Comparative Study of Different Facility Layout
Group Members
Amee Thakkar 56
Bhagyashree Shinde
51
Dhara Shah 49
Gurunadham RP
45
Ashish Totala 58
Anshupriya
03
Things You Will Be Familiar
After
This Presentation
1. What is Facility Layout?
2. Characteristics of Layout
3. Selection of Facility Layout
4. Types Of Layout
Process Layout
Product Layout
Cellular Layout
Fixed-Position Layout
Hybrid Layout
5. Concept of Service layout
What Is Facility Layout?
Facility layout refers to the specific arrangement of physical
facilities.
These studies become necessary when:
A new facility is constructed
There is a significant change in demand or throughput volume
A new good or service is introduced to the customer benefit
Different processes, equipment, and/or technology is
introduced.
Basic Principle:
The total movement of materials should be minimum.
The arrangement of the work should have as much congruence
as possible with the flow of material within the plant.
The layout should ensure safety and healthy working condition
for employees.
Layout should be flexible enough so as to enable for probable
changes in the future as all system should anticipate changes in
the future.
Procedure for Facility Location
The Preliminary Screening
Resources
Local Condition
Detailed Analysis
Factors Ratings
Importance of Facility Layout
Primary Factors: Secondary Factors:
Soil & Climate
Availability of raw material
Industrial atmosphere
Nearness to market
Financial & other acids
Transport facilities
Availability of facilities like housing,
Availability of Labor
schools, hospitals etc.
Availability of Fuel & Power Momentum of an early start.
Availability of water- Special advantage of the place
Personal Factors
Historical Factors
Political Stability
Factors Affecting Selection of Plant Layout
Location and Site of the plant Service Facilities
Product and material specification Design of building
Manufacturing Process Flexibility
Material Handling Work areas and equipment
Storage of in-process inventory Working condition
Plant personnel and employee Disposal of waste and dangerous
facilities gases.
Objectives of Good layout:
Provide enough production Utilize available space efficiently and
capacity. effectively.
Reduce material handling costs. Provide ease of supervision.
Reduce congestion that impedes Facilitate co-ordination and face-to-
the movement of people or face communication when
material. appropriate.
Reduce hazards to personnel. Provide employee safety and health.
Utilize labour efficiently. Allow ease of maintenance.
Increase employee morale. Allow high equipment utilization.
Reduce accidents. Improve productivity.
High material turnover.
Features of Good Layout:
Reduce bottleneck in moving people or material.
Minimizes material handling costs.
Reduces hazards to personnel.
Utilizes labour efficiently.
Increases Morale.
Utilizes available space effectively and efficiently.
Provides Flexibility.
Provides ease of supervision.
Facilitates co-ordination and face-to-face communication.
Problems with Improper Facility
Layout:
The layout decision will certainly affect the Flow of materials,
in-plant Transportation cost, equipment utilization, and
general productivity and effectiveness of the business.
Therefore, plant layout should be carefully arranged, AND It
must satisfy specific objectives.
Usually the layout is planned to minimize a particular
criterion: For example, minimizing total traveling time, total
cost, total delays, etc.
There are also situations in which the layout may be
designed to maximize a criterion: For example, maximize
quality, flexibility, or space utilization.
Need for Facility Layout:
Inefficient operation. Accidents and Safety
Hazards.
For example: Changes in Design of
High cost products or service.
Bottleneck.
Changes in
environmental or
Introduction of new other legal Changes in volume
product or services. requirements. of output.
Types Of Facility Layout:
Process (Job Shop) Layout
Product (Assembly Line) Layout
Cellular Layout
Fixed-Position (Project) Layout
Hybrid (Mixed) Layout
Process Layout or Layout by Functions
It is typical of the job-shop type of production where the
equipment performing similar operations are grouped
together.
Layouts are usually where the volume of production is
low and variety of jobs is great.
Examples: car servicing, hospitals, Universities &
colleges, Airlines.
Example of Process layout:
Washing Servicing
Oiling Repairing
Painting
Product or Line Production Layout:
The equipment here are laid out according to the sequence in which
it is used for making the product.
It is appropriate for producing one standardized product, usually in
large volume. It is also called as flow shop layout or straight line
layouts.
Example: Automobile Industry, Chemical, Paper, Rubber etc.
Example of Product layout:
Operation 1 Operation 2 Operation 3
Assembling Testing Sub assembling
Testin
Packing Shipping
g
Cellular manufacturing layout
Machines are grouped into cells, and the cells functions some
what like product layout.
Each Cell in cellular manufacturing layout is formed to produce
a single parts family.
Grouping technology is made for a single part family i.e. parts
with common characteristics.
Example of cellular layout:
Fixed position layout
Material remains in fixed position
Machinery, men and material are brought to the raw material
Example: construction of a building, assembly of an aircraft or ship
Raw Material
Machines
Work Place
Tools
Workmen
Example: Fixed product layout
Hybrid layout
Hybrid layout can be used in different departments in one
organization where combination of various layouts like process,
product etc. is used
It is also called as Mixed layout or Combined layout
It is generally adopted by a industry to meet requirements of its
total operations
Example: A Hospital, cement industry etc.
Hybrid layout - Case of a cement plant:
Clay Cyclone Blending
yard storage
cyclone
Bauxite
yard
Rotary
kiln
Iron ore Raw meal Inlet
yard chamber
of kiln
Lime stone
yard
Clinker
cooler
ESP
Cement
Chimney Mill
Process layout for a part of cement plant Product layout for a part of cement plant
Comparison of different layouts:
Parameter Product Process Fixed Cellular Hybrid
Description Standardized General Flexible Group Suitability
Technology
Processing Repetitive or Job shop Continuous Continuous Batch
Continuous or Batch
Product or Low Moderate Low High High
to High
service variety
Flexibility Very Low Moderate High Moderately High
to high High
Volume Large Medium Large Small Large
Production Long Relatively Minimum Minimum According
Short to Process
time
Material Flexible Fixed Flexible Easier Flexible &
Fixed
Handling
Layouts depending upon the process:
Type of process Type of Layout Example
Project Fixed Position Road-resurfacing
Jobbing Process Hospital kitchens
Batch Hybrid Airport terminals
Mass Product Assembly line
Continuous Product Oil-refiners
Network Cellular Mobile network
Service Layout:
Service layout is basically concerned to the effective circulation of customer
through the layout.
Facilities to be considered while selecting a service layout.
Service layout is basically important to achieve client-customer goal of fast
service.
Factors influencing the layout
Degree of customer contact
Line of visibility
Types of Service layout
Warehouse and Storage Layouts
Retail Layouts
Office Layouts