines
Easier to handle breakdown of
equipment
DISADVANTAGES
Requires more floor space
Difficulty in production control
Difficulty in movement of
materials
Production times is more
Accumulation of WIP at
different places
10. GROUP LAYOUT
Combined layout or Hybrid Layout
A combination of the product and process layouts, with an emphasis on either
(Plants are never laid out in either pure form)
Fabrication tends to employ the process layout, while the assembly areas often
employ the product layout
Eg: Soap manufacturing plants, the machinery is arranged in product line where
as ancillary services are arranged in process line
11.
12. ADVANTAGES
Increased job utilization
Supports the use of general
purpose equipment
Shorter travel distances and
smoother flow lines than for
process layout
DISADVANTAGES
General supervision required
Higher skill level required for
employees
Depends on balanced material
flow through the cell, orelse
buffers and WIP storage are
required
13. FIXED POSITION LAYOUT
Static Layout
Involves the movement of men and machinery to the product which remains
stationery
Cost of moving men and machine < Cost of moving the product
Eg: Ship building, Dam construction, Flyover Construction
14.
15. ADVANTAGES
Men and machines can be used
for a variety of operations
Invesment on layout is very
small
Flexible : Can accommodate
changes in product design,
product mix and production
volume
DISADVANTAGES
High capital investment
Higher skill requirements for
personnel
Increased movement of
personnel and equipment
16. CELLULAR MANUFACTURING LAYOUT
Machines are grouped into cells
Cells function somewhat like a product layout within a larger shop or process
layout
17.
18. ADVANTAGES
Flexibility
Small batches of production
Higher machine utilization
Workers empowerment
Low cost of production
DISADVANTAGES
Poorly balanced cells
Expanded training and
scheduling of workers
Increased capital investment
19. SERVICE FACILITY LAYOUT
Service facilities exist to bring together customer and services
Layouts should provide for easy entrance to the facilities from freeways and busy
thoroughfares
2 types of service facility layouts
Customer receiving and servicing function (such as banks)
Designed around the technologies, processing of physical materials and
production efficiency (such as hospitals)