Facility Layout :

Meaning :
Arrangement of –
Machinery

Equipment

Other industrial facilities

Achieveing Quick production at least cost.
 What is Facility Layout?

The layout facility is the physical location of the various

departments/units of the facility within the premises of the facility.

The departments may be located based on the considerations such

as:
Less walking distance
Logical sequence of the processing requirements of the product
Emergency services, etc
Objectives of Good Layout
-Material handling costs.
-Movement of people and material
-Hazards to personnel
-Accidents

-Production capacity
-labour efficiency
-Employee morale
-Space utilization
-Ease of Supervision and Maintenance
Principles For Ideal Layout

Ideal
Layout
 Types of Layout

 Product Layout
 order in which the resources are placed follow exactly the
visitation sequence dictated by a product
 Process Layout
 arrangement of resources on the basis of the process
characteristics of the resources available
 Group Technology ( Cellular) Layout
 seeks to exploit commonality in manufacturing and uses this
as the basis for grouping components and resources
 Fixed Position Layout
 emphasis is not so much on optimum position of resources
required for the process, since the product itself largely
dictates this; the focus is on gaining better control of material
flow and reducing delays
1 Product Layout

•It is appropriate for producing one standardized product, usually

in large volume. It is also called as flow-shop layout or straight
line layouts. The machines are arranged according to the
progressive steps by which the product is made.
•Example: chemical, paper, rubber, refineries, cement industry.
 Advantages:
•Mechanization of materials is possible and material
handling cost can be reduced.
•It requires less floor area.
•It facilitates better production control.
•Production bottlenecks are avoided.

Disadvantages:
•Expansion of product line is difficult.
•There is difficulty is supervising.
•Breakdown of equipment disrupts the production.
 Process layout:

Functionallayout /job lot manufacture or batch

production layout.
Involves grouping of like machines in one department.
General purpose machines.
 Advantages of Process Layout:
•Greater Flexibility
•Better and more efficient supervision possible through
specialization
•Capacity of different product line can be expanded
easily.
•Better utilization of men and machine.

Disadvantages:
•More floor space
•More work in progress
•More distance travelled by the product.
 3) Group Technology Layout / Cellular
Grouping technology layout of cellular manufacturing layout is made for
a single part family i.e parts with common characteristics. In this layout
dissimilar machines are grouped into cells and each cell functions like
product layout.

Advantage and Disadvantages:

It reduces material handling cost and simplifies machine changeovers. It
reduces in-process inventory and automate the production but reduces
the flexibility.
 Cellular manufacturing:

Machines grouped into cells.

Each cell is formed to produce a few parts with
common characters.
4) Fixed Position Layout
When due to size, shape and other characteristics
constraints, the products cannot be moved, the machine and
operators move around the product.
Example: construction of a building, assemble of an aircraft
or ship.

Advantage:
Less investment is required in
this layout and less transport
cost as
bulky machines are not moved.
Fixed Position Layout

Movement of men and machines to the product.

Bulky product.
Eg: Aircraft assembling, ships etc.
 Service facility layout
Service oriented industries like Banks, Hospitals etc
 Store Layout.. example
Sporting
Goods Shoes House wares

Women’s Cosmetics &

Children’s
department Jewellery
department

Furniture Entry & Men’s

display area department
 Process Layouts in Service Organizations

Wide variety of services, use Process Layouts

•Libraries
– Reference materials, serials, microfilms in separate
areas.
•Hospitals
– X-ray, Surgery, Oncology, Maternity.
•Insurance
– Claims, underwriting, filing are individual depts.
 Product Layouts in Service
Organizations
• When volume of demand is high.

• Customs and Immigration at Airports.

• Registration.
 Line Balancing

Line Balancing is the process of assigning tasks to

workstations in such a way that the workstations have
approximately equal time requirements.
 Line
Balancing

Line balancing
A method by which the tasks are optimally combined without
violating precedence constraints and a certain number of
workstations designed to complete the tasks
Key decision variables are production rate, cycle time and the
number of workstations, which are inter-related
Solving the “line balancing” problem calls for striking the right
trade-off between increased production and better utilisation of
resources
Cycle time is the ratio of the available time to the actual
(desired) production rate
 Line
Balancing

Available Time
Actual ( Desired ) Cycle Time 
Actual ( Desired ) Pr oduction

Sum of all task times

Minimum No. of work stations required 
Cycle Time

Sum of all task times

Average Re source Utilisation 
Number of workstations * Cycle time
 Example

 A factory working in 2 shifts each of 8 hours produces

24,000 electric bulbs using a set of workstations. Using this
information compute the actual cycle time of the plant
operation.

 There are 8 tasks required to manufacture the bulb. The

sum of all task times is equal to 12 seconds. How many
workstations are required to maintain this level of
production if combining of tasks into that many
workstations is a feasible alternative?
Solution to
example

Available time = 2*8*60*60 =

57,600 seconds
Actual production = 24,000 electric
bulbs
57,600
Therefore,  2.4
24,000
Cycle time for each
bulb is seconds
12
5
This means that the factory is 2 .4
producing a bulb every 2.4 seconds.
No. of work stations required =

Therefore the tasks are to be split

among the five stations such that
each workstation will have sum of
 Lead Time
• Adding in non-value added time (queue time, wait or blocked
time … etc.) makes up lead time.

• Order to delivery lead time is a lead time that the customer

feels.
– From the time the customer places the order to the time the
product is delivered.
– Effective lead time reduction, is lowering order to delivery
lead time, customer feels the improvement.
End of END OF SESSION
Seession