Types of layout
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The document discusses various types of manufacturing layouts, including process, product, cellular, and fixed position layouts, highlighting their advantages and disadvantages in terms of material handling, space utilization, worker skill requirements, and flexibility. It notes how process layouts offer better equipment utilization and quality but require more space and skilled workers, while product layouts provide efficiency but can lead to excessive idle time and difficulties in scaling production. Hybrid layouts are also mentioned as a combination of processes, demonstrating that most manufacturing facilities incorporate multiple layout types.
Types of layout
- 2. • Integration • Minimum movements and Material handling • Smooth and Continuous flow • Cubic Space Utilization • Safe and Improved Environments • Flexibility
- 4. • If a manufacturing facility produces a variety of products in relatively small batches will use a process layout • Process layout typically use general purpose machines that can be changed rapidly to new operations for different product designs. • Machines are arranged according to the type of process being performed • Workers must be highly skilled
- 5. • Wide flexibility exists as regards allotment of work to equipment and workers. • Better utilization of the available equipment. • Comparatively less number of machines are needed, thus involving reduced capital investment. • Better product quality, because the supervisors and workers attend to one type of machines and operations. • Varieties of jobs coming as different job orders make the work more interesting for the workers.
- 6. • For the same amount of production, process layout needs more space. • Automatic material handling is extremely difficult. • More material-in-process remains in queue for further operations. • Work-in-process inventory is large. • Production control becomes difficult. • It needs more inspections and efficient co-ordination.
- 8. • Product layout is often called Production line or assembly line • Use specialized machines to perform specialized operations. • Changeover takes greater expenses and long down times. • The amount of skill, training and supervision required is small. • Planning and scheduling activities associated with these layouts are complex.
- 9. • Less space requirements for the same volume of production. • Automatic material handling, lesser material handling movements, times and costs. • Less in-process inventory. • Product completes in lesser time. • Better co-ordination and simple production planning and control. • Smooth and continuous work flow. • Less skilled workers may serve the purpose.
- 10. • Change in product involves major changes in layout and thus the layout flexibility is considerably reduced. • The pace or rate of working depends upon the output rate of the slowest machine. This involves excessive idle time for other machines if the production line is not adequately balanced. • It becomes difficult when one inspector has to look after many machines in two or more production lines. • It is difficult to increase production beyond the capacities of the production lines.
- 12. • In Cellular manufacturing, machines are grouped into cells, and the cells function, like a product layout island within a larger job shop or process layout. • The layout of a cell can take on many different forms, the flow of parts tends to be more like a product layout than a jobshop.
- 13. • Reduced material handling and transit time • Reduced set up time • Reduced work in process inventory • Better use of human resources • Easier to control • Easier to automate
- 14. • Poorly balanced cells • Expanded training and scheduling of workers • Increased capital investment
- 16. • Missile assembly, large aircraft assembly, ship construction, and bridge construction are examples of fixed position layouts. • Fixed position layouts are used when a product is very bulky, large, heavy and fragile. • Fixed position nature of the layout minimizes the amount of product movement required.
- 17. • It is possible to assign one or more skilled workers to a project from start to finish in order to ensure continuity of work. • It involves least movement of materials. • There is maximum flexibility for all sorts of changes in product and process. • A number of quite different projects can be taken with the same layout.
- 18. • It usually involves a low content of work-in-progress. • There appears to be low utilization of labour and equipment. • It involves high equipment handling costs.
- 20. • Most manufacturing facilities are combination of layout types. In hybrid layout departments are arranged according to the types of processes but the products flow through on a product layout • Final assembly of Boeing’s commercial aircraft is the perfect example of hybrid layouts