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Facilities Layout Design and Facilities Location

Facilities layout design refers to the arrangement of all equipment, machinery, and furnishings

within a building envelope after considering the various objectives of the facility. The layoutconsists of production areas, support areas, and the personnel areas in the building (( Tompkins,

J. ., et al., Facility Planning, !econd "dition , John #iley $ !ons, %&,') *.

Need of Facilities Layout Design

The need for facilities layout design arises both in the process of designing a new layout and in

redesigning an e+isting layout. The need in the former case is obvious but in the latter case it is because of many developments as well as many problems with in the facility such as change in

the product design, obsolescence of e+isting facilities, change in demand, frequent accidents,

more scrap and rework, market shift, introduction of a new product etc.

Objectives of Facilities Layout Design

rimary objectives of a typical facility layout include

('* -verall integration and effective use of man, machine, material, and supporting services,

(* /inimi0ation of material handling cost by suitably placing the facilities in the best possible

way,

(1* 2etter supervision and control,

(3* "mployee4s convenience, safety, improved morale and better working environment,

(5* 6igher fle+ibility and adaptability to changing conditions and

()* #aste minimi0ation and higher productivity.

Types of Layout

The basic types of layouts are7

• roduct layout

• rocess layout

• Fi+ed position layout

• 8ellular layout

Product layout

This type of layout is generally used in systems where a product has to be manufactured or

assembled in large quantities. 9n product layout the machinery and au+iliary services are located



according to the processing sequence of the product without any buffer storage within the line

itself. pictorial representation of a product type of layout is given in Figure '. The advantages

and disadvantages are given in Table '.

Figure 1: A Pictorial Representation of Product Type of Layout

Table 1: Advantages And Disadvantages of Product Type of Layout

:;%T<"! D!AD"ANTA#$!

• =ow material handling cost per

unit

• =ess work in process

• Total production time per unit

is short

• =ow unit cost due to high

volume

• =ess skill is required for

personnel

• !mooth, simple, logical, anddirect flow

• 9nspection can be reduced

• :elays are reduced

• "ffective supervision and

• /achine stoppage stops the

line

• roduct design change or

process change causes thelayout to become obsolete

• !lowest station paces the line

• 6igher equipment investment

usually results

• =ess machine utili0ation

• =ess fle+ible



control

Process layout

9n a process layout, (also referred to as a job shop layout* similar machines and services are

located together. Therefore, in a process type of layout all drills are located in one area of thelayout and all milling machines are located in another area. manufacturing e+ample of a process layout is a machine shop. rocess layouts are also quite common in non>manufacturing

environments. "+amples include hospitals, colleges, banks, auto repair shops, and public

libraries ( /uther, ?, Systematic Layout Planning, !econd "dition , 829 ublishing 8ompany,9nc. 2oston, '@1 *.

pictorial representation of a process type of layout is given in Figure . The advantages and

disadvantages are given in Table .

Figure %: A Pictorial Representation of Process Type of Layout

Table %: Advantages And Disadvantages of Process Type of Layout


• 2etter machine utili0ation

• 6ighly fle+ible in allocating

personnel and equipment

because general purposemachines are used.

• :iversity of tasks for personnel

• <reater incentives to individual

worker

• 9ncreased material handling

• 9ncreased work in process

•

=onger production lines

• 8ritical delays can occur if the

part obtained from previous

operation is faulty

• ?outing and scheduling pose

continual challenges



• 8hange in roduct design and

process design can be

incorporated easily

• /ore continuity of production

in unforeseen conditions like breakdown, shortages,

absenteeism

Fi&ed location layout

9n this type of layout, the product is kept at a fi+ed position and all other materialA components,tools, machines, workers, etc. are brought and arranged around it. Then assembly or fabrication

is carried out. The layout of the fi+ed material location department involves the sequencing and

placement of workstations around the material or product. 9t is used in aircraft assembly,shipbuilding, and most construction projects. pictorial representation of a fi+ed location type of

layout is given in Figure 1. The advantages and disadvantages are detailed in Table 1.

