Facility layout

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• Facility layout

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Contents

• 1- What is Facility layout?
• 2- Importance of layout decision.
• 3- Characteristics of a good layout
• 4- Types of manufacturing layout.
• 5- Service layout.

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• 1-What is facility layout?

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1- What is facility layout?

• A layout is the physical configuration of
  -departments, work stations, and equipment .
• It is the spatial arrangement of physical
  resources used to create the product.

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• 2- Importance of layout decision

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2- Importance of layout decision

• The need for layout planning arises both in the
  process of designing new facilities and in
  redesigning existing facilities.
• Layout decisions are important for three basic
  reasons
• 1-They may require substantial investments of
  money and effort
• 2-They may involve long-term commitments, which
  makes mistakes difficult to overcome
• 3-They may have significant impact on the cost ,
  efficiency and productivity of operations
• In brief, layout decisions tend to be-
• Infrequent
• Expensive to implement
• Studied and evaluated extensively
• Long-term commitments

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• 3- Characteristics of a good layout

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3-Some characteristics of a good layout

• Reduces bottlenecks in moving people or
  material.(If the rate at which each processing
  area handles work is unbalanced, or one area is
  slower or has stopped working due to problems
  with equipment, materials, or people)
• Minimizes materials-handling costs, and minimize
  delays in material handling
• Reduces hazards to personnel.
• Utilizes available labor and space effectively
  and efficiently.
• Provides flexibility.
• Provides ease of supervision.
• Facilitates coordination and face-to-face
  communication where appropriate.

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• 4- Types of manufacturing layout

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Types of manufacturing layout

• Manufacturing plants use three basic types of
  layout
• (a) Product layout,
• (b) Process layout, and
• (c) Fixed-position layout.
• In addition, there is one hybrid that is
  referred to as a group technology or cellular
  layout, which is a combination of process and
  product layout.

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Types of manufacturing layout

• Product Layout-
• linear arrangement of workstations to produce a
  specific product-
• used for repetitive processing
• Process Layout- (job-shop layout or layout by
  function)
• machines grouped by process they perform-
• used for intermittent processing
• Fixed Position Layout-
• used in projects where the product cannot be
  moved-
• used when projects require special layout

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Types of manufacturing and service
operations-Two types of operations-
Intermittent operations Repetitive (continuous) operations
made- to- order products Standardized products made -to- stock
low product volume high volume
labor -intense capital -intense
large product mix small product mix
general purpose equipment special purpose equipment
interrupted product flow continuous product flow
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Layout types
(a) Process Layout
(b) Product Layout
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• Product layout

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Product layout

• - Product layout is appropriate for producing one
  standardize product , usually in large volume.
  (Without high standardization , many of the
  benefits of repetitive processing are lost)
• Each unit of output requires the same sequence of
  operations from beginning to end.
• - Work centers and equipment are arranged in a
  line to afford specialized sequence of tasks.
• Each work center performs one highly
  specialized part of the total product buildup
  sequence .
• The work is divided into a series of
  standardized tasks, permitting specialization of
  labor and equipment
• The large volumes handled by these systems
  usually make it economical to invest substantial
  sums of money in equipment and job design
• Automatic car washes, cafeterias (where a
  customer's tray moves through a series of
  stations to assemble the components of a meal ) ,
  automobile makers, and soft drink use product
  layout.

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Product layout advantages

• 1- Achieve a high degree of labor and equipment
  utilization, (High rate of output )which tends to
  offset their high equipment cost.
• 2- Because items move quickly from operation to
  operation, the amount of work-in-process is often
  minimal
• 3-Low unit cost
• 4- Labor specialization- reduces training costs
  and time and results in a wide span of
  supervision
• 5- Material handling is simplified because units
  follow the same sequence of operations
• 6-Routing and scheduling which are established in
  the initial design of the system( they do not
  require much attention once the system is
  operating)
• 7-Routine accounting, purchasing and inventory
  control
• 8-Short unit- production time,
• 9- Low labor-skill requirements .

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Product layout disadvantages

• 1- A breakdown in one machine can cause an entire
  production line to shut down (operations are so
  closely tied to each other that the entire system
  is highly vulnerable to being shut down because
  of mechanical failure or high absenteeism )
• 2- Since the layout is determined by the product,
  a change in product design or the introduction of
  new products may require major changes in the
  layout thus flexibility can be limited
• 3- The jobs in a product layout facility, such
  as those on mass production line, may provide
  littlie job satisfaction.
• This primary because of the high level of
  division of labor often required, which usually
  results in monotony (The intensive division of
  labor usually creates dull, repetitive jobs that
  provide little opportunity for advancement and
  may lead to morale problems and to repetitive
  stress injuries)
• 4- Needs preventive maintenance (preventive
  maintenance- periodic inspection and replacement
  of worn parts or those with high failure rate
  reduce the probability of breakdowns during
  operations)
• 5- Large investments special-purpose equipment

