Layout and Flow

Facility Layout
Facility layout means planning for:
◦ Location of all machines, utilities, employee workstations, customer service
areas, material storage areas, aisles, restrooms, lunchrooms, internal walls,
offices, and computer rooms
◦ The flow patterns of materials and people around, into, and within
buildings
 What makes a good layout?
•Inherent safety

•Length of flow

•Clarity of flow

•Staff conditions

•Management coordination

•Accessibility

•Use of space

•Long-term flexibility
The Basic Layout Types
● Fixed-position layout

● Functional layout

● Cell layout

● Product layout.
Fixed-position layout
•Product remains in a fixed
position, and the personnel,
material and equipment come to
it

•Used when the product is very

bulky, large, heavy or fragile
Functional layout
Similar resources or processes are located together
 Cell layout

Machines are grouped according to

the process requirements for a set of
similar items
Product layout
Machinery and Materials are placed following the product path

The sequence of processes in paper-making

Mixed Layouts/ Hybrid Layouts

A restaurant complex with all four basic layout types

Selecting a Layout Type
The advantages and disadvantages of the
basic layout types
 Principles of Plant Layout
1. Principle of integration
2. Principle of minimum distance
3. Principle of cubic space utilization
4. Principle of flow
5. Principle of maximum flexibility
6. Principle of safety, security and satisfaction
7. Principle of minimum handling
Flow Analysis
Study of path that the part takes
while moving through the plant
Why to study Flow Analysis?
The purpose is to minimize

(1)Distance Traveled,

(2)Backtracking,

(3)Cross Traffic, And

(4)Cost Of Production
Method to study flow of Individual
parts
1. A string diagram

2. A multi-column process chart

3. A from-to chart

4. A process chart
String Diagram
Circles represent equipment and the line between circles will indicate flow
Example
A metal worker became fed up
with walking what seemed to be
half-way around the machine
room just to build a metal box.

Help him re-design the layout and

draw the flow diagram.
Answer