Integrated Systems Management

CT068-3-M-ISM

Plant Layout

MSc in Information Technology Management

MSc in Technology Management
 Topic and Structure of Lesson

Plant Layout
• Types of Layout
– Product Layout
– Process (Functional) Layout
– Group (Cell) Layout
– Fixed Position Layout

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 Learning Outcomes

By the end of this lecture, you should be

able to:
• Identify the different plant layouts in a
manufacturing environment
• Critically compare the differences between
between the plant layouts

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 Plant Layout

• Minimise delays and materials handling

• Maintain flexibility

• Use labour and space effectively

• Promote high employee morale

• Promote good housekeeping and

maintenance

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 Four Major Types

• Product Layout

• Process (Functional) Layout

• Group (Cell) Layout

• Fixed Position Layout

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 Product Layout

• Based upon operation sequence

• Products move in continuous path from one

area to next

• Found in flow shops (repetitive assembly

and process or continuous flow industries)
which produce high-volume, highly
standardised products

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 Product Layout - Example

Product 1
Mixing Ageing

Product 2

Bottling

Shipping Packaging Capping

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 Product Layout - Advantages

• Smooth and logical flow

• Promotes use of specialist materials
handling devices
• Reduced WIP
• High throughput
• Low labour skill requirements
• Simple planning and control

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 Product Layout - Disadvantages

• Potential of line shut down due to one

machine failure
• Limited flexibility (product
modifications)
• Potential high cost of quality problems
• Poor job satisfaction

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 Process Layout

• Functional grouping based upon

similar work content
• drills
• lathes
• saws
• etc
• Parts moved in different sequences
among areas
• Process dependent

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 Process Layout - Example

Grinding

Product 1
Drilling
Painting

Product 2

Sanding

Assembly
Milling

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 Process Layout - Advantages

• Increased worker satisfaction

• Low capital outlay

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 Process Layout - Disadvantages

• Considerable handling and

transportation
• Complicated planning and control
systems
• Low throughput
• High WIP
• High worker skill requirements

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 Group Layout

• Tries to combine benefits of mass

production layouts with that of job shop
layouts
• Based upon families of parts
• Groups of machines into cells using a
technique known as group technology
(GT)
• Supports cellular manufacturing

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 Group Layout - Example

GROUP A PARTS GROUP B PARTS

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 Group Layout - Example
DIRECTION OF PART MOVEMENT WITHIN CELL

IN SAW LATHE LATHE

MATERIAL

MILLER

WORKER 2 WORKER 3
WORKER 1
MILLER
OUT
FINISHED FINAL
PART INSPECTION MILLER

GRINDER

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 Process Layout - Example

SHEARING
MILLING

FAMILY B

LATHE
DRILLING

FAMILY A

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 Group Layout - Example

MILLING &
DRILLING SHEARING
FOR B
FAMILY B

MILLING &
DRILLING
LATHE
FOR A
FAMILY A

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 Group Layout - Advantages

• Reduced WIP

• Increased throughput

• Reduced material handling and

transportation

• Quick response to quality and general

problems

• Increased morale
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 Group Layout - Disadvantages

• Disruption when building and

implementing

• May take resource away from other

areas

• Only designed for specific parts

families
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 Fixed Position Layout

• Product is fixed in place

• Appropriate for a product that is too large or

too heavy to move

• Workers come to the product to work

• Eg. Shipbuilding, assembling locomotives,

making huge pressure vessels, building
dams, or repairing home furnaces
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 Fixed Position Layout - Disadvantages

• Space
• Material handling problems
• Administration

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 Other Layouts

• Warehouse/storage layouts
• Retail layouts
• Office layouts

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 Quick Review Question

Identify the type of layout that might be suitable in

the following settings:
– airport
– bank
– classroom
– office of product designers
– law firm
– fabrication of sheet
– parking lots
– human resources department

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 Follow-up Assignment

None

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 Summary of Main Teaching Points

Plant Layout
• Types of Layout
– Product Layout
– Process (Functional) Layout
– Group (Cell) Layout
– Fixed Position Layout

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 Next Lesson

Cellular Manufacture
• Objective
• Definition
• Product Criteria
• Planning
• Developing the cell layout
• Pareto analysis
• Benefits
• Success Constraints

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 Question and Answer Session

Q&A

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