Module 4
Facility Layout
By-
Team 4
Facility Layout
• Facility layout refers to how machinery, equipment, and workstations are
arranged within a production facility or manufacturing plant. It involves
the proper design, planning, and integration of the various components
required for efficient operations.
Facility layout planning
• Facility layout planning is the process of designing and arranging the
physical layout of a facility, such as a manufacturing plant, warehouse,
office, or service facility, to optimize various aspects of the operations. It
involves careful planning and consideration of various factors to achieve
efficient material flow, effective space utilization, and a safe and
productive work environment
Objectives
• To provide optimum space to organize equipment facilitate the movement of goods and
create a safe and comfortable work environment.
• To promote order in production towards a single objective
• To reduce the movement of workers, raw materials, and equipment
• To promote the safety of the plant as well as its workers
• To facilitate extension or change in the layout to accommodate new product line or
technology upgradation
• To increase the production capacity of the organization
Principles
• Principle of Integration • Principle of Process and Operation
• Principle of Minimum Movement Relationships:
• Principle of Cubic Space Utilization • Principle of Building and Equipment
Utilization
• Principle of Safety and Satisfaction
• Principle of Accessibility:
• Principle of Flexibility
• Principle of Service and Support
• Principle of Material Flow Facilities
Types
Process layout (or functional layout):
• In a process layout, similar operations or processes are grouped. Machines and
workstations are arranged according to their function, such as machining, welding,
painting, or assembly. This layout is suitable for job shops or batch production
where a variety of products are produced in small quantities
Product layout (or flow-line layout):
• In a product layout, workstations and equipment are arranged in the same
sequence as the production process flow. This layout is designed for mass
production or continuous production of a standardized product. The
materials and products move in a linear flow from one operation to the
next.
Fixed-position layout:
• In a fixed-position layout, the product remains stationary, and workers,
tools, and materials are brought to the product. This layout is commonly
used for large, immobile products like ships, aircraft, or construction
projects.
Cellular layout (or group technology layout):
• A cellular layout groups machines or workstations into cells or mini-
factories based on similar processing requirements or product families.
Each cell is dedicated to a specific part or product family, allowing for
efficient material handling and shorter cycle times.
Combination layout:
• A combination layout combines features of different layout types to meet
the specific requirements of a facility. For example, it may have a process
layout for some operations and a product layout for others, or it may have
a cellular layout within a larger process layout
Office layout:
• Office layouts are designed to optimize the workflow and productivity of
office staff. Common office layouts include open-plan, private offices,
cubicles, and team-based layouts.
Retail layout:
• Retail layouts are designed to maximize customer flow, product visibility,
and sales. Common retail layouts include grid, racetrack, and free-flow
layouts.
Factors influencing layout change
• Changes in product design or mix • Space constraints or expansion
• Changes in production volume or needs:
demand • Operational inefficiencies
• Introduction of new technology or • Changes in organizational strategy or
processes goal
• Inefficient material flow or handling • Environmental or regulatory changes
• Safety and ergonomic concerns: