Facility layoutFacility layout

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ContentsContents

1- What is Facility layout?1- What is Facility layout?2- Importance of layout decision.2- Importance of layout decision.3- Characteristics of a good layout3- Characteristics of a good layout4- Types of manufacturing layout.4- Types of manufacturing layout.5- Service layout.5- Service layout.

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1-What is facility layout?1-What is facility layout?

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1- What is facility layout?1- What is facility layout?

A layout is the physical A layout is the physical configuration of :-departments, configuration of :-departments, work stations, and equipment . work stations, and equipment .

It is the spatial arrangement of It is the spatial arrangement of physical resources used to physical resources used to create the product. create the product.

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2- Importance of layout 2- Importance of layout decisiondecision

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2- Importance of layout decision2- Importance of layout decision The need for layout planning arises both in the process The need for layout planning arises both in the process

of designing new facilities and in redesigning existing of designing new facilities and in redesigning existing facilities.facilities.

Layout decisions are important for three basic Layout decisions are important for three basic reasons:reasons:

1-They may require substantial investments of money and 1-They may require substantial investments of money and efforteffort

2-They may involve long-term commitments, which makes 2-They may involve long-term commitments, which makes mistakes difficult to overcomemistakes difficult to overcome

3-They may have significant impact on the cost , efficiency 3-They may have significant impact on the cost , efficiency and productivity of operationsand productivity of operations

In briefIn brief, layout decisions tend to be:-, layout decisions tend to be:- InfrequentInfrequent Expensive to implementExpensive to implement Studied and evaluated extensivelyStudied and evaluated extensively Long-term commitmentsLong-term commitments

3- Characteristics of a good layout3- Characteristics of a good layout

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3-Some characteristics of a good layout 3-Some characteristics of a good layout

Reduces bottlenecks in moving people or Reduces bottlenecks in moving people or material.(material.(If the rate at which each processing area handles work is If the rate at which each processing area handles work is unbalanced, or one area is slower or has stopped working due to problems unbalanced, or one area is slower or has stopped working due to problems with equipment, materials, or people)with equipment, materials, or people)

Minimizes materials-handling Minimizes materials-handling costs,costs, and and minimize minimize delaysdelays in material handling in material handling

Reduces Reduces hazardshazards to personnel. to personnel. UtilizesUtilizes available labor and space available labor and space effectivelyeffectively and and

efficiently.efficiently. Provides Provides flexibility.flexibility. Provides ease of Provides ease of supervision.supervision. Facilitates coordination and face-to-face communication Facilitates coordination and face-to-face communication

where appropriate.where appropriate.

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4- Types of manufacturing 4- Types of manufacturing layoutlayout

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Types of manufacturing layoutTypes of manufacturing layout

Manufacturing plants use three basicthree basic typestypes of layout:

(a) Product layout, (a) Product layout,

(b) Process layout, and (b) Process layout, and

(c) Fixed-position layout(c) Fixed-position layout.. In addition, there is one hybrid that is referred to

as a group technology or cellular layout,group technology or cellular layout, which is a combination of process and product layout.

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Types of manufacturing layoutTypes of manufacturing layout

Product Layout:-Product Layout:-linear arrangement of workstations to produce a specific product- used for repetitive processingused for repetitive processing

Process Layout:- Process Layout:- (job-shop layout or layout by(job-shop layout or layout by function)function) machines grouped by process they perform- used for intermittent processingused for intermittent processing

Fixed Position Layout:-Fixed Position Layout:-used in projects where the product cannot be moved- used when projects require special layoutused when projects require special layout

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Types of manufacturing and service operations:-Types of manufacturing and service operations:-Two types of operations:-

Intermittent Intermittent operationsoperations

Repetitive (continuous) Repetitive (continuous) operationsoperations

made- to- order productsmade- to- order products Standardized products made -to- stockStandardized products made -to- stock

low product volumelow product volume high volumehigh volume

labor -intenselabor -intense capital -intensecapital -intense

large product mixlarge product mix small product mixsmall product mix

general purpose general purpose equipmentequipment

special purpose equipmentspecial purpose equipment

interrupted product flowinterrupted product flow continuous product flowcontinuous product flow

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Layout types

(a) Process Layout(a) Process Layout

FoundryMilling

machines

LathesGrinding

Painting Drills

Office

Welding

Forging

(b) Product Layout(b) Product Layout

Station 1 Station 2 Station 3 Station 4

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Product layoutProduct layout

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Product layoutProduct layout- Product layout is appropriate for producing one standardize one standardize product , product ,

usually in usually in large volumelarge volume. (. (Without high standardization , many of Without high standardization , many of the benefits of repetitive processing are lostthe benefits of repetitive processing are lost))

Each unit of output requires the same sequence of operations from beginning to end.

- Work centers and equipment are arranged in a line to afford Work centers and equipment are arranged in a line to afford specialized sequence of tasks.specialized sequence of tasks.

Each work center performs one highly specializedone highly specialized part of the total product buildup sequence .

