Chapter 10

Layout Planning:
Process Layout
Charlene Ann Molina
Jean Carla L. Merino
Layout Planning
Layout Planning is determining
the best physical arrangement
of resources within a facility


Importance
Eliminates unnecessary costs for space and
materials handling
Reduces work-in-process inventory
Produces goods and services faster
Reduces distances that workers must travel
in the workplace
Improves communication and morale
Increases retail sales
Improves brand image
Types of Layouts
Process layouts: Group similar resources together
Product layouts: Designed to produce a specific
product, or a small number of products efficiently
Hybrid layouts: Combine aspects of both process
and product layouts
Example: cellular layout
Fixed-Position layouts: Product is too large to
move
Examples: building construction, shipyard
Resources must be brought to where they are
needed
Process Layouts
Used in project and batch manufacturing
(intermittent processes)
Also used in department stores, offices,
hospitals, and universities
Able to make or sell a variety of products
Use general purpose resources
Less automation than in product layouts



Process Layouts (2)
Material handling costs per unit are higher
than in product layouts
Scheduling production is more complex than
in product layouts

Designing Process Layouts
Step 1: Gather information:
Space needed, space available, importance of
proximity between various units
Step 2: Develop alternative block plans:
Using trial-and-error or decision support tools
2 approaches
Relationship (REL) chart
From-to matrix
Can use both
Decision support systems are heuristic methods
Usually give a "good" solution
Solution may not be optimal (best solution)
Designing Process Layouts (2)
Step 3: Develop a detailed layout
Consider exact sizes and shapes of
departments and work centers including
aisles and stairways
Tools like drawings, 3-D models, and
computer-assisted design (CAD) software
are often used
Process Layout Example
Block layout for a sports medicine clinic


A
Radiology

B
Laboratory

C
Lobby &
Waiting
D
Examining
Rooms
E
Surgery &
Recovery

F
Physical
Therapy
Process Layout Example (2)
Process Layout Example (3)
Proposed Layout
Process Layout Example (4)
A
Radiology

B
Examining
Rooms

C
Lobby &
Waiting
D
Surgery &
Recovery
E
Laboratory

F
Physical
Therapy
Process Layout Example (5)
THE END
:D