LAYOUT AND FLOW DESIGNS
IN OPERATIONS
MANAGEMENT
Presented by:
Isaac Owusu
Key questions
➤ What is ‘layout’?
➤ What are the basic layout types
used in operations?
➤ What type of layout should an
operation choose?
➤ How should each basic layout type
be designed in detail?
FACILITY LAYOUT
Definition:
The layout may be defined as
“a floor plan for determining and arranging the
desired machinery and equipment of a production
facility in the one best place to permit the quickest
flow of materials with the least amount of handling
and at the lowest cost in processing the component
parts of a product or service from receipt of inputs
(raw material) to the dispatch of outputs (finished
products)”.
Facilities layout aims to achieve the following
objectives:
1. Overall integration of facilities
2. Closeness – minimum distances moved.
3. Orderliness – logical flow of materials.
4. Utilization – effective use of cubic space.
5. Safety and satisfaction of workers.
6. Flexibility for change and expansion.
Importance of Effective Layout
1. Utilizes labour efficiently
2. Eliminates bottlenecks
3. Facilitates communication and interaction between
workers and their supervisors or between workers
and their customers.
4. Reduces manufacturing time and customer service
time
5. Eliminates waste or redundant movement
Importance of Effective Layout
(Cont…)
6. Promotes product and service quality
7. Provides a visual control of activities
8. Provides flexibility to adapt to changing conditions
9. Increases capacity
Symptoms of poor Layout
1. Lack of control
2. Congestion of men and materials (crowded conditions)
3. Excessive re-handling
4. Long transportation lines
5. Frequent accidents
6. Production line bottlenecks
7. Unexplainable delays and idle time
Marks of a Good Layout
1. Planned materials flow pattern
2. Straight, clear, marked aisles
3. Related operations close together
4. Minimum of work-in-progress
5. Easy adjustment to changing conditions
6. Good quality with minimum inspection
7. Minimum materials handling distances
TYPES OF FACILITIES LAYOUT
Product/Flow Layout
In this layout, machines or stations are arranged in a
sequence to correspond to the requirements for
processing a specific product or group of highly similar
products.
The work passes or moves from one work station to the
next without delay.
Product/Flow Layout (Cont…)
Conceptually, the flow is an unbroken line from raw
material input to finished goods. This type of layout is
exemplified in:
1.Automobile assembly
2.Food processing, and
3.Bottling of drinks
In general, flow layout is best adapted to mass or
continuous production industries where the products are
standardized.
Product/Flow Layout
Waiting Cars
Final Hot Hand
Clean Hot Top Wash Side Rinse Blowe Wipe &
Out Water & Brush Wash & & r clean-
Spray Brush Spray up
Exit
Advantages of Product/Flow Layout
1.Reduced throughput time (i.e. total production time per
unit)
2.Reduced work-in progress inventory, since the work
from one station is fed directly into the next.
3.Reduced material handling, since the machines are
located so as to minimize distances between consecutive
operations.
Advantages of Product/Flow Layout (Cont...)
1.Training is simple, short and inexpensive
2.Simple production planning and control systems are
possible
3.Reduced total floor space required per unit of production
4.Simplified process inspection.
Disadvantages of Product/Flow Layout:
1.This Layout system is inflexible, being unable to
accommodate changes readily.
2.One machine/equipment breakdown may immobilize a
complete production line.
3.Unless volume is high, machine utilization may be low
with a subsequent high capital investment.
Process Layout:
In this layout all machines and equipment that perform
the same function or type of work are grouped together,
without regard to any particular product.
In a typical mechanical engineering factory, the main
groups of equipment may comprise lathes, milling
machines, grinding machines, power saws and bending
machines.
Process Layout
Each machine will manufacture a variety of parts, the
tooling being reset between batches.
This layout is generally adopted in engineering
workshops, hospitals, medical clinics, etc.
Process Layout for Medical Clinic
Neurology Gynaecology Laboratory
Tests
Patient Waiting X-Ray
Restroom
Room
Plastic
Reception Surgery
Room
Paediatrics
Pharmacy
Advantages of process Layout
Extremely flexible to accommodate changes in product.
Comparatively low capital investment in machines is
required.
Specialized supervision is possible.
Mechanical breakdowns do not halt complete
production.
Disadvantages of process Layout
1.Total production time is usually longer.
2.Work control is difficult.
3.Production planning and control systems are more
involved.
4.Higher grades of skill required because of the diversity
of the job and specialized department.
5.Material handling is more expensive, since longer flow
lines usually result.
Fixed–position Layout
In this layout, the product, because of its size, weight or
other characteristics, is not feasible to move and therefore
remains in one location or a fixed position.
The equipment, tools and labour required to
manufacture are brought or moved to the product to
perform the appropriate stage of build-up.
Fixed–position Layout (Cont...)
Typical applications of the fixed-position layout are in
ship building, aircraft production, dam building, highway,
and bridge construction, etc.
Fixed-position layout operations often enjoy high
flexibility for scheduling and design changes. However,
the required movement of materials and machines may be
cumbersome and costly.
Fixed-Position layout for a home plumbing repair
operation
Service Truck
Equipment Supplies
Repairman
Home plumbing
problem
QUESTIONS
THANK YOU
