Layout

To be Help by Bhuiyan Consultant Farm
1

What is layout?
Layout is nothing but arrangement of
various elements within an product
Manufacturing. How these elements are
conceived is know as visualization. once
the artist conceives, he decides to put up
the ad either at the top. or middle or
bottom and decides whether it should be
large or small. Visualization and layout
put together constitutes an ad
Shamim Hasan Bhuiyan 10/1/20172

PURPOSE OF LAYOUT
• Attract the Reader.
• Clear message delivery to the target audience.
• Provide logical starting and end points.
• Draw favorable reaction from the reader.

Laws to create an effective layout.
• Law of unity
• Law of contrast
• Law of movement
• Law of rhythm
• Law of emphasis
• Law of simplicity

• Attracting attention.
• Communicating a relevant idea
quickly and effectively.
• Interest the audience in the headlines
and copy.
• Make the message believable.

10/1/2017Shamim Hasan Bhuiyan 6
Need for line layout requirements.
Process Break down
SMV/ SAM calculation
Process wise Select Machine.
Process wise Operator Required
Process wise Operator Allocated
Work Placement & station select
Suggest presser feet, folder, gage, Attachment & etc.
Select process wise machine use Needle size with
thread type & etc.

WORK PROCESS FLOW
NEW SAMPLE OR SKETCHS
IE DEPT
Bulletin make
Man, MC requirement & Production Target
Folder Gauge
Foot and attachment
Needle type
Thread consumption
Thread Tex or Count
Placement of thread
Total meter of thread
HOGO
Merchandising Dept
Maintenance Dept
Lay out make
Final MC requirement
Line Balance
Man Power allocation
CPU operation allocation (Critical Path Unit)
Technical Dept
Prepared by Shamim Hasan

Manufacturing layout
Product layout
Process layout
Cellular layout
Office layout
Retail store layout
Warehouse layout
Fixed position layout.
Combination Layouts
Just In Time Layout

*Product Layout
>Product or line layout refers to the arrangement of productive
machines and equipment in the order of manufacturing operations.
>Layout that uses standardized processing operations to achieve
smooth, rapid, high volume flow
>Operations are arranged in the sequence required to make the
product
> Used when the operations system must handle a narrow variety of
products in relatively high volumes

*In Product or Line Layout all machines that are needed to
produce a product are arranged sequentially in a continuous
line and the raw materials are fed into the first machine
and the final product comes out of the last machine.
*Line layout is used in a number of continuous type of
industries such as sugar, paper, cement etc.
*In a product layout the whole emphasis is given to the
product that is manufactured. There will be a separate
production line for each type of product. The same type of
machines may be arranged differently in different lines.
Sometimes, the machines for each line may also be
different.
*The object here is to arrange machines in the order of
operations that are performed. Therefore, each work
station – either machine or work bench does whatever
operation on the product that follows the work done at the
preceding work station, then passes the product to the next
station in the line in which the next operation is performed.

*Characteristics of Product Layouts
• Special-purpose equipment are used
• Changeover is expensive and lengthy
• Material flow approaches continuous
• Material handling equipment is fixed Little direct
supervision is required
• Planning, scheduling and controlling functions are
relatively straight-forward
• Production time for a unit is relatively short
• In-process inventory is relatively low

>Equipment that perform
similar processes are
grouped together
>Used when the
operations system must
handle a wide variety of
products in relatively
small volumes (i.e.,
flexibility is necessary)

Office Layout

Cellular Manufacturing and Teamwork Concepts in Garment
Manufacturing
Typical layout of a garment manufacturing line includes on average about 30
machines arranged in a straight line configuration. Normally one skilled
operator works on one machine and semi skilled operators are employed at
some machines to help the skilled operator. This arrangement hinders work
sharing and team work, as no communication is possible between operators in
this long line. Work sharing in manufacturing cells and teamwork concepts are
indispensible in lean manufacturing environments. Further, balancing of lines
for one-piece-flow or near one–piece–flow is only possible with a large balancing
loss or impossible due to large variations between cycle times of operations.
The new layout proposed in this research facilitates work sharing and team
working concepts and proved dramatic improvement when implemented. An
algorithm to balance the cell based on the garment type and the skill matrix of
operators too is proposed.
Keywords: Cellular manufacturing, group technology, garment manufacturing,
line balancing, sub-cell,
teamwork

Features of Product or Line Layout
According to Harold T. Amrine the features of product layout can
be listed as follows:
1. Conveyorized movement of inventories.
2. Mechanical pacing of movement either partially or completely.
3. Semi-skilled operations operating two or more machines often.
4. Making use of highly specialized machines, jigs and fixtures etc.
5. Less need for detailed scheduling regarding production control.
6. Relatively small-in process inventory of parts with most of them
in temporary storage on the inventory handling system.
7. Heavy investment in specialized machines, which has little
flexibility.
8. Integration of the points of inspection into the line.
An important point to be noted here is that some of the features
are advantages of the product layout, whereas others are its
disadvantages.

Advantages of Product or Line Layout
1. Installation of Automatic Devices
As product layout ensures continuous flow of work through direct lines and
short distance of travel, the installation of labor-saving and low-cost
mechanical movement devices is made possible. This would reduce the cost of
materials handling.
2. Elimination of Delay
In a product layout, material after completion of one operation flows to the
next operation without any delay. Because of this, time required for
production is reduced considerably.

3. Reduced Accumulation of Work-in-process
In a product layout, there is not much accumulation of work-in-process at one
particular point because as soon as an operation is completed it passes on to
the next machine for the next operation. As a result the overall productivity
of the undertaking is enhanced.
4. Effective Control of Production
Production is designed according to an orderly sequence, and the work-in-
process automatically flows from machine to machine. So the production
control will be comparatively easy and simple. There would be lesser need
for further clerical and administrative work for regulating the production.
5. Lesser Need for Inspection
There is lesser need for inspection because each complete product is made
on one line, which requires minimum supervision work over it. Besides,
efficiency of inspection increases due to the repetitive nature of the work.
6. Maximum Utilization of the Floor Area
Under this type of layout, there will be a greater productive utilization of the
floor space. As the work-in-process spreads over the entire production line
and there is a lesser need for temporary storage of materials, the vast floor
area is not jam packed with materials, work-in-process etc. This would result
in a smaller floor area per unit of output and thus making the total floor area
more productive.

Disadvantages of Product or Line Layout
The important drawbacks of a product layout can be summarized as follows:
1. Less possibility of Optimum Utilization of Machines
There is lesser machine utilization, as it is suitable only for a continuous
process. In a continuous process, if the production is stopped, all the machines
that form the layout shall become idle. Similarly, if any machine in the line
breaks down, the other machines in the same line cannot operate. Hence,
optimum utilization of machines is impossible.
2. Inflexibility in its Operation
Inflexibility is a drawback of this type of layout. The machine layout is designed
to perform certain operations. No machine in the line is perfectly
interchangeable in capacity or type of work with any other machine. Any
change over would lead to costly interruptions in manufacture.
3. Heavy Capital Investment
This type of layout requires heavy capital investment in machines and
equipment due to duplication. If the same type of machine is needed for two
production lines, two machines must be provided for each line to maintain the
sequence of operation. Thus the whole enterprise becomes highly capital-
intensive venture.

4. High Supervision Costs
Specialized supervision is necessary on account of diversity of operations
in the same line of production, which always requires the appointment of
expert personnel at a higher salary.
5. Difficulty in Expansion
The scope for further expansion is very much limited and almost
impossible in cases where product lines are laid out for specific capacity.

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Layout

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