Figure ': A Pictorial Representation of Fi&ed Location Type of Layout

Table ': Advantages And Disadvantages of Fi&ed Location Type of Layout


• /aterial movement is reduced

• romotes pride and quality

because an individual cancomplete the whole job

• 6ighly fle+ibleA can

accommodate changes in product design, product mi+,

and production volume

• /ay result in increase space

and greater work in process

•

?equires greater skill for personnel

• ersonnel and equipment

movement is increased

• ?equires close control and

coordination in production and



personnel scheduling

(ellular type layout

This type of layout is based on the grouping of parts to form product B part families. !imilar parts

may be grouped into families based on common processing sequences, shapes, toolingrequirements, and so on. The processing equipment required for a particular product family are

grouped together and placed in a manufacturing cell. The cells become, in effect, miniature

versions of product layouts. The cells may have movements of parts between machines viaconveyors or have a flow line connected by a conveyor. This type of layout is used when various

products have to be produced in medium to large quantities. pictorial representation of a

cellular type of layout is given in Figure 3. The advantages and disadvantages are given in Table

3.

Figure ): A Pictorial Representation Of (ellular Type Of Layout

Table ): Advantages And Disadvantages Of (ellular Type Of Layout

Advantages Disadvantages

• 6igher machine utili0ation

• !moother flow lines and

shorter travel distances are

• <reater labor skills required

• Flow balance required in each



e+pected than for process

layout

• -ffers some benefits of both

product and process type of

layout because it is acompromise between the two

• "ncourages consideration of

general purpose equipment

cell

• 6as some of the disadvantages

of product and process type oflayoutA it is a compromise

between the two

Layout !election

The basis of selection of a layout is the volume>variety analysis. ;olume>variety analysis is

based on the areto4s principle, which focuses on the fact that a majority of the resources areconsumed by a small fraction of the population. For e+ample C5D of the wealth of the world is

held by '5D of the people. This rule also applies to facilities design i.e. C5D of the productionvolume is attributed to '5D of the product line. To decide a layout, a part>population analysis

must first be completed. bar chart between the type of products and the quantity to be producedis developed. This chart is also called product>quantity chart (Figure 5* and, based on this chart,

decision regarding the type of layout to be used is taken. For the products lying in the area X

(Figure 5* >a product type of layout is recommended and for the products lying in the area Y , a process type of layout is recommended. 9n the middle (area between X and Y *, a combination of

product and process type layouts, is recommended (( /uther, ?, Systematic Layout Planning,

!econd "dition , 829 ublishing 8ompany, 9nc. 2oston, '@1 *.

Figure *: Product + ,uantity -P.,/ (0art

Types of Flo Patterns



9n the facilities layout problem, the decision regarding placement of the machines is typically

made. :epending on the application and availability of space, the machines are placed in one of

the following pattern ( (( Tompkins, J. ., et al., Facility Planning, !econd "dition , John #iley$ !ons, %&,')*

•

!traight line pattern,• E>shaped pattern,

• !>shaped pattern and

• #> shaped pattern

pictorial representation of flow patterns is given in Figure ).

Figure 2: Flo Patterns

!traig0t line pattern

The straight>line pattern is normally used when products are produced in large quantities and the

number of steps required for their production is few. /oreover, the shipping and receiving

sections are on the opposite sides.

3.s0aped pattern

E>shaped patterns are often used when it is necessary to keep the beginning (receiving* and end

(shipping* of the line at the same side and same end of the plant . E>shaped patterns are also

preferred in just>in>time layouts. #orkers are generally placed in the center of the E. From therethey can monitor more than one machine at a time.

!.s0aped pattern

!>shaped patterns are used for long assembly processes that have to fit in the same area as wellas when it is necessary to keep the receiving and shipping ends on the opposite sides.

4.s0aped pattern

#>shaped pattern, like the !>shaped pattern is also used for long assembly processes, which have

to fit in the same area. #hen it is also necessary to keep the receiving and shipping ends on the

same side, the #>shaped pattern is preferred.



Layout Design Procedure

The major steps that needed to be followed in the layout design are 7

• !tatement of the problem in terms of its objective, scope and factors to be considered.

•

8ollection of basic data on sales forecast, production volume, production schedules, partlists, operations to be performed etc.

• 8alculation of production rate and equipment requirements

• :ata analysis and its presentation in the form of various charts .

• 8alculations of space requirements and allocation of activity areas

• :evelopment of block plan, plot plan, and detailed layout.

• "valuation , selection , and installation of layout.

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