The work is divided into a series of standardized tasks, The work is divided into a series of standardized tasks, permitting specialization of labor and equipmentpermitting specialization of labor and equipment

The large volumeslarge volumes handled by these systems usually make it economical to invest substantial sums of invest substantial sums of moneymoney in equipment and job design

Automatic car washes, cafeterias (where a customer's tray moves through a series of stations to assemble the components of a meal ) , automobile makers, and soft drink use product layout.

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1- Achieve a high degree of labor and equipment utilization, high degree of labor and equipment utilization, (High rate of outputHigh rate of output )which tends to offset their high equipment cost.

2- Because items move quickly from operation to operation, the amount of work-in-process is often minimalwork-in-process is often minimal

3-Low unit cost3-Low unit cost4- Labor specialization-4- Labor specialization- reduces training costs and time and

results in a wide span of supervision 5- 5- Material handling is simplifiedMaterial handling is simplified because units follow the same same

sequence of operationssequence of operations6-Routing and scheduling which are established in the initial design of

the system( they do not require much attention once the they do not require much attention once the system is operating)system is operating)

7-RoutineRoutine accounting, purchasing and inventory control8-Short unit- production timeShort unit- production time,9- Low labor-skill Low labor-skill requirements .

Product layout advantagesProduct layout advantages

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Product layout disadvantagesProduct layout disadvantages 1- A 1- A breakdown breakdown in one machine can cause an in one machine can cause an entire production line to entire production line to

shut down shut down (operations are so closely tied to each other that the entire (operations are so closely tied to each other that the entire system is highly vulnerable to being shut down because of mechanical system is highly vulnerable to being shut down because of mechanical failure or high absenteeism )failure or high absenteeism )

2- Since the layout is determined by the product, 2- Since the layout is determined by the product, a change in product a change in product design design or the introduction of new products may require or the introduction of new products may require major major changes in the layoutchanges in the layout; thus ; thus flexibility can be limited flexibility can be limited

3- The jobs in a product –layout facility, such as those on mass 3- The jobs in a product –layout facility, such as those on mass production line, may provide production line, may provide littlie job satisfactionlittlie job satisfaction. .

This primary because of the This primary because of the high level of division of labor often required, which usually results in monotony (The intensive , which usually results in monotony (The intensive division of labor usually creates dull, repetitive jobs that provide little division of labor usually creates dull, repetitive jobs that provide little opportunity for advancement and may lead to morale problems and to opportunity for advancement and may lead to morale problems and to repetitive stress injuries)repetitive stress injuries)

4- Needs 4- Needs preventive maintenance preventive maintenance (preventive maintenance- periodic (preventive maintenance- periodic inspection and replacement of worn parts or those with high failure rate –inspection and replacement of worn parts or those with high failure rate –reduce the probability of breakdowns during operations)reduce the probability of breakdowns during operations)

5- Large investments5- Large investments: special-purpose equipment: special-purpose equipment

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Product LayoutProduct Layout

IN

OUT

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Process layoutProcess layout

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Process layoutProcess layout A process layout consists of a functional A process layout consists of a functional

grouping of machines or activities that do grouping of machines or activities that do similar work. similar work.

For example , all drills presses may be grouped together in one For example , all drills presses may be grouped together in one department, and all milling machines in another.department, and all milling machines in another.

Depending on the processing they require, Depending on the processing they require, parts may parts may moved in different sequences among departments moved in different sequences among departments

( A part being worked on travel from one area to the next, ( A part being worked on travel from one area to the next, according to the specific sequence of operations required) according to the specific sequence of operations required)

This type of layout often found This type of layout often found in high-mix, low-volume manufacturing plants plants that use an intermittent process. that use an intermittent process.

Process layout are designed to process Process layout are designed to process items or provide servicesitems or provide services that that

involve involve a variety of processing requirementsof processing requirements. . The variety of jobs that are processed required frequent adjustments to

equipment. This causes discontinuous work flow which is referred to as intermittent

processing.

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Process layoutProcess layout Process layout are quite Process layout are quite common in service common in service

environment. environment. Examples include hospital, universities, banks, auto Examples include hospital, universities, banks, auto

repair shops, airlines, and public libraries.repair shops, airlines, and public libraries. Universities Universities have separate schools or departments have separate schools or departments

that that concentrate on one area of studyconcentrate on one area of study such as such as business , engineering, science or math.business , engineering, science or math.

A hospitalA hospital provides a good example of a process provides a good example of a process layout in the service sector; customers (patients) go to layout in the service sector; customers (patients) go to Radiology for X-rays and to the lab for blood tests .Radiology for X-rays and to the lab for blood tests .

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Process layoutProcess layout

Process Layout - work travels to dedicated process centers

Milling

Assembly& Test Grinding

Drilling Plating

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Process layout Process layout advantagesadvantages1- 1- Compared to product layout, process layout generally require a Compared to product layout, process layout generally require a

lower investment in equipment lower investment in equipment ((General General ––purpose purpose equipment used is often less costly than the specialized equipment used is often less costly than the specialized equipment used in product layout and is easier and less costly to equipment used in product layout and is easier and less costly to maintain)maintain)

2- The 2- The diversity of jobsdiversity of jobs inherent process layout can lead to inherent process layout can lead to increased working satisfaction increased working satisfaction .(Diversity of tasks: .(Diversity of tasks: changing work assignments make work more satisfying for changing work assignments make work more satisfying for people who prefer variety.)people who prefer variety.)

