Facility Layout:

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 Overview


Facility Layout
 Manufacturing Facility Layouts

Service Facility Layouts

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 Facility Layout

Facility layout means planning:


Where to place (position) machines, utilities,
employee workstations, customer service areas,
material storage areas, aisles, restrooms,
lunchrooms, internal walls, offices, and computer
rooms etc. within a facility

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Locate All Areas In and Around Buildings


Equipment

Work stations
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Material storage

Rest/break areas
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Utilities
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Eating areas
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Aisles
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Offices

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Characteristics of the Facility Layout Decision

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Location of these various areas impacts the flow
through the system.

The layout can affect productivity and costs generated
by the system.
 . . . more

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Characteristics of the Facility Layout Decision

Layout decisions tend to be:


Infrequent

Expensive to implement

Studied and evaluated extensively
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Long-term commitments

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Manufacturing Facility Layouts

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 Focus of layout planning in Mfg.

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The central focus of most manufacturing layouts is to
minimize the cost of processing, transporting, and
storing materials throughout the production system.
…from the receiving material to the storage of finished
goods
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Materials used in manufacturing include:
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Raw material
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Purchased components
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Work-in-progress
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Finished goods

Packaging material
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Maintenance, repair, and operating supplies 9
 Basic Layout Forms


Fixed-Position
 Product

Process

Hybrid ( combination)

Cellular (not in course)

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 Fixed-Position Layouts- in course


Product remains in a fixed position, and the
personnel, material and equipment come to it
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Used when the product is very bulky, large, heavy or
fragile
 Eg. Bridges, airports, roads, buildings

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 Product (Assembly Line) Layouts

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Used for continuous process types.
 Used when the operations system must handle a
narrow variety of products in high volumes
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Speed is required.
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Equipment/operators are arranged in the sequence
required to make the product
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Operations and personnel are dedicated to producing
one or a small number of products

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Example of product layout

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 Characteristics of Product Layouts

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Material flow approaches continuous
 Special-purpose equipment are used

Material handling equipment is fixed

Production time for a unit is relatively short

Planning, scheduling and controlling functions are
relatively straight-forward

Little direct supervision is required

Operators need not be as skilled
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Changeover is expensive and lengthy
 In-process inventory is relatively low
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 Process (Job Shop) Layouts

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This works well for intermittent process types
 Used when the operations system must handle a wide
variety of products in relatively small volumes (i.e.,
flexibility is necessary
 As product type and the volume required to be made
changes frequently.
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So dedicated equipment and person
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So Equipment that perform similar processes are
placed together

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Process layout

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 Characteristics of Process Layouts

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General-purpose equipment is used
 Changeover is rapid

Material flow is intermittent

Material handling equipment is flexible

Operators are highly skilled
 . . . more

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 Characteristics of Process Layouts


Technical supervision is required
 Planning, scheduling and controlling functions are
challenging

Production time is relatively long

In-process inventory is relatively high

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Cellular Manufacturing Layouts- Not in course

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Operations required to produce a particular family
(group) of parts are arranged in the sequence required
to make that family
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Used when the operations system must handle a
moderate variety of products in moderate volumes

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 Characteristics of Cellular Manufacturing
Relative to Process Layouts
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Equipment can be less general-purpose
 Material handling costs are reduced
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Training periods for operators are shortened
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In-process inventory is lower
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Parts can be made faster and shipped more quickly

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 Characteristics of Cellular Manufacturing
Relative to Product Layouts

Equipment can be less special-purpose
 Changeovers are simplified

Production is easier to automate

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 Hybrid Layouts- in course

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Actually, most manufacturing facilities use a
combination of layout types.
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An example of a hybrid layout is where departments
are arranged according to the types of processes but
the products flow through on a product layout.

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