MODULE - II

LAYOUT
FACILITY LAYOUT
 It is refers to the arrangement of machinery, equipment and other
industrial facilities- such as receiving & shipping departments,
tool rooms, maintenance rooms and employee amenities- for the
purpose of achieving the quickest and smoothest production at
the least cost
 Layout planning in manufacturing & service organizations 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
 A good layout design ensures that a vast majority of jobs in a
manufacturing system travel shortest distances possible to ensure
shortest processing time.
IMPORTANCE OF A LAYOUT
 Economies in handling
 Effective use of available area
 Minimization of production delays
 Improved quality control
 Minimum equipment investment
 Avoidance of bottlenecks
 Better production control
 Better supervision
 Improved utilization of labor
 Improved employee moral
DIFFERENCES BETWEEN PRODUCT AND PROCESS
FOCUSSED LAYOUTS
PRODUCT LAYOUT PROCESS LAYOUT

Description Sequential arrangement Functional grouping of

of activities activities
Product Standardized, Made to Varied products, Made
stock products to order
Demand Stable Fluctuating

Volume High Low

Equipment Special Purpose General Purpose

Workers Limited Skills Varied Skills

Inventory Low-In Process High-In Process

High- Finished Goods Low- Finished Goods
Storage Space Small Large

Material Handling Fixed Path Variable path

Advantage Efficiency Flexibility

Wage Rate Low High

Ease in Work No bottlenecks Wasteful Backtracking

Inspection Less inspection Requires more

inspection
Machines More automated Less use
machines used
PRODUCT FOCUSED LAYOUT
 It is a straight line layout
 It is also called Assembly line Layout or Continuous
Production System
 The flow of manufacturing is streamlined
 In this system the product passes through all the machines in a
sequence
 It is single product oriented appropriate for standardized
product and for large volume-less variety production
 Raw materials are also standardized
 Products are made for anticipated demand rather than for
orders
 E.g. Bottling of beverages, car manufacture, cafeteria, Fast
food restaurants, chocolate manufacturing, electronic
products, sugar, customer served in a queue, television sets,
pencils, and computers, automatic carwash.
 ROTARY MOULDER

COOLING CONVEYOR
MANUFACTURING PROCESS FOR BISCUITS

RAW MATERIAL MIXING MOULDING

TESTING

BAKING

COOLING

PACKING
Process of Blending
 Washing process
 Grading of oranges
 Juice extractors
Types of Product Focused Layout
 MASS PRODUCTION SYSTEM
 It is also called Discreet Unit Manufacturing
 It combines several raw materials to produce the
end product
 PROCESS MANUFACTURING
 It is an extended form of Mass Production
 Only one raw material is processed to get the end
product i.e. finished product of one process is
used as raw material in next process
 very high volume of non discrete, highly
standardized output is desired
 No variety in output
 E.g. Petroleum refining, heavy chemical
industries, steel, sugar, flour, and salt
PRODUCT FOCUSED LAYOUT
Advantages:
(1) Low total flow time of the product from the input stage to the
output stage (i.e. higher rates of output/productivity) due to:
(a) Continuous flow without intermediate stoppages and
storages;
(b) Repetitive, small, fragmented jobs learnt to perfection by
the concerned workers; and
(c) Minimum set-up times of machines.
(2) Lesser inspection required
(3) Lower degrees of skills in the manpower
(4) Lower work-in-process inventories
(5) Production promptly
(6) No bottlenecks in production
Disadvantages:
(1) None or very little variety possible.
(2) Inflexibility
(3) Entire line or significant portions of the line may come to a
grinding halt if any equipment in the line breaks down,
resulting in high stoppage costs.
(4) Larger maintenance crew needed.
(5) Very low job variety and therefore lower job satisfaction
and higher boredom for the workers.
(6) More coordination required by supervisors.
(7) Duplication of machines and equipments may be necessary
resulting in higher capital investment.
(8) More space may be required.
(9) Additional output not possible
PROCESS FOCUSED LAYOUT
 It is also called Functional Layout or Intermittent Production
system
 Production is done for customers orders rather than forecasted
demand i.e. customized products are produced
 Components are made for inventory and combined for different
customers differently
 The machines and equipments of similar types are grouped
together and placed in one area
 Product here is given secondary consideration and process has
dominance
 Sequence of production process is as per requirement of each
individual product i.e. no single sequence of operations follow
 This layout can produce different variety of products in
relatively small batches
 E.g. Airplanes, Medicines, Hospitals, Banks, Fashion House
Process focused layout :

Hospital

A B C
Radiology Laboratory Lobby &
Waiting

D E F
Examining Surgery & Physical
Rooms Recovery Therapy
 Patient A - broken leg
ER triage
room
Emergency room admissions

Surgery Patient B - erratic heart

pacemaker

Laboratories

Radiology ER Beds Pharmacy Billing/exit

Types of Process Focused Layout
 JOB PRODUCTION
 Production is according to customers orders

 Very rarely the orders are similar

E.g. Tailor-made clothes, Airplanes, Restaurant food

 BATCH PRODUCTION

 It is an extension of Job production

 It has medium scale production

 Items are produced in Batches

 E.g. Medicines, Cosmetics, Bakeries which make
bread, cakes, or cookies in batches, Movie theaters,
which show movies to groups (batches) of people,
PROCESS FOCUSED LAYOUT
Advantages:
(1) Very high degree of variety in products is possible.
(2) Greater flexibility
(3) Machine breakdowns do not cause crippling production
stoppages.
(4) Requires small maintenance crew.
(5) Good level of variety, skills requirement and therefore
higher job satisfaction.
(6) Effective supervision
(7)Low capital investment
(8) Easy expansion
Disadvantages:

(1) Production planning and control is more complex

(2) Frequency of inspection
(3) Larger processing time
(4) Higher work-in-process inventories
(5) More handling of materials
(6) Wasteful backtracking
CELLULAR OR GROUP TECHNOLOGY LAYOUT

 It includes both the advantages of process & product

layouts
 Machines are placed in a group
 Each machine cluster or cell makes a family of parts

or components which needs near identical processing

Advantages:
1. Reduced material-handling costs
2. Quick manufacturing
3. Reduced In-Process inventory
4. More automated production
Disadvantages:
1. Lower manufacturing facility
FIXED POSITION LAYOUT
 It is generally employed in large project types of
organizations
 Product manufactured is very bulky and hard to move
 Production remains stationery
 Men, machine, materials are brought to construction site
 E.g. Ships, Airplanes, buildings construction
Advantages:
 Less investment in layout
 Avoidance in transportation of bulky materials

HYBRID LAYOUT
 It is a combination of several layouts
COMPARITIVE STUDY OF DIFFERENT LAYOUTS

 Manufacturing Cost
Highest 1) Job Production
2) Batch Production
3) Mass Production
Lowest 4) Process Production
 Size & Capital Investment
Highest 1) Process Production
2) Mass Production
3) Batch Production
Lowest 4) Job Production
 Variety

Highest 1) Job Production

2) Batch Production
3) Mass Production
Lowest 4) Process Production
 Technical Ability

Highest 1) Job Production

2) Batch Production
3) Process Production
Lowest 4) Mass Production