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LAYOUT
FACILITY LAYOUT
It is refers to the arrangement of machinery, equipment and other
industrial facilities- such as receiving & shipping departments,
tool rooms, maintenance rooms and employee amenities- for the
purpose of achieving the quickest and smoothest production at
the least cost
Layout planning in manufacturing & service organizations deals
with the physical arrangement of various resources that are
available in the system with an objective to improve the
performance of the operating system, thereby providing better
customer service
A good layout design ensures that a vast majority of jobs in a
manufacturing system travel shortest distances possible to ensure
shortest processing time.
IMPORTANCE OF A LAYOUT
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
DIFFERENCES BETWEEN PRODUCT AND PROCESS
FOCUSSED LAYOUTS
PRODUCT LAYOUT PROCESS LAYOUT
COOLING CONVEYOR
MANUFACTURING PROCESS FOR BISCUITS
BAKING
COOLING
PACKING
Process of Blending
Washing process
Grading of oranges
Juice extractors
Types of Product Focused Layout
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 Production
Only one raw material is processed to get the end
product i.e. finished product of one process is
used as raw material in next process
very high volume of non discrete, highly
standardized output is desired
No variety in output
E.g. Petroleum refining, heavy chemical
industries, steel, sugar, flour, and salt
PRODUCT FOCUSED LAYOUT
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 by
the 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
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) Duplication of machines and equipments may be necessary
resulting in higher capital investment.
(8) More space may be required.
(9) Additional output not possible
PROCESS FOCUSED LAYOUT
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
Process focused layout :
Hospital
A B C
Radiology Laboratory Lobby &
Waiting
D E F
Examining Surgery & Physical
Rooms Recovery Therapy
Patient A - broken leg
ER triage
room
Emergency room admissions
Laboratories
HYBRID LAYOUT
It is a combination of several layouts
COMPARITIVE STUDY OF DIFFERENT LAYOUTS
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
Variety