PROCESS LAYOUT
Process layout is recommended for batch production. All machines performing similar type of
operations are grouped at one location in the process layout e.g., all lathes, milling machines, etc.
are grouped in the shop will be clustered in like groups.
Thus, in process layout the arrangement of facilities are grouped together according to their
functions. The flow paths of material through the
facilities from one functional area to another vary from product to product. Usually the paths are
long and there will be possibility of backtracking.
Process layout is normally used when the production volume is not sufficient to justify a
product layout. Typically, job shops employ process layouts due to the variety of products
manufactured and their low production volumes.
Process layout
For process layouts, jobs don’t flow in an orderly fashion, and backtracking is a common problem.
Workers tend to experience a lot of down time because they are waiting for work or materials to
arrive from another department. This type of layout requires flexible material handling equipment—
such as forklifts—in order to follow multiple paths, move in any direction, and start and stop
material flow as needed.
For the Process Layout design, material handling is more of an after thought, only used to move
parts and processes to the product, rather than the other way around. To avoid the use of
expensive, cumbersome, and high-maintenance forklifts, or to add to a pre-existing forklift fleet,
consider incorporating a three-way adjustable manual gantry crane, which can be easily moved
under load from any one part of a facility to another. These highly flexible gantry cranes are portable
enough to reach all corners of your plant. They are totally re-locatable, making them ideal for
Process Layouts and future workflow changes. With adjustable height, span, and tread, these
gantries are ideal for use through doorways, aisles, and under mezzanines or other overhead
obstacles. What’s more, they can be used as a supplementary material handling solution to reduce
downtime and ensure continuous workflow.
Suitability of process layout
PROCESS LAYOUT
The process layout is suitable in the case of job order production, i.e., production is based
on customer orders in which different varieties of goods are produced in small quantities. It
is suitable in the case of catalytic crackers used in the refining of crude oil into petrol,
kerosene, wax, rolling mills, wire drawing, chemical plants etc.
Advantages of process layout
The important advantages offered by a process layout are as follows:
1. Flexibility
It is more flexible when compared to a product layout. Changes in operations as well as their
order can be made without disturbing the existing layout. Any new operation can be added.
2. Lower investment
General purpose machines which are usually of low cost are used. Duplication of machinery
is avoided. Further general purpose machines do not become obsolete as rapidly as special
purpose machines.
3. No stoppage of production's in
In case of breakdown of any machine, the whole process does not come to a standstill.
Work of the machine which suffers from breakdown can be transferred to the other
machines.
4. Scope for expansion
Different capacity lines can be expanded under this type of layout. New machines and labor
can be added without upsetting the existing order of arrangement.
5. Full utilization of equipment
Process layout facilitates full utilization of equipment. General purpose machines are used in
each department which can perform a variety of jobs. There is no need to provide a
separate machine for each product line.
6. Better supervision
Because of specialization in operation, an efficient and Better supervision is possible.
Disadvantages of process layout
The following are the disadvantages of process layout:
1. Inefficient material handling
Materials have to be carried forward and backward quite frequently. Mechanization
of material handling becomes difficult. Fixed path material handling equipment like
conveyor belts, chutes etc cannot be used and cost of material handling is quite.
2. High space requirement
PROCESS LAYOUT
Space requirement is more than product layout. More storage space is to be provided
around machines for waiting material to be processed.
3. High investment in inventory
Due to the lack of continuous flow of production there is high in-process inventory.
Frequently materials have to be carried back and forth. This results in delays and therefore
the investment in inventory is high.
4. High supervision cost
Cost of supervision is high because the number of employees per supervisor is less resulting
in reduced span of control. Further, the work is to be checked after each operation.
5. Longer production time
Time required for production is more in the case of product layout.
6. Skilled labor required
Skilled labor needs to be employed to perform variety of operations in general purpose
machines.