4. What is Layout?
Layout of planning is deciding the best physical
arrangement of all resources within a facility
including personnel, operating equipment, storage,
space, material handling equipment and all other
supporting service to satisfy the anticipated demand
at lowest cost.
5. Types of Layout of planning
Layout of planning are generally five types
Process layout
Product layout
Combine layout
Fixed position layout
Group layout
6. Process Layout
The process layout is particularly useful where low
volume of production is needed. In this type of
layout, the m/c are not arranged according to the
sequence of operations but are arranged according
to the type of the operation. This layout is
commonly suitable for non-repetitive jobs.
7. Advantages of Process
Layout
• Machines are better utilized and fewer machines are
required
• Flexibility of equipment personnel is possible
• Lower initial investments
• Higher utilization of production facility
8. Disadvantages of Process
Layout
• Material handling cannot be mechanized
• Process time is prolonged
• Lower productivity due to number of set-ups
9. Product Layout
If all the processing equipment and machine are
arranged according to the sequence of operations of
the product, the layout is called product type layout. In
this type of layout, only one product of one type of
products produced in an operating area.
It is mainly used in chemical industry, cement industry,
rubber industry etc.
10. Advantages of Product Layout
• Reduced material handling activities.
• Work In Process almost eliminated.
• Minimum manufacturing time.
• Simplification of the production planning and control
systems.
• Tasks simplification.
11. Disadvantages of Product
Layout
• No flexibility in the production process.
• Low flexibility in the manufacturing times.
• High capital investment.
• Every workstation is critical to the process.
• The lack of personnel or shut down of a machine
stops the whole process.
• Monotonous work.
12. Combine Layout
A combination layout combines the advantages of both
the process and product layouts. It is used when the
same item is being manufactured in different types or
sizes. In this, the machines are arranged in the
process layout format but process grouping is
arranged in a sequence. The sequence of operation
with each of the product variety however remains the
same.
13. Advantages of Combine Layout
• Low unit cost due to high volume.
• High rate of output.
• High utilization of labor and equipment.
• Minimum manufacturing time
• Low material handling cost per unit.
14. Disadvantages of combine
Layout
• Morale problems and to repetitive stress injuries.
• Inflexible for output or design.
• Highly susceptible to shutdowns.
• Lack of maintaining equipment or quality of output.
15. Fixed Position Layout
A fixed-position layout is appropriate for a product that
is too large or too heavy to move. Fixed position layout
involves the movement of manpower and machines to
the product which remains stationary. The movement
of men and machines is advisable as the cost of
moving them would be lesser.
16. Advantages of Fixed Position
Layout
• The investment on layout is very small.
• The layout is flexible as change in job design and
operation sequence can be easily incorporated.
• Adjustments can be made to meet shortage of
materials or absence of workers by changing the
sequence of operations.
17. Disadvantages of Fixed
Position Layout
• As the production period being very long so the
capital investment is very high.
• Very large space is required for storage of material
and equipment near the product.
18. Group Layout
Group Layout is also a combination of Product and
Process Layout. It identifies the families of
components that require similar types of requirements
and machines which are clubbed together as cells.
The cellular layout is also called a multi-objective
layout because this layout tries to minimize the sum of
the cost of transportation and the cost of equipment.
19. Advantages of Group Layout
• Reduced material handling.
• Reduced in process inventory.
• Improved human relation.
• Increase operator expertise.
• Implied reduction of necessary control.
20. Disadvantages of Group Layout
• Reduced shop flexibility.
• Possible reduced machine utilization.
• Possible extended job flow time.
• Possible increased job tardiness.
