Lesson 9 – Layout Decisions: Facilities Layout

Facility layout
- is an arrangement of different aspects of manufacturing in an appropriate manner as
to achieve desired production results.
- the arrangement of 3M’s (men, materials, machine) in a workspace
- ex, factory – machine, equipment, materials, workers

Layout Design Objectives

• Basic Objective
– Facilitate a smooth flow of work, material, and information through the system.

- To have an effective and efficient workflow or in other words, to maximize the

productivity of 3 M’s (men, materials, machine)

Basic Layout Types

1. Product layout (Line Layout)

• In this layout, resources are arranged sequentially, based on the routing of the
products. In theory, this sequential layout allows the entire process to be laid out
in a straight line, which at times may be totally dedicated to the production of
only one product or product version.
• Usually, it is used in manufacturing industries or large-scale industries that has a
continuous processes) mass production
• Example: Certain industries like, paper, cement, electronic appliances like
printers, refrigerators. Our daily needs like food (canned goods, bread, sugar)
automotive industries, (car)
• Chipotle - walking through the lines - ordering as you go - first thing they ask is
what do you want salad, a burrito, a taco –
• First station: cook burrito, add some rice, beans, or meat
• Next station: adding in some vegetables, salsa, guacamole, lettuce, tomato
• Next station: drinks, give u basket, bag
• Final station: Pay

2. Process layout (Functional Layout)

 • In this layout, the workstations and machinery are not arranged according to a
particular production sequence. Instead, there is an assembly of similar
operations or similar machinery in each department.
• are found primarily in job shops, or firms that produce customized, low-volume
products that may require different processing requirements and sequences of
operations.
• Example: Services that utilize process layouts include school, banks, hospitals,
and auto repair. (pagkuha ng clearance)

3. Fixed-Position layout

• In this layout, the product or project remains stationary, and workers, materials,
and equipment are moved as needed.
• appropriate for a product that is too large or too heavy to move.
• Example: construction and maintenance of ship, dam, aircraft. For services,
(e.g., a hospital operating room where doctors, nurses, and medical equipment
are brought to the patient). For construction (e.g., buildings, electric or nuclear
power plants), farming, drilling for oil, home service, and automated car washes.

4. Combination layout (Hybrid Layout)

• mixture of the three main layout types.

• Example, one firm may utilize a process layout for the majority of its process
along with an assembly in one area. Alternatively, a firm may utilize a fixed-
position layout for the assembly of its final product but use assembly lines to
produce the components and subassemblies that make up the final product (e.g.,
aircraft).
• Hospitals, (ER, Room, Department; blood test) (Xray machine) Supermarket, and
Shipyards. (yachts, military vessels, cruise liners or other cargo or passenger
ships)

5. Cellular manufacturing

• a type of layout where machines are grouped according to the process

requirements for a set of similar items that require similar processing.
• These groups are called cells. Each of these cells is composed of one or multiple
different machines which accomplish a certain task. The product moves from one
cell to the next, each station completing part of the manufacturing process. Often
 the cells are arranged in a "U-shape" design because this allows for the overseer
to move less and can readily watch over the entire process.
• Example: game systems, piano manufacturer
• Flexible manufacturing system (FMS) – is an automated version of cellular
manufacturing. With an FMS, a computer controls the transfer of parts to the
various processes.

6. Other Layout
- others that are more appropriate for use in service organizations. These include
warehouse/storage layout, retail layout, and office layout.

• With warehouse/storage layouts, order frequency is a key factor. Items that are
ordered frequently should be placed close together near the entrance of the
facility, while those ordered less frequently remain in the rear of the facility. In this
way, order picking is made more efficient.
• retail stores - to influence the customers to buy or to buy more. (Clothing store –
trend in fashion)
• Office layouts – if the goal of the company/ organization is to have collaboration
and proper communication then they can use no partitions and glass walls for
higher position. (The intern)