FACTORS AFFECTING FACILITY LAYOUT

5. PRODUCTION
Methods and Volume of Production
Production methods are the heart of the physical layout, for they determine the machinery
and equipment, which in turn determine the entire layout. There may be different methods of
producing an item, one method may require a number of operations and a number of
machineries, whereas by another method only one machine or a few number of machines may do
the entire job, making a lot of saving in the space requirement and the efficiency of the layout. It
is therefore essential that a decision about the methods to be used for the process should be taken
before attempts are made to plan a layout. Sequence of operations or the order in which
operations occur influence the final shape of layout. It dictates the methods of arranging work
area, machinery, handling systems and the relationship of different departments with each other.
It is very important to list the operations necessary and the order in which they are to be
performed.
Any of the following three methods may be adopted for production-
(i) Job order production,
(ii) batch production, and
(iii) mass production.
(i) Job Production: goods are produced according to the orders of the customers and therefore,
specification vary from customer to customer and the production cannot be standardized. As
each product is non- standardized varying in size and nature, it requires separate job for
production. The machines and equipment can be arranged in a manner to suit the need of all
types of customers.
Job production involves intermittent process as the work is carried as and when the order is
received. Ship building is an appropriate example of this kind. This method of plant layout viz.,
Stationery Material Layout is suitable for job production.
(ii) Batch Production: carries the production of goods in batches or group at intervals. In this
type of manufacturing the product is standardized and production is made generally in
anticipation of sales. In such cases functional or process layout may be adopted. It should be
remembered here that one batch of products has no resemblance with the next batch.
This method is generally adopted in case of biscuit and confectionary manufacturing, medicines,
tinned food and hardware’s like nuts and bolts etc.
(iii) Mass Production: involves a continuous production of standardized products on large scale.
Under this method, production remains continuous in anticipation of future demand. There is a
continuous or uninterrupted flow of production obtained by arranging the machines in a proper
sequence of operations. Product layout is best suited for mass production units.
Volume of Production
Volume of production and the standardization of the product also affect the type of
layout. Plant layout is generally determined by taking into consideration the quantum of
production to be produced. If standardized commodities are to be manufactured on large scale,
line type of layout may be adopted. Functional layout is suitable if production is based on
customers’ orders. It is better suited for low volume job production.
6. HUMAN FACTOR AND WORKING CONDITIONS
Men are the most important factor of production and therefore special consideration for
their safety and comforts should be given while planning a layout, specific safety items like
obstruction-free floor, workers not exposed to hazards, exit etc. should be provided. The layout
should also provide for the comforts to the workers such as provision of rest rooms, drinking
water and other services. Sufficient space is also to be provided for free movement of workers.
For every plant layout under consideration proper thought must be given to the comfort
and convenience of the employees so that they feel satisfied and safe while they are in the
factory. If the employees feel dissatisfied with the arrangement of plant and layout they may be
feel unsafe, and the productivity maybe less. It is well said that the success of a layout depends
as much as how well it is accepted as on how efficient it is.
Many factors contribute to employees working conditions, some of which are heat, light,
noise and vibrations, space etc. Good Layout should take care for proper illumination, control of
noise, vibration and dust, arrangement for proper ventilation and discharge of fumes and other
harmful gases. Provision for air conditioning if necessary and providing sufficient space for the
working and movement of the employees make things comfortable as well as safe.
All these facilities, affect the layout and an alert layout engineer keeps all these points in
view so that he has not to feel sorry or change or modify, the layout later on.
7. BASIC MANAGERIAL POLICIES & DECISIONS
The type of layout depends very much on the decisions and policies of the management
to be followed in producing the commodity with regard to the size of plant, kind and quality of
the product, scope for expansion to be provided for, the extent to which the plant is to be
integrated, amount of stocks to be carried at any time, possibility of future expansion, the kind of
employee facilities to be provided, sales and marketing policies and purchasing policies, etc.
These policies and plans have positive impact in deciding plant layout.
8. CHARACTERISTICS OF THE BUILDING
The building is basically the shell that houses and protects man, material and machinery,
and supporting activity necessary for production. Building should be an integral part of the
layout plans as it contributes immediately to the effectiveness of the process within it.
 Shape of building, covered and open area, number of storey, facilities of elevators, stairs,
parking area, floor loads, window areas, and so on influence the layout plan. The building will
influence the layout most if it is already in existence. Here the consideration of the building
factor immediately becomes a limitation on the free hand of the layout engineer. In most of the
cases where building is hired, layout is to be adjusted within the spaces available in the building.
Although minor modification may be done to suit the needs of the plants and equipment. But if
any building is to be constructed, proper care should be given to construct it according to the
layout plan drawn by experts. Special type of construction is needed to accommodate huge or
technical or complex or sophisticated machines and equipment.
9. FACILITY LOCATION
The size shape and topography of the site at which the plant (facility) is located will
naturally affect the type of layout to be followed in view of the maximum utilization of the space
available. Layout is greatly influenced by the size and shape of the plot, climatic conditions and
by laws of the areas where the plot is located. If the plot is more in length than the width, the
material moves forward continuously in a straight line in the course of manufacturing. On the
other hand, if the shape is square and too many machines and operations are involved in
production process, then the machines have to be arranged in different patterns as the layout will
be in a different shape.
Availability of floor space can be other decisive factor in adopting a particular mode of
layout. If there is a scarcity of space, product layout may be undertaken. On the other hand, more
space may lead to the adoption of process layout.
Accessibility and nearness to raw materials are of particular importance when the
materials used are bulky relative to value and when weight and bulkiness of the product can be
greatly reduced by processing. Under such conditions, location near the source of raw materials
is of considerable importance because it not only reduces the materials transportation costs, but
also decreases the amount of raw material inventory to be carried and thus less storage space
needs to be provided in the layout.
10. CLIMATE
Sometimes, temperature, illumination and air are the deciding factors in the location of
machines and their establishments. For example, in lantern manufacturing industry, the spray-
painting room is built along the factory wall to ensure the required temperature control and air
expulsion and the process of spray painting may be undertaken. This factor should be considered
in order to improve the health and welfare of employees.