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Product Layout
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• Process layout

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Process layout

• A process layout consists of a functional
  grouping of machines or activities that do
  similar work.
• For example , all drills presses may be grouped
  together in one department, and all milling
  machines in another.
• Depending on the processing they require, parts
  may moved in different sequences among
  departments
• ( A part being worked on travel from one area to
  the next, according to the specific sequence of
  operations required)
• This type of layout often found in high-mix,
  low-volume manufacturing plants that use an
  intermittent process.
• Process layout are designed to process items or
  provide services that involve a variety of
  processing requirements.
• The variety of jobs that are processed required
  frequent adjustments to equipment.
• This causes discontinuous work flow which is
  referred to as intermittent processing.

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Process layout

• Process layout are quite common in service
  environment.
• Examples include hospital, universities, banks,
  auto repair shops, airlines, and public
  libraries.
• Universities have separate schools or departments
  that concentrate on one area of study such as
  business , engineering, science or math.
• A hospital provides a good example of a process
  layout in the service sector customers
  (patients) go to Radiology for X-rays and to the
  lab for blood tests .

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Process layout
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Process layout advantages

• 1- Compared to product layout, process layout
  generally require a lower investment in equipment
  (General purpose equipment used is often less
  costly than the specialized equipment used in
  product layout and is easier and less costly to
  maintain)
• 2- The diversity of jobs inherent process layout
  can lead to increased working satisfaction
  .(Diversity of tasks changing work assignments
  make work more satisfying for people who prefer
  variety.)
• 3- Because items are often processed in lots
  (batches) there is considerably less
  interdependence between successive operations
  than with a product layout.
• 4- Maintenance costs tend to be lower because the
  equipment is less specialized than that of
  product layout,
• 5- Flexibility equipment and personnel can be
  used where they are needed The systems can
  handle a variety of processing requirements)

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Process layout disadvantages

• 1- In-process inventory costs can be high if
  batch processing is used in manufacturing systems
• 2- routing and scheduling pose continual
  Challenges
• 3- Equipment utilization rates are low (It is not
  uncommon for such systems to have equipment
  utilization rate under 50 percent because of
  routing and scheduling complexities related to
  the variety of processing demands being handled)
• 4- Material handling slow and inefficient, and
  more costly per unit than in product layout
• 5- Job complexities often reduce span of
  supervision and result in higher supervisory
  costs than with product layout
• 6- Special attention necessary for each product
  or customer( e.g., routing, scheduling machine
  setups) and low volumes result in higher unit
  cots than with product layout
• 7- Accounting, inventory control and purchasing
  are much more involved than with product layout

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• Fixed-position layout

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Fixed-position layout

• Layout in which the product or project remains
  stationary, and workers, materials, and equipment
  are moved as needed .
• Move machines and/or workers to the site
  products normally remains in one location for its
  entire manufacturing period.
• Examples
• Large construction projects (buildings, power
  plants, dams)
• Shipbuilding, production of large aircraft
• Rockets used to launch space missions

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Disadvantages of fixed position layout

• Since the same workers are involved in more
  operations, skilled and versatile workers are
  required.
• The necessary combination of skills may be
  difficult to find and high pay levels may be
  necessary.
• Movement of people and equipment to and from the
  work site may be expensive.
• Equipment utilization may be low because the
  equipment may be left at a location where it will
  be needed again in a few days rather than moved
  to another location where it would be productive.

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Fixed position layout
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• 5 - Service layout

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Types of service layout

• We use the three basic types of manufacturing
  facility layout that were described earlier this
  chapter as a framework for identifying the types
  of layout that are used in operations.
• 1- Process Layout
• The support services for an emergency room in a
  hospital offer a good example of a process
  layout, with radiology, blood analysis, and the
  pharmacy each being located in a specific area of
  the hospital.
• Patients requiring any of these specific
  services therefore must go to the locations where
  they are provided.

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Types of service layout

• 2- Product layout
• A good service example of a product layout is a
  cafeteria line where all of the stations (for
  example, salads, hot and cold entrees, desserts,
  and beverages) are arranged in a specific order,
  and customers visit each station as they move
  through the line.
• 3- Fixed-Position Layout
• Examples of fixed-position layout in services
  include
• (A) an automobile repair shop (where all of the
  processes such as brake repair, oil change, etc.,
  typically take place in the same location),
• (B) an operating room in a hospital (where the
  patient remains in a given location on the
  operating table), and
• (C) a table at a restaurant where all of the
  different courses in a meal are brought to the
  customer (and in some cases even prepared at the
  table in front of the customer).