Facility Layout

Production Layout Formats

Work centre
Assembly Line
Manufacturing Cell
Project Layout

Facility Layout
A layout is the physical configuration
ofdepartments, workstations, and equipments in
the conversion process. it is arrangement
ofphysical resources used to create the product.
Success of operations depends on the physical
layouts of the facilities. Flow of raw material.
Productivity and human relationship are all affected
by the arrangements of the conversion facilities.
Plant layout involves:
planning and arranging facilities in new plant
improvements in existing layout tointroduce new
methods.

Factors Affecting Layout

Material
Product
Machinery
Labour
Location
Management policies
Type of industry

Types of Layouts

Process layout
Product layout
Grouping technology layout
Fixed position layout
Hybrid layout

Process Layout
Appropriate for intermittent operations where
work flow is not consistent for all output.
Variable workflow occurs when variety ofproducts
or variation of single product are produced.
Also called as functional layout or job-shop layout.
Similar equipments are grouped and located at
one place like lathe, drilling machines etc.
Workers should be highly skilled.
Intensive job instructions should be given
Technical supervision required.
Quicktochangeandadapttotheunique batches
of the products.

Process Layout Advantages

GreaterFlexibility
Better and more efficient supervision
possible through specialization
Breakdownscan betaken
carebyshiftingthejob to another
machine
Capacityofdifferentproduct linecan
be expanded easily.
Better utilisation of men and machine

Process Layout
Disadvantages
Moreworkinprogress
Morefloorspace
More distances travelled by the
product.

Product Layout
Appropriate for producing one
standardized product, usually in large
volume.
Also called as flow shop layout
orstraight line layouts.
Machines are arranged according to
the progressive steps by which the
product is made.
Examples: Chemical, paper, rubber,
refineries, cement industry.

Product Layout Advantages

Advantages:
ii)Mechanizationofmaterials is
possible andmaterial handling cost
can be
reduced.iii)Itrequireslessfloorare
a.iv)Itfacilitatesbetter production
controlv)Productionbottlenecks
areavoided.
Disadvantages

Product Layout
Disadvantages
Expansion of production line is
difficult
There is difficulty in supervising
Breakdown of equipment
disrupts the production.

Product Layout in Machining Piston

Casting

Rough turning
Lathe

Pinhole
Boring
Machine

Circlip Grooving
Machine

Cam Turning Lathe

Grooving
Machine

Inspecti
on

Packin
g

Group Technology Layout

Grouping technology or cellularmanufacturing
layout is made for a single part family i.e. parts
with common characteristics.
Dissimilarmachines are grouped into cells and
each cell functions like product layout.
Reduces material handling cost and simplifies
machine changeovers.
Reduces in-process inventory and automate the
production.
Reduces flexibility.

Fixed Position Layout

When due to size , shape and
othercharacteristic constraints, the products
can not be moved, the machine and operators
move around the product.
Example-constructionofabuilding, assembly
of an aircraft or ship.
Less investment is required in this layout and
less transport cost as bulky materials are not
moved.

Hybrid Layout
No single layout like process, product offixed
position layout is used in strict meaning.
Combination of these layouts are used.
Called a hybrid orcombined layout.
Example, in process layout, one section may
use product layout like parts may follow
process layout and assembly as product
layout. (Used in aircraft manufacturing)

Computer Models - CRAFT

ComputerizedRelativeAllocationofFacilities
Technique (CRAFT) is one such program which can
handle up to 40 work centres.
The model considers various type of layouts and
different material handling methods that a firm can
use among the work centres.
The analyst provides initial layout, a matrix
identifying the number of loads moved among work
centres and matrix identifying the cost
oftransportation.
After calculating the initial effectiveness, the CRAFT
exchanges the location ofpairs or triplets of work
centres and by many iteration and evaluation final
solutions printed out.

Developing Cellular manufacturing

Layout
Major problems
Developing and classification a coding
scheme for items of different shape,
sizes, materials etc.
Grouping parts in families to form cell
groups on the basis of processing
requirements and routings
Creating physical layouts forpositioning
cells relative to each other

Service Facility Layouts

Service facilities exist to bring together
customerand organisation's services.
Features like easy entrance, well organized parking
lots, well marked entries and exits, powered doors,
escalators and lobbies for customers, create a
convenience to customer and increase the business.
Thelayoutsdependondegreeofcustomercontacts.
One case, it may be designed around the customer
and other around the technology, process materials
and production efficiency.
Example: Banks designed around customer and
hospitals around the technology.