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Facility Layout

Facility Layout
Refers to:- the arrangement of activities, processes, departments, workstations, storage
areas, aisles, and common areas within an existing or proposed production
or service facility
Objective of the layout decision: to ensure a smooth flow of work, material, people, and
information through the system
Determines:

PROFESSOR DR. MD. ARIFUL ISLAM The movement of materials, information, or customers
The efficiency of operations
The cost of handling and delays

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Layout- Why is the part of Strategic

Typical Layouts in Manufacturing Plant Decision?

Operating Costs
Production Speed
Worker Safety
Communication between Departments
Ability to respond to Demand Changes

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Objectives of a Good Facility Layout Types of Layout

A. Ensure smooth workflow 1. Fixed-position Layout

B. Minimize material handling and movement 2. Process Layout (Functional layout)
C. Use space, labor, and equipment efficiently 3. Product (line) Layout
D. Improve communication and supervision
4. Cellular Layout
E. Enhance safety and working conditions
F. Provide flexibility for future changes

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Fixed-position Layout Fixed Position Layout

Fixed-position layouts: typical of projects in which the product produced is too fragile, bulky, or
heavy to move…
Basic Characteristics:
The product remains stationary for the entire manufacturing cycle
Equipment, workers, materials, and other resources are brought to the production site
Equipment utilization is low
Worker skill requirement is high
Fixed cost is low; variable cost is high
Specialized to individual projects
Examples:
Ships, houses, and aircraft The fixed-position layout is also common for on-site services such as
Example: Boeing 787 Dreamliner housecleaning services, pest control, and landscaping.

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Process Layout Process Layout

Known as Functional Layouts

Characteristics:
Group similar activities together in departments or work centres according to the process or
function they perform
Intermittent operations, service shops, job shops, or batch production, which serve different
customers with different needs
The volume of each customer’s order is low
The sequence of operations required to complete a customer’s order can vary considerably

Examples: Hospitals (X-ray unit, Pathological Lab, Pharmacy); University (Departments);

Machine Shops

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Manufacturing Process Layout Process Layout- Service

Milling
Lathe Department Department Drilling Department
M M D D D D
L L

M M D D D D
L L

G G G P
L L

G G G P
L L
Grinding Painting Department
Department
L L
Receiving and A A A
Shipping Assembly

Copyright 2006 John Wiley & Sons, Inc. 7-11

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Process Layout Product (line) layout

Advantages:
Very flexible for different products or services
Can handle customized work
Equipment is often general-purpose, reducing investment risk

Disadvantages:
Long and irregular movement paths
Higher material handling costs
Complex scheduling
Higher work-in-process (WIP) inventory
Difficult to control workflow
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Example: Product Layout Product Layout

Characteristics:
Arrange activities in a line according to the sequence of operations
Workstations are arranged according to the sequence of operations required
Each unit follows the same path
Product layouts are suitable for mass production or repetitive operations
The product or service is made for a general market, not for a particular customer
Because of the high level of demand, product layouts are more automated
Workers perform narrowly defined assembly tasks that do not demand as high a
wage rate

Examples:
Automobile assembly lines; Bottling plants; Fast-food preparation lines

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Cellular Layout Cellular Layout

Cellular layout: groups
machines into cells, where
Advantages:
each cell produces a family of Shorter movement distances
similar products Faster production flow
Based on Group Technology: Reduced work-in-process inventory
identifies products with similar Improved teamwork and responsibility
processing needs Better quality control
Combination of:
The flexibility of process layout Disadvantages:
The efficient flow of product Possible duplication of equipment
layout
Requires careful analysis to form product families
May be less flexible than process layouts for extreme variety

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Mixed or Hybrid Layout Mixed/Hybrid Layout

A Mixed layout: combines elements of two or more basic layout
types within the same facility

Usage of hybrid Layouts:

Different departments perform different kinds of work
Some tasks need flexibility, others need high flow efficiency
Services especially require different layouts in different areas

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Comparison: Product vs Process Layout

Decision Product Layout Process Layout
Material handling
Description Sequential arrangement of activities Functional Grouping
Types of Process Continuous/ Mass Production Intermittent/ Job Shop/ Batch production
Product Standardized; Made to Stock Varied; Made to Order
Demand Relatively Stable Fluctuating
Volume High Low
Equipment Special purpose General purpose
Worker skill level Limited skills Varied skills; Multi skills
Inventory Low in process; High in finished goods High in process; Low in finished goods
Storage space Small Large
Material handling Fixed path Variable path Product layout: Fixed Path- e.g., Conveyor Process layout: Variable Path- e.g., Forklift
Aisles Narrow Wide
Advantage Efficiency Flexibility

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Aisles Factors Affecting Layout Decisions

Nature of product or service

Production volume
Product variety
Degree of automation
Available space

Product Layout- Narrow Aisle

Safety and environmental requirements
Process Layout- Wider Aisle
Need for future expansion

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Thanks
for
your keen interest in Learning…

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