Types of Plant Layout

Layouts can be classified into the following

categories:

Types of Layout: Product Layout

v/s Process Layout

Process Layout
Product Layout
Combination Layout
Fixed Position Layout
Group Layout

Presented By:
Anupam Kumar
Reader
SMS Varanasi
E mail: anupamkr@gmail.com

Copyright 2013 Anupam Kumar

Copyright 2013 Anupam Kumar

Process Layout

Process Layout
Advantages:

In process layout:
All machines performing similar type of operations
are grouped together at one location.
Production volume remains limited.
The production happens in batches or lots.
A large variety of products can be produced from
the same plant.
Backtracking and long movements reduces the
material handling efficiency.
Space and capital are tied up in WIP inventory.
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Material handling cannot

be mechanized
Process time is
prolonged
Lower productivity due
to number of set-ups
Throughput time is
longer
Space & capital is tied up
by work in progress/
process.

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Product Layout
Advantages:

The product layout is selected when the

volume of production is high enough to justify
a separate production line.
In this type of layout, the machines and
auxiliary services are located according to the
processing sequence of the product.
The facilities are arranged to ensure efficient
flow of material and lower cost per unit.

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Disadvantages:

Machines are better

utilized and fewer
machines are required
Flexibility of equipment
& personnel is possible
Lower initial investments
Higher utilization of
production facility
Diversity of tasks makes
the work challenging &
interesting.

Product Layout

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Disadvantages:

Reduced material
handling activities.
Work In Process almost
eliminated.
Minimum manufacturing
time.
Simplification of the
production planning and
control systems.
Tasks simplification.

No flexibility in the
production process.
Low flexibility in the
manufacturing times.
High capital investment.
Every workstation is
critical to the process.The lack of personnel or
shut down of a machine
stops the whole process.
Monotonous work.

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Combination or Matrix Layout

Combination or Matrix Layout

A combination layout combines the advantages of

both the process and product layouts.
It is used when the same item is being manufactured
in different types or sizes.
In this, the machines are arranged in the process
layout format but process grouping is arranged in a
sequence.
The sequence of operation with each of the product
variety however remains the same.
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Fixed Position Layout

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Group Layout or Cellular Layout

This type of layout is suitable when one or a few

identical heavy items are to be manufactured.
The materials are kept fixed because the cost of
transportation of material is very high.
In this type of layout,

Group Layout is also a combination of Product and

Process Layout.
It identifies the families of components that require
similar types of requirements and machines which
are clubbed together as cells.
The cellular layout is also called a multi-objective
layout because this layout tries to minimize

the material or the major component remain fixed and

the tools, machinery, men and other materials move
around it.

The sum of the cost of transportation

The cost of equipment

This type of layout is also called project type layout.

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Copyright 2013 Anupam Kumar

Group (Cellular) Layout

ABC Electronics has a facility with six production areas.

It proposes to locate 6 departments (A,B,C,D,E,F), which have the
number of moves per day between departments as shown in the
table below.
What type of layout would be suitable for the facility?
Develop a layout for the facility.

A cluster
or cell
T

CG

CG

SG

SG

SG

CG

CG

M
M

M
M

Similar resources placed together

10

Layout Design

Group Layout or Cellular Layout

Process (Functional) Layout

T
M

SG

Resources to produce similar products

placed together

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11

10

B
C
D

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12
10

16

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Bibliography

For further details

Contact

Anupam Kumar
Reader
SMS Varanasi
E mail: anupamkr@gmail.com

Copyright 2013 Anupam Kumar

Copyright 2013 Anupam Kumar

13

Buffa, E.S. and Sarin, R.K., Modern Production/Operations Management, Eighth Edition.
Singapore: John Wiley & Sons (Asia). 1994.
Martinich, J.S., Production and Operations Management: An Applied Approach, Singapore: John
Wiley & Sons (Asia), 2003.
Badi, R.V. and Badi, N.V., Production and Operations Management, Second Edition, New Delhi:
Vrinda Publication, 2008.
Chary, S.N., Productions and Operations Management, Third Edition, New Delhi: Tata McGraw
Hill, 2004
Goel, B.S., Production Operations Management, Twenty Second Edition, Meerut, U.P.: Pragati
Prakashan, 2010.
Kachru, U. Production and Operations Management: Text and Cases, New Delhi: Excel Books,
2007.
Rama Murthy, P., Production and Operations Management, New Delhi: New Age International,
2012.
Chunawalla, S.A., and Patel, D.R., Production and Operations Management, Mumbai: Himalaya
Publishing House, 2006.
Jauhari, V. and Dutta, K., Services: Marketing Operations and Management, New Delhi: Oxford
University Press, 2010.
Verma, H.V., Services Marketing: Text and Cases, New Delhi: Dorling Kindersley, Pearson
Education, 2009.

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