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LAY OUT

Layout is a physical configuration ofworkstation facilities for operations. It is a

spatial arrangement of physical resourcesused for producing a product or providing

service

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Need for lay out

When new facilities are created or added

Rearrangement of existing facilities due to

inefficiency, accidents, legal requirements Business Process Reengineering

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Principles of lay out

Minimum movement/transportation

Integrated work flow

Safety Ambience

Flexibility

Space utilization Cost minisation

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Types of lay out

Basically there are 2 types of processes

depending on flow of work

1) Flow process (oil refining, milk Dairy 2) Discrete (car, bike,TV,book)

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Types of lay out for discrete

process

product lay out

Process lay out

Combination lay out Fixed position lay out

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Product lay out

Product layout ( line layout, sequential

layout, mass production layout)

Ex car, bike ,bread

Dissimilar equipments are grouped

together in a line to manufacture a product

in a series of steps

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Advantages of product lay out

High rate of out put

Low unit cost

High utilization of equipment Low material handling cost

Routing & scheduling built in

Employee specialization Skill requirement of employees low

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Disadvantages of product lay out

Dull, monotonous, repetitive work

Inflexibility to changes in design of product/

volume

Shut down of line due to failure of a work station,abseneeism

No resale value of dedicated equipments

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Process lay out

Similar facilities /equipments are grouped

together to produce a variety of

items/provide variety of service, but in

small volume

Ex: hospital, university, DTP centre, work

shop

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Advantages of process lay out Variety of products /service

Low volume

General purpose machines Multi function worker, with high skill level

No major impact due to failure of a work

station

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Disadvantages of process layout

High cost of product/service

Material handling cost high

Less utilization of workstations

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Types of process layout

Job shop (very high variety, volume can

be one unit) DIAGRAM

Batch production( medium volume

medium variety)

Group technology layout/Cellular

manufacturing DIAGRAM

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Fixed position lay out

Heavy products like ship, air craft

Materials, equipments tools are taken to

site

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Product -process matrix

Variety of out put vs volume of out put

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SINGLE PIECE FLOW U

SHAPED LAYOUT

EX: LUCAS TVS

Just in Time

workers move from work station to workstation and complete assembly

Multi function worker

Compact lay out. Efficient

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CRAFT (Computerized relative

allocation of facilities technique) Initial lay out is done

Distance matrix, load matrix & cost per unit are fedinto computer

Initial total cost is worked out . no ofloads*distance* cost per unit

It compares two work stations and exchanges if totalcost is reduced

Continues till no further improvements are possible

Does not give optimal solution