BPE3533 / BPE4143

Mohd Ghazali bin Maarof

Email: mohdghazali@ump.edu.my
CHAPTER 7: M: +60107123936
Office: 1st Floor-Chain Office KKB222
Cellular Production
 LAYOUT
MANAGEMENT
Arrangement of activities, processes,
departments, workstations, storage
areas, aisles, & public areas within
company facilities.

©2022 – Dr. Gusman Nawanir Image: unsplash.com

 MAIN
OBJECTIVE
To ensure the smooth flow of
works, materials, people, &
information in a production
system

©2022 – Dr. Gusman Nawanir Image: unsplash.com.

 DESIGNING LAYOUTS

FLEXIBILITY SPACE UTILIZATION CAPITAL

Flexibility for expansion or Must be optimum, material Investment must be

modification & human movements are minimum
minimum & smooth

©2022 – Dr. Gusman Nawanir

Benefit of Layout
Management
❖Minimize material-handling costs
❖Utilize space & labor efficiently
❖Eliminate bottlenecks
❖Facilitate entry, exit, & placement of material, products, & people
❖Facilitate communication & interaction
❖Reduce manufacturing cycle time
❖Reduce customer service time
❖Eliminate wasted or redundant movement
❖Increase capacity
❖Incorporate safety & security measures
❖Promote product & service quality
❖Encourage proper maintenance activities
❖Provide a visual control of activities
❖Provide flexibility to adapt to changing conditions.
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 FOUR TYPES OF LAYOUT

FIXED-POSITION PROCESS PRODUCT CELLULAR

LAYOUT LAYOUT LAYOUT LAYOUT

©2022 – Dr. Gusman Nawanir Image: unsplash.com.com

 FIXED-POSITION
LAYOUT
The product is fragile, bulky, or heavy to
move.

Product remains stationary for the entire

manufacturing cycle.

Equipment, workers, materials, & other

resources are brought to the production
site.

Equipment utilization is low because it is

often less costly to leave equipment idle at
a location.

©2022 – Dr. Gusman Nawanir Image: unsplash.com

 PROCESS LAYOUT
Also known as functional layouts.
It groups similar activities together in
departments or work centres according
to the process or function they perform.

©2022 – Dr. Gusman Nawanir Image: unsplash.com.

 MANUFACTURING PROCESS LAYOUTS
Lathe Milling
Department Drilling Department
Department

M M D D D D
L L

M M D D D D
L L

G G G P
L L

G G G P
L L Grinding Painting Department
Department

L L
Receiving and A A A
Shipping
Assembly

Machine shop, all drills would be located in one work center, lathes in
another work center, & milling machines are another work center
©2022 – Dr. Gusman Nawanir Image: unsplash.com
PROCESS LAYOUT

©2022 – Dr. Gusman Nawanir Image: unsplash.com

 PROCESS LAYOUT

©2022 – Dr. Gusman Nawanir Image: unsplash.com

 PRODUCT LAYOUT
Better known as assembly lines.
It arranges activities in a production line according to the
sequence of operations for a particular product or service.

©2022 – Dr. Gusman Nawanir Image: unsplash.com

 PRODUCT LAYOUT
P1 P2 P3 P4
IN

P6 P5
P8 P7

P9 P10 P11 P12

OUT
©2022 – Dr. Gusman Nawanir Image: unsplash.com
 PRODUCT VS PROCESS LAYOUTS
Product Process
Sequential arrangement of Description Functional grouping of
activities activities

Continuous, mass production, Type of process Intermittent, job shop, batch

mainly assembly production, mainly fabrication

Standardized, made to stock Product Varied, made to order

Stable Demand Fluctuating

High Volume Low

Special purpose Equipment General purpose

©2022 – Dr. Gusman Nawanir

 PRODUCT VS PROCESS LAYOUTS
Product Process
Limited skills Workers Varied skills
Low in-process, high finished goods Inventory High in-process, low finished goods
Small Storage space Large
Fixed path (conveyor) Material handling Variable path (forklift)
Narrow Aisles Wide
Part of balancing Scheduling Dynamic
Line balancing Layout decision Machine location
Equalize workload at each station Goal Minimize material handling cost
Efficiency Advantage Flexibility

©2022 – Dr. Gusman Nawanir

 PROCESS LAYOUT FIXED-POSITION LAYOUT

PRODUCT LAYOUT PRODUCT LAYOUT WITH

EXCEPTION
©2022 – Dr. Gusman Nawanir
 CELLULAR LAYOUT
Combines flexibility of process layout with
efficiency of product layout based on the
concept of group technology (GT).

GT combines the strengths of each type of layout.

Cells group dissimilar machines together to

process a family of parts with similar shapes or
process requirements.

©2022 – Dr. Gusman Nawanir Image: unsplash.com

 MAIN FEATURES OF
CELLULAR LAYOUT
The machines are laid out in close
proximity to each other

Workstations and machines are

arranged in relation to each other

Cells tend to utilize small-scale

machine/equipment

©2022 – Dr. Gusman Nawanir Image: unsplash.com

 CELLULAR LAYOUT

Cells group different machines to process Parts/products move within the cell, from one
products that require the same process. process to the next.

Ideally one unit at a time.

©2022 – Dr. Gusman Nawanir Image: Russell & Taylor (2014)
 SHOJINKA
FLEXIBLE MANPOWER LINE

JANUARY FEBRUARY
Cycle time = 1 minutes per unit Cycle time = 2.5 minutes per unit
Number of workers = 10 Number of workers = 3
©2022 – Dr. Gusman Nawanir Image: Russell & Taylor (2014)
 “ SHOJINKA
Producing with a flexible number of workers without
affecting productivity.

By applying shojinka, number of workers in a shop floor can

adapt to demand changes
“
©2022 – Dr. Gusman Nawanir
OTHER BENEFITS
✓ Minimizes transportation, handling of
materials, and part storage.

✓ Abridges workers to handle multiple

operations. Thus, workers have broad
responsibility, instead of very narrow tasks.

✓ Easy to adapt to variations in volume, design,

or product developments.

✓ Increases the ability to adjust to demand

change.

©2022 – Dr. Gusman Nawanir Image: unsplash.com

THANK YOU
For your full attention and
strong commitment