Professional Documents
Culture Documents
Facility Layout
Facility Layout
Principles of Layout
Types of Layout
task quickly.
o Assembly line such as automobile factory
Suitable for
Product
Layout
Figure 6.4
Raw
materials
or customer
Station
1
Station
Station
22
Station
Station
33
Material
Material
Material
Material
and/or
labor
and/or
labor
and/or
labor
and/or
labor
Station
Station
44
Finished
item
Racks containing
headlight subassembly
Workstation 1
Car
1
Conveyor
Racks containing
backlight subassembly
Workstation 2
Car
2
Racks containing
steering wheels
sub-assembly
Workstation 3
Car
3
4
5
Workers
6
Out
10
A high
output rate
and, thus,
low cost of
item per unit
Advantages
Easier material
handling and
lesser inventory
costs
Maintenance cost
is fairly high to
ensure smooth
running of the line
High
efficiency of
labor &
equipment
Product
Layout
Disadvantages
Inflexible to design
changes in products
or processes (the
changes in line are
usually expensive)
No need of routing or
scheduling once the line
is operational (as it is
already done during the
design of the line)
Monotonous repetitive
tasks lead to frustration
on part of workers
Breakdown of a
machine or high
absenteeism of workers
leads to halt in
production
are needed.
Smaller investment in equipment: duplication is not
necessary unless volume is large.
Expertise: supervisors for each department become highly.
knowledgeable about their functions
Diversity of tasks: changing work assignments make work
more satisfying for people who prefer variety.
Engine
Repairs
Paint
Booth
Car
washing &
cleaning
Office
Spare
Oil
Parts Replacemen
Store
t
Wheel
Alignme
nt
Electrical
Repairs
Interiors,
Door
Repairs,
etc.
Dents
Repair
Routing &
scheduling is
tedious and time
consuming for
different products
Disadvantages
Process
Layout
Advantages
High cost of
supervision because of
special treatment to
every product to be
processed
The system promotes
creativity on part of
workers due to variety
of tasks performed by
them
Breakdown of a
machine does not
lead to halt in
production as
substitute machines
are kept ready for
such situations
Disadvantages
Lack of process efficiency: backtracking and long
or cost of moving.
More continuity of the assigned work force (since the
item does not go from one department to another). This
reduces the problems of re-planning and instructing
people each time a new type of activity is to begin.
Group Technology
Layout
Lathe
machines
Fitting shop
Foundry
Drilling
machines
Paint shop
Welding
shop
Lathe
Fitting
Drilling
Drilling
Paint
Welding
Welding
Manufacturing Cell
Advantages/Disadvantag
es
Advantages
Disadvantages
Reduced shop flexibility
Possible reduced machine utilization
Possible extended job flow times
Implementation Issues
Reorganization - machine layout need reorganization
every so often.
Work cell supervision - supervisors must be expert in
several field (milling, turning, grinding, etc.) represented
in the cell.
Shop floor control / production planning - cell concept
leads to unbalanced workload on machines.
1.
2.
Computer Packages
Systematic Layout
planning
Product Layout
1. Flow of Materials
2. Activity Relationships
Analysis
3. Relationship Diagram
4. Space Requirements
5. Space Available
7. Modifying Considerations
8. Practical Limitations
Search
10. Evaluation
Selection