Facility Layout

FACILITY LAYOUT

Definition : Layout is an effort to

arrange machines and equipment,
and other services within a
predesigned space -ensuring steady,
smooth and economical flow of
material
Significance of Facility
Layout

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THE NEED FOR LAYOUT
DECISIONS
Types Of Layouts
 Product Layouts

 In Product Layout operations are

arranged in the sequence required to make
the product
 A job is divided into a series of
standardized tasks, permitting
specialization of both labor and
equipment.
 Used to achieve a smooth and rapid flow
of large volumes of products or customers
through a system.
Product-Oriented Layout

Operatio
ns

Belt Conveyor
 Linear Product

Raw materials Station Station Station Station Finished

1 2 3 4 item

Material Material Material Material

and/or and/or and/or and/or
labor labor labor labor

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A U-Shaped Production
Line

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 Product layout

Advantages Disadvantages
 High volume  Lacks flexibility
 Low unit cost Volume, design, mix
 Low labour skill  Large initial
needed investment
 Low material  Individual incentive
handling plans are not
 High efficiency and possible
utilization
 Can not
 Simple routing and
scheduling accommodate
partial shut
 Simple to track and
control downs/breakdowns
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PROCESS LAYOUTS
PROCESS LAYOUT -2
PRODUCTS
DESIGNING PROCESS
LAYOUTS

1. Gather information

3. Develop alternative block

plans

5. Develop a detailed layout

MEDICAL CLINIC LAYOUT-
3750 sq ft
 PROCESS LAYOUTS IN
SERVICES

Women’s ethnic
wear Shoes Housewares

Women’s dresses Cosmetics and Children’s

jewelry department

Women’s Entry and display Men’s department

sportswear area
MANUFACTURING PROCESS
LAYOUT
Milling
Lathe Department Department Drilling Department
M M D D D D
L L
M M D D D D
L L

G G G P
L L
G G G P
L L Painting Department
Grinding
Department
L L
Receiving and A A A
Shipping Assembly
 Process Layout

ADVANTAGES disadvantages

 Better utilization of  This type of layout

machines requires more floor
 Greater flexibility in space
production  Production requires
 Breakdown of more time
equipment can be
easily handled
 Accumulation of work
 Better and more at different work
efficient supervision is stations
possible through  Challenging routing
specialization and scheduling
 Less costly to maintain  Equipment utilization
 DIFFERENCE BETWEEN
PRODUCT AND PROCESS
LAYOUTS
PRODUCT PROCESS
 Machinery dedicated  Machinery can be used
to a particular product for a wide range of
 Arranges activities in products
a line according to the  Groups all similar
sequence of activities together
operations according to the
 Workers required to process or function.
perform relatively  Workers are skilled
simple tasks
 Mass production  Wide variety in
 Individual incentives relatively low volumes
not possible  Individual incentives
Fixed-Position Layouts

 Product remains stationary.

 Scheduling important.
 Used for farming, firefighting, road building,
home building, remodeling and repair, and
drilling for oil.
 Examples : Projects (One-Off Process)
 Fixed Position Layout

 ADVANTAGES  DISADVANTAG
ES
Ø Less handling of
material . Ø High skilled
Ø Labour involved workers are
can be saved. needed.
Ø Cost of operations Ø Bulk & heavy
is insured. machines required
to be taken to the
work-place.
 Hybrid (mixed) Layouts

 Most
manufacturing facilities use a
combination of layout types.
 CombinationLayout makes use of two
or more Layouts.
 Eg : Hospital
Soap Manufacturing
 Cellular Layout

 Cellularmanufacturing, incorporates
Group Technology, arranges factory
floor labour into semi-autonomous
and multi-skilled teams, or work cells,
who manufacture complete products
or complex components.
 Cellular Manufacturing

Advantages disadvantages
 production is  setup costs
enhanced  duplication of
 easily machinery
 loss in routing
isolated/upgraded flexibility
 high-variety  demand diminishes -
products break cell
 worker flexibility  conversion to

and versatility cellular

manufacturing can
involve the costly
realignment of