Facility layout

Production & Operation
Management
Topic : Facility Layout

By: Ajay Mishra
Jeev Sewa Sansthan Group of Institutions for
women,
( Faculty of Management)

Facility Layout
 Planning and arranging
manufacturing
machinery, equipment and
services for the first time in
completely new plants.

 The improvements in layouts
already in use in order to
introduce new methods and
improvements in manufacturing

Objectives of a good Layout
 Provide enough  Provide for volume and
production capacity. product facility.
 Reduces handling costs.  Provide ease for
 Reduces congestion. supervision.
 Reduces hazards to  Facilitate co-ordination
personnel. communication.
 Utilizes labour efficiently.  Provide safety and
 Increase employee health.
morale.  Allow ease of
 Reduce accidents. maintenance.
 Utilizes available space  Allow high
efficiently and effectively. machine/equipment
utilization.

FACTORS INFLUENCING FACILITY
LAYOUT
 MATERIALS (Type of raw materials and
availability)
 PRODUCT (Type of product and its position)
 WORKER (Type , position and requirements)
 MACHINERY(Product, volume and process)
 INDUSTRY (Type of industry:
Synthetic, Analytical, Conditioning and
Extractive)
 LOCATION (Factor of production)
 MANAGERIAL POLICIES ( volume, provision for
expansion, automation, making or buying
decisions, desire for rapid delivery, purchasing

Principles of Layout
 Principle of minimum travel
 Principle of sequences
 Principle of usage
 Principle of compactness
 Principle of safety and
satisfaction
 Principle of flexibility
 Principle of minimum

Types of layout
 Process layout or functional or job shop
layout.

 Product layout or line processing layout.

 Fixed position layout or static layout.

 Cellular manufacturing layout or Group
Technology layout .
 Combination layout or Hybrid layout.

Process layout

 The distance between departments
should be as short as possible.
 Machines should be grouped in
accordance with the principle of
sequence of operation.
 Convenience for inspection.
 Convenience for supervision.

Process Layout or Functional Layout
Inward good Planers Packing
stores Automatics Grinders and
Milling Shipping
Raw Material
machines
holding Central Heat
stores treatment
inspection
shop
Area
Drilling
shop Electro Assembly Finished
plating shop goods
Training Shop
Painting shop storage
(Lathes)

Advantages of Process layout
 Reduced investment of machine.
 Greater flexibility.
 Better and efficient supervision.
 Scope for expansion as the capacity can be
easily increased.
 Better utilisation of men and machine.
 Easier to handle breakdown of equipment.
 Full utilisation of equipments.
 Investment of equipment would be comparatively
lower.
 Greater incentive to individual worker .

Disadvantages of Process
Layout.
 Difficulty in the movement of
material.
 Requires more space.
 Difficult in production control.
 More production time as work in
progress has to travel from place to
place.
 Accumulation of work in progress
at different places.

Product Layout (Straight Line)
 All the machine tool and equipment
must be placed at the point demanded
by the sequences of operations.
 There should be no points where one
line crosses another line.
 Materials may be fed where they are
required for assembly but not
necessarily all at one point.
 All the operations , including assembly,
testing and packing should be included

Line Layout or Product Layout
Recei Raw Materials Fabrication line for part Packing
ving stores C and

Finished goods
Fabrication for part B shipping

Raw Material Finishing
Fabrication line for t goods
Part A store
WC- 1

WC-2

WC-3

TEST
Assembly line for the product

Product Layout (advantages)
 Reduction in material handling cost due to
mechanization.
 Avoid production bottleneck.
 Economy in manufacturing time.
 Better production control.
 Require less floor area per unit of production.
 Work-in-progress is reduced and so on
investment.
 Early detection of mistakes.
 Greater incentive to a group of workers to raise
their level of performance.

Product Layout (disadvantages)
 Product layout is known for its
inflexibility.
 This is an expensive layout
 Difficulty in supervision.
 Expansion is also difficult.
 Breakdown can disrupt the
whole system.

Fixed position layout

 Movement of men and machine to the
product.
 Product remain stationary.
 Material or major components remain in
a fixed location.
 Cost of moving the machine and men is
lesser than the cost of moving the
product.

Fixed Position Layout

Raw Material
Machine & Aircraft
Finished Product Assembly
Equipment
(Aircraft)

Labour

Fixed Position Layout
(Advantages)

 Men and machine can be used for a
wide variety of operations producing
different products.
 The investment on layout is very small.
 The worker identifies himself with the
product and takes pride in it when the
work is complete.
 The high cost of, and difficulty in
transporting a bulky product are

technology layout or Hybrid
layout)
Product Layout

F
Raw Forging Gear Cutting Heat Gear Grinding i
Mat. Press Machine Treatment Machine n
i
s
h
Proces Forging Gear cutting Heat Gear Grinding e
s Press Machine Treatment Machine d
layout
O
u
Gear cutting
t
Machine
p
u
t

Facility layout

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