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LAYOUT
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` 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
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PRODUCT LAYOUT PROCESS LAYOUT
Description Sequential arrangement
of activities
Functional grouping of
activities
Product Standardized, Made to
stock products
Varied products, Made
to order
Demand Stable Fluctuating
Volume High Low
Equipment Special Purpose General Purpose
Workers Limited Skills Varied Skills
Inventory Low-In Process
High- Finished Goods
High-In Process
Low- Finished Goods
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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 automatedmachines used
Less use
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` It is a straight line layout
` It is also called Assembly line Layout or ContinuousProduction System
` The flow of manufacturing is streamlined
` In this system the product passes through all the machines in asequence
` It is single product oriented appropriate for standardizedproduct 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, andcomputers, automatic carwash.
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ROTARY MOULDER
COOLING CONVEYOR
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MANUFACTURING PROCESS FOR BISCUITS
RAW MATERIAL
TESTING
MIXING MOULDING
BAKING
COOLING
PACKING
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` Washing process
` Grading of oranges
` Juice extractors
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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 ProductionOnly one raw material is processed to get the end
product i.e. finished product of one process is used asraw material in next process
` very high volume of non discrete, highly standardized
output is desired` No variety in outputE.g. Petroleum refining, heavy chemical industries,
steel, sugar, flour, and salt
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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 bythe 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
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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)D
uplication of machines and equipments may be necessaryresulting in higher capital investment.
(8) More space may be required.
(9) Additional output not possible
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` 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
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Process focused layout :
Hospital
A
Radiology
B
Laboratory
C
Lobby &Waiting
DExamining
Rooms
ESurgery &Recovery
FPhysicalTherapy
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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,
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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 thereforehigher job satisfaction.(6) Effective supervision
(7)Low capital investment(8) Easy expansion
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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
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It includes both the advantages of process & productlayouts
Machines are placed in a group
Each machine cluster or cell makes a family of parts
or components which needs near identical processingAdvantages:
1. Reduced material-handling costs
2. Quick manufacturing
3. Reduced In-Process inventory4. More automated production
Disadvantages:
1. Lower manufacturing facility
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` 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
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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
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Variety
Highest 1) Job Production2) Batch Production
3) Mass Production
Lowest 4) Process Production
Technical AbilityHighest 1) Job Production
2) Batch Production
3) Process Production
Lowest 4) Mass Production
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