3- 3- Because items are often processed in lots (batches) Because items are often processed in lots (batches) there is considerablythere is considerably less interdependence between less interdependence between successive operations than with a product layout. successive operations than with a product layout.

4- 4- Maintenance costs tend to be lowerMaintenance costs tend to be lower because the equipment because the equipment is less specialized than that of product layout, is less specialized than that of product layout,

5- 5- Flexibility: Flexibility: equipment and personnel can be used where they equipment and personnel can be used where they are needed + The systems can handle a variety of processing are needed + The systems can handle a variety of processing requirements)requirements)

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Process layout disadvantagesProcess layout disadvantages1- 1- In-process inventory In-process inventory costs can be high if batch processing is used in costs can be high if batch processing is used in

manufacturing systemsmanufacturing systems

2- 2- routing and scheduling pose continual Challengesrouting and scheduling pose continual Challenges

3- 3- Equipment utilization rates Equipment utilization rates are low (It is not uncommon for such systems to are low (It is not uncommon for such systems to

have equipment utilization rate under 50 percent because of routing and scheduling have equipment utilization rate under 50 percent because of routing and scheduling

complexities related to the variety of processing demands being handled)complexities related to the variety of processing demands being handled)

4- 4- Material handling slow and inefficientMaterial handling slow and inefficient , and more costly per unit than in , and more costly per unit than in

product layoutproduct layout

5- 5- Job complexities often reduce span of supervision Job complexities often reduce span of supervision and result in higher and result in higher

supervisory costs than with product layoutsupervisory costs than with product layout

6- 6- Special attention necessary for each product or customerSpecial attention necessary for each product or customer ( e.g., routing, ( e.g., routing,

scheduling machine setups) and low volumes result in higher unit cots than with scheduling machine setups) and low volumes result in higher unit cots than with

product layoutproduct layout

7- Accounting, inventory control and purchasing 7- Accounting, inventory control and purchasing are much more involved than are much more involved than

with product layoutwith product layout

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Fixed-position layoutFixed-position layout

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Fixed-position layoutFixed-position layout Layout in which the product or project Layout in which the product or project

remains stationary, and workers, materials, remains stationary, and workers, materials,

and equipment are moved as needed and equipment are moved as needed .. MoveMove machines and/or workers to the siteto the site;

products normally remains in one location for its entire manufacturing period.

ExamplesExamples:: Large construction projects (buildings, power

plants, dams)

Shipbuilding, production of large aircraft

Rockets used to launch space missions

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Disadvantages of fixed Disadvantages of fixed position layoutposition layout

Since the same workers are involved in more Since the same workers are involved in more operations, operations, skilled and versatile workers skilled and versatile workers are required. are required.

The necessary combination of skills may be The necessary combination of skills may be difficult difficult to find and high pay levels may be necessary.to find and high pay levels may be necessary.

Movement of people and equipment to and from the Movement of people and equipment to and from the work site may work site may be expensive.be expensive.

Equipment Equipment utilization may be low utilization may be low because the because the equipment may be left at a location where it will be equipment may be left at a location where it will be needed again in a few days needed again in a few days rather than moved to rather than moved to another location where it would be productive.another location where it would be productive.

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Fixed position layoutFixed position layout

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5 - Service layout5 - Service layout

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Types of service Types of service layoutlayout We use the three basic types of manufacturing facility

layout that were described earlier this chapter as a framework for identifying the types of layout that are used in operations.

1- Process Layout: The support services for an emergency room in a The support services for an emergency room in a

hospital offer a good example of a process layout, hospital offer a good example of a process layout, with radiology, blood analysis, and the pharmacy with radiology, blood analysis, and the pharmacy each being located in a specific area of the hospital.each being located in a specific area of the hospital.

Patients requiring any of these specific Patients requiring any of these specific services therefore must go to the locations services therefore must go to the locations where they are provided. where they are provided.

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Types of service Types of service layoutlayout 2- Product layout:

A good service example of a product layout is a cafeteria line where all of the stations (for example, salads, hot and cold entrees, desserts, and beverages) are arranged in a specific are arranged in a specific order, and customers visit each station as they move order, and customers visit each station as they move through the line. through the line.

3- Fixed-Position Layout: Examples of fixed-position layout in services include Examples of fixed-position layout in services include (A) an automobile repair shop (where all of the processes such as brake (A) an automobile repair shop (where all of the processes such as brake

repair, oil change, etc., typically take place in the same location), repair, oil change, etc., typically take place in the same location), (B) an operating room in a hospital (where the patient remains in a given (B) an operating room in a hospital (where the patient remains in a given

location on the operating table), and location on the operating table), and (C) a table at a restaurant where all of the different courses in a meal are (C) a table at a restaurant where all of the different courses in a meal are

brought to the customer (and in some cases even prepared at the table in brought to the customer (and in some cases even prepared at the table in front of the customer). front of the customer).