Gintawan, Sittie Raizaril A.

4-BSABE-B

ABE 423 - Design and Management of AB Processing Systems Engineering

BASIC TYPES OF LAY-OUT

1. Read Food Processing Plant design and Lay-out and discussed the following types of
lay-out:

a. Product or line layout

This layout is designed for product-centric systems. In this form of arrangement,

only a single product or product category is manufactured in a given region. The work
centers are arranged according to their order of appearance. This arrangement suggests
that various processes on raw material are performed sequentially and machines are
situated along the product flow line where machines are arranged according to the order
in which raw material will be processed.

Further, all machines are arranged in a line according to the sequence of

operations where each subsequent machine or section is arranged to perform the
operation succeeding that of its predecessor. Raw materials begin at one end of
manufacturing lines and travel sequentially from one machine to the next.

b. Process or functional layout

This layout is designed for process-centric systems. Based on their functions,

machines, production facilities, and manufacturing operations are placed together in this
form of structure. Machine tools of the same type are grouped together so that similar
operations are always performed in the same location. For instance, all lathes may be
grouped together for all types of turning and threading operations, all drilling machines in
one area for carrying out drilling work, all tapping machines in one area for carrying out
tapping work, all milling machines in one area for carrying out milling work, and all buffing
and polishing machines in one area for carrying out buffing and polishing work.
c. Cellular or group layout

It is a type of layout in which the facilities are grouped into cells. In this style of
arrangement, a set of machinery or equipment is grouped together in a section, and so
on, so that each set or group is utilized to execute comparable operations to manufacture
a family of components. When a product is being manufactured in several sizes and
shapes, a combination layout is available. In such instances, machinery and production
equipments are put in a process layout, but a set of comparable machines are then
arranged sequentially to produce a variety of product types and sizes. This arrangement
demonstrates that regardless of the size and kind of the product, the sequence of
processes remains the same or similar.

This is appropriate for systems utilizing the concepts, principles, and methodology
of group technology. This structure provides the benefits of mass production with a high
degree of adaptability. We can utilize a high level of automation even if the number of
goods with flexible specifications increases. In such a system, facilities are organized into
cells that can execute similar functions for a collection of items.

d. "Fixed Position" layout

It is also known as stationary design. The majority of an assembly or material

remains in a fixed position. All of its accessories, auxiliary materials, machinery,
equipment, tools, and labor are transported to the work site. Thus, the product remains in
a single spot due to its mass or density. Consequently, the placement of the principal
assembly, semi-assembly component, and materials is not altered until the product is
ready for shipment.

This is appropriate for the production of single, costly, massive components or

goods. The product at hand is static. Labor, tools, and equipment are brought to the
construction site.
2. Cite best example to which each above plant lay-out must be adopted.

a. Product or line layout

This layout is utilized for mass manufacturing and enables a continuous flow of
materials with minimal material handling. Since the material is fed into the first machine
and the final product is produced by the last machine, the material is fed into the first
machine and the final product is produced by the last machine. It is relevant to the
fabrication of smart cards from plastic, bamboo, and sugarcane. It is appropriate for items
with a constant demand and a continuous production system.

Product layout is implemented when the following conditions are met:

✓ One or a small number of standard products are manufactured.

✓ A vast quantity of each product must go through the production process over an
extended period of time.
✓ Time and motion studies can be performed to establish the work rate.
✓ There is a prospect of a favorable labor-to-equipment ratio.
✓ A minimum level of inspection is required during the operation's sequence.
✓ Materials and products are amenable to bulk or continuous mechanical
manipulation.
✓ Few setups are required.

b. Process or functional layout

This style of layout is typically favoured by industries whose production,

manufacturing, and/or maintenance activities are not of a repetitive nature. In addition, it
is widely utilized for modest or batch production.

Process layout is appropriate in the following instances:

✓ Non-standardized products are manufactured, since special requests are

prioritized.
 ✓ It is tough to strike a fair balance between labor and machinery.
✓ Production is conducted on a modest scale.
✓ It is challenging to conduct sufficient time and motion investigations.
✓ It is often required to use the same equipment or workstation for two or more
demanding tasks.
✓ During the operation sequence, several inspections are required.
✓ The process may have to be transported to the materials or products, rather than
vice versa, if the materials or products are too massive or heavy for bulk or
continuous mechanical handling.

c. Cellular or group layout

This layout is appropriate when similar tasks are performed concurrently, hence
avoiding time-consuming transitions between unrelated tasks. It is also beneficial when a
number of goods are created in the same order, but none of the items are to be
manufactured in quantity and, therefore, none of the items requires a separate and
independent production line. It is used to produce circular metal saws, hacksaws,
hardwood saws, files, and crankshafts.

d. "Fixed Position" layout

This layout is appropriate when only one or a few units of a product are to be
produced and the material shaping or treatment operations require only simple tools and
machinery. This layout is highly preferred when the cost of moving the largest piece of
material is high and a single skilled worker or group of skilled workers is expected to be
responsible for product quality. Ships, airplanes, aircraft, locomotives, ship assembly
shops, shipyards, boilers, steam turbines, hydraulics,and reactors are examples of
extremely large items that are typically produced in very small quantities using this layout.
It is also utilized in the building of structures, dams, and bridges.