03 Sisprod - Layout Types

8/11/2019 03 Sisprod - Layout Types

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LAYOUT TYPESAYOUT TYPES

Presentasi KuliahTKI-313 Sistem Produksi

Jurusan Teknik Universitas Muhammadiyah Surakarta

Dosen : Much Djunaidi


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Product layouts

Process layouts

Basic Layout TypesBasic Layout Types

Fixed-Position layout

Combination layouts


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Product layout Layout that uses standardized processing

operations to achieve smooth, rapid, high-

volume flow

Basic Layout TypesBasic Layout Types

Layout that can handle varied processing

requirements

Fixed Position layout Layout in which the product or project

remains stationary, and workers, materials,and equipment are moved as needed


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Raw

materials

or customer

Finished

item

Station

2

Station

3

Station

4

Station

1

Product LayoutProduct Layout

6-4

Material

and/or

labor

Material

and/or

labor

Material

and/or

labor

Material

and/or

labor

Used for Repetitive or Continuous Processing


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High rate of output

Low unit cost

Labor specialization

Advantages of Product LayoutAdvantages of Product Layout

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Low material handling cost

High utilization of labor and equipment

Established routing and scheduling

Routing accounting and purchasing


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Creates dull, repetitive jobs

Poorly skilled workers may not maintain

equipment or quality of output

Disadvantages of Product LayoutDisadvantages of Product Layout

6-6

Highly susceptible to shutdowns

Needs preventive maintenance Individual incentive plans are

impractical


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1 2 3 4

5

In

Figure 6.6

A UA U--Shaped Production LineShaped Production Line

6-7

6

78910Out

Workers


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Work

Station 1

Work

Station 2

Work

Station 3

Figure 6.7 (contd)

Product Layout(sequential)

Product LayoutProduct Layout

6-8

Used for Repetitive ProcessingRepetitive or Continuous Processes


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Dept. A Dept. C Dept. E

Process Layout(functional)

Figure 6.7

Process LayoutProcess Layout

6-9

Dept. B Dept. D Dept. F

Used for Intermittent processing

Job Shop or Batch Processes


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Can handle a variety of processingrequirements

Not particularly vulnerable to equipment

failures

Advantages of Process LayoutsAdvantages of Process Layouts

6-10

Equipment used is less costly

Possible to use individual incentive

plans


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In-process inventory costs can be high

Challenging routing and scheduling

Equipment utilization rates are low

Disadvantages of ProcessDisadvantages of Process

LayoutsLayouts

6-11

a er a an ng s ow an ne c en

Complexities often reduce span of

supervision Special attention for each product or

customer

Accounting and purchasing are more


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Fixed Position LayoutsFixed Position Layouts

Fixed Position Layout: Layout in which theproduct or project remains stationary, and

workers, materials, and equipment are

moved as needed.

6-12

Nature of the product dictates this type of

layout

Weight

Size

Bulk

Large construction projects


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Cellular Production

Layout in which machines are grouped into

a cell that can process items that have

similar processing requirements

Cellular LayoutsCellular Layouts

Group Technology

The grouping into part families of items with

similar design or manufacturingcharacteristics


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Dimension Functional Cellular

Number of moves

between departments

many few

Travel distances longer shorter

Travel paths variable fixed

Table 6.3

Functional vs. Cellular LayoutsFunctional vs. Cellular Layouts

o wa ng mes grea er s or er

Throughput time higher lower

Amount of work in

process

higher lower

Supervision difficulty higher lower

Scheduling complexity higher lower

Equipment utilization lower higher


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Warehouse and storage layouts Retail layouts

Office layouts

Service la outs must be aestheticall

Service LayoutsService Layouts

pleasing as well as functional


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Information Requirements:1. List of departments

2. Projection of work flows

Designing Process LayoutsDesigning Process Layouts

4. Amount of money to be invested

5. List of special considerations

6. Location of key utilities


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30

Example 3: Interdepartmental Work FlowsExample 3: Interdepartmental Work Flows

for Assigned Departmentsfor Assigned Departments

1 3 20

A B C


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Milling

Assembly

& Test Grinding

Process LayoutProcess Layout

Process Layout - work travels

to dedicated process centers

Drilling Plating


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Mill Drill Grind

222

444

222

111

444

222

3333

Functional LayoutFunctional Layout

Gear

cutting

LathesHeat

treat

111

333

111 333

111

444

111


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-1111 -1111

222222222 - 2222b

l

Lathe Mill

Mill

Drill

Drill

Heat

treat

Heat

treat

Gear

cut

Grind

Cellular Manufacturing LayoutCellular Manufacturing Layout

Asse

3333333333 - 3333

44444444444444 - 4444

Lathe Mill

Mill Drill

Heat

treat

Gear

cut

Grind

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03 Sisprod - Layout Types