TYPES OF FACILITY LAYOUT AND ITS ADVANTAGES AND DISADVANTAGES - OPERATIONS MANAGEMENT

TYPES OF FACILITY LAYOUT
Product Layout
Process Layout
Group Layout
Fixed Position Layout
Cellular Layout
Service Layout

1. OPERATIONS MANAGEMENT TYPES OF FACILITY LAYOUT SNEKA R S I MBA IT & FINANCE

2. FACILITY LAYOUT Facility layout is an arrangement of different aspects of manufacturing in an appropriate manner as to achieve desired production results OBJECTIVES Minimize material handling costs Eliminate bottlenecks Utilize labor efficiently Utilize space efficiently Facilitate communication Reduce manufacturing cycle time / customer service time

3. TYPES OF FACILITY LAYOUT 1. Product Layout 2. Process Layout 3. Group Layout 4. Fixed Position Layout 5. Cellular Layout 6. Service Layout

4. PRODUCT LAYOUT Straight-line layout or layout for serialized manufacture Arrangement of machines in one line, depending upon the sequence of operations Materials are fed into first machine and partly finished goods travel automatically and finished products comes out from the last machine (Output of one machine becoming the input for the next) Eg : Sugarcane mill, Paper mill

5. ADVANTAGES Avoid production bottlenecks Better production control Requires less floor area per unit of production Reduction in material handling cost DISADVANTAGES Known for its inflexibility Expensive Difficulty of supervision Expansion is so difficult Any breakdown of equipment disrupt the whole system

6. PROCESS LAYOUT Functional layout or Job shop layout or batch production layout Involves grouping of like machines together in one department General purpose machines Eg : Process oriented layout for hospital

7. ADVANTAGES Reduced investment of machines Greater flexibility in production More efficient supervision Better utilisation of men and machines Easier to handle breakdown of equipment DISADVANTAGES Requires more floor space Difficulty in production control Difficulty in movement of materials Production times is more Accumulation of WIP at different places

8. GROUP LAYOUT Combined layout or Hybrid Layout A combination of the product and process layouts, with an emphasis on either (Plants are never laid out in either pure form) Fabrication tends to employ the process layout, while the assembly areas often employ the product layout Eg : Soap manufacturing plants, the machinery is arranged in product line where as ancillary services are arranged in process line

9. ADVANTAGES Increased job utilization Supports the use of general purpose equipment Shorter travel distances and smoother flow lines than for process layout DISADVANTAGES General supervision required Higher skill level required for employees Depends on balanced material flow through the cell, orelse buffers and WIP storage are required

10. FIXED POSITION LAYOUT Static Layout Involves the movement of men and machinery to the product which remains stationery Cost of moving men and machine < Cost of moving the product Eg : Ship building, Dam construction, Flyover Construction

11. ADVANTAGES Men and machines can be used for a variety of operations Invesment on layout is very small Flexible : Can accommodate changes in product design, product mix and production volume DISADVANTAGES High capital investment Higher skill requirements for personnel Increased movement of personnel and equipment

12. CELLULAR MANUFACTURING LAYOUT Machines are grouped into cells Cells function somewhat like a product layout within a larger shop or process layout

13. ADVANTAGES Flexibility Small batches of production Higher machine utilization Workers empowerment Low cost of production DISADVANTAGES Poorly balanced cells Expanded training and scheduling of workers Increased capital investment

14. SERVICE FACILITY LAYOUT Service facilities exist to bring together customer and services Layouts should provide for easy entrance to the facilities from freeways and busy thoroughfares 2 types of service facility layouts Customer receiving and servicing function (such as banks) Designed around the technologies, processing of physical materials and production efficiency (such as hospitals)