Facility Layout Planning and Design

Chapter 11

Sections:
1. Types of Production Plant Layouts
2. Other Types of Layouts
3. Systematic Layout Planning

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Facility Layout
Refers to the size and shape of a facility as well as
the relative locations and shapes of the
functional areas (e.g., departments), equipment,
workstations, storage spaces, aisles, and
common areas (e.g., restrooms)
Concerned with problems of
Laying out a new facility
Making changes in an existing facility
Also called plant layout
Usually associated with production plants
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Objectives in Layout Planning

Efficient movement of materials and people

Logical work flow and minimum travel distances
Efficient utilization of space
Safety and satisfaction of those who use the
facility
Flexibility to meet changing future requirements
Advancing the operational mission of the facility

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Types of Production Plant Layouts

1.
2.
3.

Process layout
Product layout
Fixed-position layout
Also: Hybrids of the three basic types

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Important Factors in Plant Layout

Q = production quantity - number of units of a
given part or product that the facility produces
Low production - 1 to 100 units
Medium production - 100 to 10,000 units
High production - 10,000 to millions of units
P = product variety - number of different
product designs or types made in the plant

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

P - Q Relationship in Plant Layout

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Process Layout
Layout in which equipment is arranged according to
function
Suited to low and medium production quantities
and medium to high product variety
Different parts or products are processed
through different operations in batches
Each batch follows its own routing
No common work flow followed by all work
units
Material handling activity is significant
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Process Layout

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Product Layout
Layout in which workstations and equipment are
located along the line of flow of the work units
Suited to high production quantities and low
product variety
Work units typically moved by powered
conveyor
At each workstation, a small amount of the total
work content is accomplished on each work unit
Each station specializes in its task, thus
achieving high efficiency
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Product Layout for Assembled Product

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Comparisons
Feature
Annual Q
Product variety
Production rate
Efficiency
Labor skill
Work-in-process
Equipment
Advantages
Disadvantages

Process Layout
Low or medium
Medium to high
Low
Low
Skilled
High WIP
General purpose
Versatility to deal
with product variety
Low production rate
Batch production

Product Layout
High
Low
High
High
Unskilled
Lower WIP
Special purpose
High production rate
High efficiency
Risk of obsolescence
Limited variety

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Fixed-Position Layout
Layout in which product remains in one location
during fabrication, and workers and equipment
are brought to the product
Suited to low production quantities and high
product variety
Reason for keeping product in one location:
Product is big and heavy
Typical plants: assembly and fabrication
Much manual labor
Equipment is portable or mobile
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Fixed-Position Layout

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Hybrid Layouts
Cellular - attempts to combine the best features
of process and product layouts
Combinations of fixed position and either
Process layout or
Product layout

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Cellular Layout
Layout in which work units flow between stations,
as in a production line, but each station can cope
with a variety of part styles without the need for
time-consuming changeovers
Combination of product and process layouts
Tries to combine efficiency of product layout
with versatility of process layout
Neither objective is achieved perfectly, but
it is more efficient than a process layout
and more versatile than a product layout
Based on principles of group technology
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Cellular Layout

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Other Combination Layouts

Fixed-position and process layout
Shipyard - ships made in modules
Parts fabricated in process layout
Modules built in fixed-position layout
Fixed-position and product layout
Commercial airplanes (e.g., Boeing 747)
Fabrication begins with fuselage and
proceeds through 7 or so stations where
specialized workers assemble parts and
modules to airplane
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Layout Types for P-Q Combinations

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Other Types of Layouts

Warehouses
Projects
Service facilities
Offices

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Space Requirements
4. If workload for station i consists of multiple
parts or products,

WLi = QijTcij
where Qij = quantity of part type j, Tcij =
cycle time of part type j
5. Determine total area required for each
workstation type
TAi = niAi

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Space Requirements
6. Determine total are in each department by
summing areas for all station types in that
department

DAk = TAi
where DAk = area of department k and
summation is carried out over all
workstation types in department k

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Step 6. Space Relationship Diagram

Extension of activity relationship diagram in which
nodes representing departments are now
assigned areas that are proportional to areas
calculated in previous step
Shapes of nodes may be changed to fit the
nodes into the diagram (e.g., use rectangular
blocks rather than round nodes)
But relative positions of blocks remain as in
the last iteration of the activity relationship
diagram

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Space Relationship Diagram

Same diagram as
before but block
sizes are
proportional to
areas

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.