Basic Layout Types

1. Product layouts
2. Process layouts
3. Fixed-Position layout
4. Hybrid/Combination layouts
 Basic Layout Types
1. Product/Service layout
1. Layout that uses standardized processing
operations to achieve smooth, rapid, high-volume
flow
2. Process layout
1. Layout that can handle varied processing
requirements
3. Fixed Position layout
1. Layout in which the product or project remains
stationary, and workers, materials, and equipment
are moved as needed
4. HYBRID/COMBINATION
Layout that makes use of the combination of
Product, Process or Fixed Position Layout.
 Product Layout Characteristics
1. Product layouts are used to achieve a smooth
and rapid flow of large volumes of goods and
customers through a system.
2. The work is divided into a series of
standardized tasks, permitting specialization of
both labor and equipment.
3. The large volumes handled by these systems
make it pertinent and necessary to invest in
equipment and job design.
 Product Layout Characteristics
4. Layouts should be arranged to make the
best use of technological processing
abilities to fulfill the requirements of both
product and services.
 Product Layout Characteristics
5. In manufacturing environments the lines
are referred to as production lines or
assembly lines, depending on the type of
activity involved.
6. In services side, the word line may or may
not be used like Healthcare/Hospital
Services line ,Carwash (absence of word
line here) or Cafeteria Line.
7. Without standardization, many of the
benefits of the repetitive processing are
lost.
 Product Layout Characteristics
8. Product Layouts achieve a high degree of
labor and equipment utilization, which tends to
offset their high equipment costs.
9. Operations are so closely tied up that a
mechanical failure or high absenteeism ( rains)
would increase vulnerability of the Systems.
10. We can prevent breakdowns if we religiously
follow preventive maintenance schedules,
inspection and replacement of worn parts.
Advantages of Product Layout
1. High rate of output.
2. Low unit cost.
3. Labor specialization.
4. Low material handling cost.
5. High utilization of labor and
equipment.
6. Established routing and scheduling.
7. Routing accounting and purchasing.
 Disadvantages of Product
Layout
1. Creates dull, repetitive jobs.
2. Poorly skilled workers may not maintain
equipment or quality of output of service.
3. Fairly inflexible to changes in volume.
4. Highly susceptible to shutdowns.
5. Needs preventive maintenance.
6. Individual incentive plans are impractical.
 A U-Shaped Production Line
Figure 6.6

In 1 2 3 4

Workers

Out 10 9 8 7
 A U-Shaped Production Line
• Straight Line designs are often not practical
because of space constraints.
• U shape Production Line is more compact,
and requires often half the length of a
Straight Production Line.
• U shaped Layouts are a must for teamwork
where communication is necessary.
• U shaped Layouts allow flexibility in work
assignments as workers can handle
adjacent stations as well as stations on
opposite ends.
 A U-Shaped Production Line
• Sometimes U shaped production line interferes
with the cross travel/movement of workers,
mobile equipment.
 A U-Shaped Production Line
• Highly automated processes do not require
teamwork or communication, noise or
contamination factors then U shaped
Production Lines are not required.
Figure 6.7 Process Layout
Process Layout
(functional)

Dept. A Dept. C Dept. E

Dept. B Dept. D Dept. F

Used for Intermittent processing

Job Shop or Batch
Figure 6.7 (cont’d) Product Layout
Product Layout
(sequential)

Work Work Work

Station 1 Station 2 Station 3

Used for Repetitive Processing

Repetitive or Continuous
Advantages of Process Layouts
1. Can handle a variety of processing
requirements.
2. Not particularly vulnerable to
equipment failures.
3. Equipment used is less costly.
4. Possible to use individual incentive
plans.
 Disadvantages of Process
Layouts
1. In-process inventory costs can be high.
2. Challenging routing and scheduling.
3. Equipment utilization rates are low.
4. Material handling slow and inefficient.
5. Complexities often reduce span of
supervision.