types of layouts

© Copyright 2013 Anupam Kumar 1

Types of Layout: Product Layout

v/s Process Layout

Presented By:

Anupam Kumar

Reader

SMS Varanasi

E mail: [email protected]

1© Copyright 2013 Anupam Kumar

Types of Plant Layout

• Layouts can be classified into the following

categories:

– Process Layout

– Product Layout

– Combination Layout

– Fixed Position Layout

– Group Layout


Process Layout

• In process layout:

– All machines performing similar type of operations are grouped together at one location.

– Production volume remains limited.

– The production happens in batches or lots.

– A large variety of products can be produced from the same plant.

– Backtracking and long movements reduces the material handling efficiency.

– Space and capital are tied up in WIP inventory.


Process Layout

• Advantages:

– Machines are better utilized and fewer machines are required

– Flexibility of equipment & personnel is possible

– Lower initial investments

– Higher utilization of production facility

– Diversity of tasks makes the work challenging & interesting.

• Disadvantages:

– Material handling cannot be mechanized

– Process time is prolonged

– Lower productivity due to number of set-ups

– Throughput time is longer

– Space & capital is tied up by work in progress/ process.


Product Layout

• The product layout is selected when the

volume of production is high enough to justify

a separate production line.

• In this type of layout, the machines and

auxiliary services are located according to the

processing sequence of the product.

• The facilities are arranged to ensure efficient

flow of material and lower cost per unit.


Product Layout

• Advantages:

– Reduced material handling activities.

– Work In Process almost eliminated.

– Minimum manufacturing time.

– Simplification of the production planning and control systems.

– Tasks simplification.

• Disadvantages:

– No flexibility in the production process.

– Low flexibility in the manufacturing times.

– High capital investment.

– Every workstation is critical to the process.-The lack of personnel or shut down of a machine stops the whole process.

– Monotonous work.



Combination or Matrix Layout

• A combination layout combines the advantages of

both the process and product layouts.

• It is used when the same item is being manufactured

in different types or sizes.

• In this, the machines are arranged in the process

layout format but process grouping is arranged in a

sequence.

• The sequence of operation with each of the product

variety however remains the same.


Combination or Matrix Layout


Fixed Position Layout

• This type of layout is suitable when one or a few

identical heavy items are to be manufactured.

• The materials are kept fixed because the cost of

transportation of material is very high.

• In this type of layout,

– the material or the major component remain fixed and

– the tools, machinery, men and other materials move

around it.

• This type of layout is also called project type layout.


Group Layout or Cellular Layout

• Group Layout is also a combination of Product and

Process Layout.

• It identifies the families of components that require

similar types of requirements and machines which

are clubbed together as cells.

• The cellular layout is also called a multi-objective

layout because this layout tries to minimize

– The sum of the cost of transportation

– The cost of equipment


A cluster

or cell

Group Layout or Cellular Layout

Process (Functional) Layout Group (Cellular) Layout

Similar resources placed togetherResources to produce similar products

placed together

T T T

MM M T

M

SG CG CG

SG

D D D

D

T T T CG CG

T T T SG SG

M M D D D

M M D D D


Layout Design

• ABC Electronics has a facility with six production areas.

• It proposes to locate 6 departments (A,B,C,D,E,F), which have the number of moves per day between departments as shown in the table below.

• What type of layout would be suitable for the facility?

• Develop a layout for the facility.

1 2 3

4 5 6

A B C D E F

A 5 10 3 2

B 12

C 10 4 8

D 16

E 7

F 812© Copyright 2013 Anupam Kumar


For further details…

Contact

Anupam Kumar

Reader

SMS Varanasi

E mail: [email protected]


Bibliography

• Buffa, E.S. and Sarin, R.K., “Modern Production/Operations Management,” Eighth Edition. Singapore: John Wiley & Sons (Asia). 1994.

• Martinich, J.S., “Production and Operations Management: An Applied Approach”, Singapore: John Wiley & Sons (Asia), 2003.

• Badi, R.V. and Badi, N.V., “Production and Operations Management”, Second Edition, New Delhi: Vrinda Publication, 2008.

• Chary, S.N., “Productions and Operations Management,” Third Edition, New Delhi: Tata McGraw Hill, 2004

• Goel, B.S., “Production Operations Management”, Twenty Second Edition, Meerut, U.P.: PragatiPrakashan, 2010.

• Kachru, U. “Production and Operations Management: Text and Cases,” New Delhi: Excel Books, 2007.

• Rama Murthy, P., “Production and Operations Management,” New Delhi: New Age International, 2012.

• Chunawalla, S.A., and Patel, D.R., “Production and Operations Management,” Mumbai: Himalaya Publishing House, 2006.

• Jauhari, V. and Dutta, K., “Services: Marketing Operations and Management,” New Delhi: Oxford University Press, 2010.

• Verma, H.V., “Services Marketing: Text and Cases,” New Delhi: Dorling Kindersley, Pearson Education, 2009.


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