Facilities Layouts

Facilities Layouts 1

Flow of presentation 2

Introduction Importance of layout Need of layout Types of layout      

Product Layout Process Layout Fixed Position Layout Cellular Layout Mixed Layout

Introduction 3

 Deals with the physical

arrangement of various resources that are available in the system with an objective to improve the performance of the operating system thereby providing better customer service

The Need for Layout Decisions 4

Inefficient operations For Example:

High Cost Bottlenecks

Changes in the design of products or services

Accidents The introduction of new products or services

Safety hazards

(Cont’d) 55

Changes in environmental or other legal requirements

Changes in volume of output

Morale problems Changes in methods and equipment

Importance 6

i. Requires substantial investments of money and efforts ii. iii.Involves long term commitments iv. v.Significant impact on cost and efficiency of operations vi. vii.

Problems if Layout is improper 7

Idle time increases Higher cost Inefficiency increases Accidents may occur

Types of Layouts 8

Types of facilities layout :1.Product layout 2.Process layout 3.Fixed position layout 4.Cellular layout 5.Mixed Layout 



Product Layout 9

Achieve smooth, rapid & high volume flow Layout should be straight, U or S shape Division of work Machines are dedicated for single task Workstations should be located closely Speed is determine with workstation having lowest

capacity  

Example of straight line 10

CUTTING

SANDING

PAINTING

PRODUCT

U & S Shape 11

Half the length of straight production line More compact Flexibility in work and workers Minimizes material handling  



Example of S shape 12 

STARTS  PRODUCTIO N

CRUSHIN G

HOMOGINISATIO N PACKAGING MACHINE

BOILING

FILTRATION FINISHED PRODUCTION

Advantages 13

Mass production is possible Low unit cost High utilization of cost and labor Scheduling is not necessary after design Standardized products are obtained Less multi-skilled labors are required 

Disadvantages 14

System is inflexible Because of repetitive job it provides little opportunity

for development Worker losses morale Poorly skilled labor can’t maintain equipment or quality of product

Process Layout 15

Based on functions equipments are placed together Intermittent process Use flexible equipments and workers Variety of jobs can be performed It includes Job shop and Batch process 



Functional Approach 16

Function A

Function B

Function C

Function D

Function E

Function F

Work travels to dedicated process centers 17

Milling Assembly & Test

Drilling

Grinding

Plating

Examples 18

Car servicing Hospitals – Patients requiring various test Universities and colleges Airlines 

Car Servicing 19

Washing

Servicing

Oiling

Repairing

Painting

Advantages 20

Reduced cost as general purpose machines are used Greater flexibility Less maintenance cost Investment is less Greater scope of expansion as the capacities on

different lines can be increased Easy to handle breakdown of equipment

Disadvantages 21

Process inventory cost can be high With more numbers of operations flow becomes

complex and difficult to manage Routing and scheduling should be done on a continual basis Equipments utilizations rates are low Material handling is slow and inefficient More costly per unit as compared to product layout 

Fixed –Position Layout 22

Product remains stationary, resources travel to

product or customer. Mostly for bulky and very large product. Limited space required. 

Examples 23

In bulky product - ship ,building, rocket…. In small size product – battery production…. In service product – operation theater in 

Hospital , movie making…

Advantages 24

Minimum product movement. Promote job enlargement Continuity of operation Higher flexibility 

Disadvantage 25

Increased movement of personnel & equipments. Higher skilled personnel required Low utilization of equipment. Greater coordination required

Cellular Layout 26

This is philosophy that seeks to exploit the

commonality in manufacturing and uses this as a basis for grouping components and resources. This is also known as cellular manufacturing. Pioneered by Russians Mid volume & mid variety scenario 70% of mfg. industry may fall under this category)

Cellular Layout- Examples 27

Reliance industries- HDPE & LDPE Titan Industry ABB( Industrial fans & blowers)

Advantages of Cellular Layout 28

PPC becomes simpler Material handling becomes easier Traceability improves Employees are able to relate better. Helps in implementing SGA, Kaizen an JIT



DISADVANTAGES

Reduced manufacturing flexibility & potentially

increased machine- down time ( since machines are contained to cells & may not be used all the time) & finally duplicate pieces of equipment may be needed so that parts need not be transported between cells.

Mixed Layout 30

Two or more layout types in single facility 

Eg :- Hospital  Restaurant 