Q.

Discuss the various types of layouts with their

characteristics, advantages and disadvantages.

Answer: Layout refers to the configuration of departments, work

centers, and equipment with particular emphasis on movement of
work through the system.

In the following different types of layouts are discussed below.

1. Product layout: Layout that uses standardized processing

operations to achieve smooth, rapid, high-volume flow of output
is known as product layout. The work is divided into a series of
standardized tasks, permitting specialization of equipment and
division of labor.

Characteristics of product layouts

i. High- volume of output;

ii. Division of labor;
iii. Workers are skilled;
iv. Low unit cost and low material handling cost;
v. Highly depend on workers;
vi. Inflexible system;
vii. Repetitive workers or jobs; i.e; continuous processes.

Advantages of product layouts

i. Low unit Cost due to high volume ;

ii. Low material-handling cost per unit;
iii. A high utilization of labor per unit;
iv. Labor specialization.
Disadvantages of product layouts

i. The intensive division of labor usually created dull, repetitive

jobs that provide little opportunity for advancement and may
lead to morale problem;
ii. The system is fairly inflexible in response to changes in the
volume of output;
iii. The system is highly susceptible to shutdowns caused by
equipment breakdowns or excessive absenteeism;
iv. Preventive maintenance, the capacity for quick repairs and
spare-parts inventories are necessary expenses.

1 2 3 4 5

Figure: A horizontal product layout

1
5
2
4
3

Figure: A circle/cycle product layout

 2. Process layout: Layout that can handle varied processing
requirements is called process layout. The variety of jobs that
are processed requires frequent adjustments to equipment. This
causes a discontinuous workflow which is referred to as
intermittent processing.

Characteristics of process layouts

i. It can use to handle multiple processing;

ii. Not depend on labor or equipment failure;
iii. Equipment utilization rates are low;
iv. Each product or customer must get special attention.

Advantages of process layouts

i. The system can handle a variety of processing requirements;

ii. The systems are not particularly vulnerable to equipment;
iii. It is possible to use individual incentive systems.

Disadvantages of process layouts

i. Routing and scheduling pose continual challenges

ii. Equipment utilization rates are low;
iii. Materials handling is slow and efficient, and inefficient, and
more costly per unit than in product layouts;
iv. Job complexities often reduce the span of supervision and
result in higher supervisory costs than with product layouts.

3. Fixed position layout: Layout in which the product or service or

project remains stationary, and workers, materials and
equipment are moved as needed is known as fixed position
layout.

Characteristics of fix position layout:

i. This type of layout remains in specific place;

ii. Workers, equipment resources are bringing to the layouts;
iii. Heavy work is done in this type of layout;
 iv. Scheduling, repetitive works etc. are common;
v. Attention must be given on timing of materials and equipment
deliveries and supply of workers;
vi. Both types of workers can work.

Advantages of fixed position layout:

i. Generally this type of layouts are used in heavy construction;

ii. Labor force are available in the surroundings.

Disadvantages of fixed position layout:

i. Huge capital is needed;

ii. Sometimes raw materials or utilities are not available.

4. Combination layout: Combination layout is the combination of the

three types of layouts. Product, process and fixed position
layouts combindly creates this type of layout.

Characteristics of combination layout:

i. Supermarkets, hospitals etc. uses types of layout;
ii. Conveyors are frequently observed in this type of layout;
iii. Sometime depend and sometime non depend on workers,
equipment failure, utilities etc.

Advantages of combination layout:

i. The systems are not particularly vulnerable to equipment;

ii. Labor specialization;
iii. It can use to handle multiple processing.

Disadvantages of combination layout:

i. Huge capital is needed;

ii. Sometimes raw materials or utilities are not available;
iii. Equipment utilization rates are low.