Facilities

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Objectives of Facility Layout

Minimize material handling costs
Utilize space efficiently
Utilize labor efficiently
Eliminate bottlenecks
Facilitate communication and interaction
between workers, between workers and
their supervisors, or between workers and
customers
Reduce manufacturing cycle time or
customer service time
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Objectives of Facility Layout

Eliminate waste or redundant movement
Facilitate the entry, exit, and placement of
material, products, or people
Incorporate safety and security measures
Promote product and service quality
Encourage proper maintenance activities
Provide a visual control of operations or
activities
Provide flexibility to adapt to changing
conditions
Increase capacity
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Basic Types of Layouts

Process Layout / Functional Layout
Machines grouped by process they perform

Product Layout
Linear arrangement of workstations to
produce a specific product

Fixed Position Layout

Used in projects where the product cannot
be moved

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Process Layout in Services

Womens
lingerie

Shoes

Housewares

Womens
dresses

Cosmetics
and jewelry

Childrens
department

Womens
sportswear

Entry and
display area

Mens
department

Figure 5.1
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Manufacturing Process Layout

Lathe Department

Milling
Department

Grinding
Department
Receiving and
Shipping

Figure 5.2

Drilling Department

Painting Department

Assembly

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Manufacturing Process Layout

Lathe Department

Milling
Department

Grinding
Department
Receiving and
Shipping

Figure 5.2

Drilling Department

Painting Department

Assembly

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Manufacturing Process Layout

Lathe Department

Milling
Department

Grinding
Department
Receiving and
Shipping

Figure 5.2

Drilling Department

Painting Department

Assembly

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A Product Layout
In

Out
Figure 5.3
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Comparison Of Product
And Process Layouts
PRODUCT LAYOUT
1. Description
2. Type of Process

3. Product
4.
5.
6.
7.

Demand
Volume
Equipment
Workers

Sequential arrangement
of machines
Continuous, mass
production, mainly
assembly
Standardized
made to stock
Stable
High
Special purpose
Limited skills

PROCESS LAYOUT
Functional grouping
of machines
Intermittent, job shop
batch production,
mainly fabrication
Varied,
made to order
Fluctuating
Low
General purpose
Varied skills

Table 5.1
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Comparison Of Product
And Process Layouts
8. Inventory
9. Storage space
10. Material
handling
11. Aisles
12. Scheduling
13. Layout decision
14. Goal
15. Advantage

PRODUCT LAYOUT

PROCESS LAYOUT

Low in-process,
high finished goods
Small
Fixed path
(conveyor)
Narrow
Part of balancing
Line balancing
Equalize work at
each station
Efficiency

High in-process,
low finished goods
Large
Variable path
(forklift)
Wide
Dynamic
Machine location
Minimize material
handling cost
Flexibility

Table 5.1
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Fixed-Position Layouts
Typical of projects
Equipment, workers, materials, other
resources brought to the site
Highly skilled labor
Often low fixed
Typically high variable costs

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Fixed-Position Layouts
Typical of projects
Equipment, workers,
materials, other
resources brought to
the site
Highly skilled labor
Often low fixed
Typically high
variable costs

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Service Layouts
Usually process layouts due to
customers needs
Minimize flow of customers or
paperwork
Retailing tries to maximize customer
exposure to products
Computer programs consider shelf
space, demand, profitability
Layouts must be aesthetically pleasing
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Designing Product Layouts

Product layouts or assembly lines
Develop precedence diagram of
tasks
Jobs divided into work elements
Assign work elements to
workstations
Try to balance the amount work of
each workstation
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Hybrid Layouts
Cellular layouts
Group machines into machining cells

Flexible manufacturing systems

Automated machining & material
handling systems

Mixed-model assembly lines

Produce variety of models on one line

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Cellular Layouts
1. Identify families of parts with
similar flow paths
2. Group machines into cells
based on part families
3. Arrange cells so material
movement is minimized
4. Locate large shared machines
at point of use

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Parts Families

A family of
similar parts

A family of related
grocery items

Figure 5.7
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Original Process Layout

Assembly

7
8

5
2

12

10
3

11
Raw materials

Figure 5.8
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Revised Cellular Layout

Assembly
8

10

12
11

Cell 1

Cell 2

Cell 3
7

A B C
Raw materials
Figure 5.9
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Advantages Of
Cellular Layouts
Reduced material handling and transit time
Reduced setup time
Reduced work-inprocess inventory
Better use of human
resources
Easier to control
Easier to automate
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Flexible Manufacturing
Systems
Automated machining operations
Automated material handling
Automated tool changers
Computer controlled system
Designed around size of parts processed
& average processing time for parts
Can process wide variety of items quickly
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FMS Layouts

Figure 5.12

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FMS Layouts

Figure 5.12

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