FACILITY LAYOUT

WHAT IS LAYOUT PLANNING?

Layout planning is deciding the best physical
arrangement of all resources within a facility
 Facility resource arrangement can
significantly affect productivity
 Two broad categories of operations:
processing systems – low
 Intermittent

volume of many different products

 Continuous processing systems – high
volume of a few standardized products
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THE REASONS FOR A RE-LAYOUT ARE BASED ON
3 TYPES OF CHANGES:

 Changes in production volumes.

 Changes in processes and technology.

 Changes in the product.

The frequency of the re-layout will

depend on the requirements of the
process.
GOALS

 minimal material handling costs

 minimal investments

 minimal throughput time

 flexibility

 efficient use of space

FACTORS AFFECTING PLANT LAYOUT

Materials
Machinery
Labor
Material Handling
Waiting Time
Auxiliary Services
The building
Future Changes
TYPES OF PLANT LAYOUT
 Fixed position plant layout
Product stays and resources move to it.
 Product oriented plant layout
Machinery and Materials are placed following the product
path.
 Process oriented plant layout (Functional Layout).
Machinery is placed according to what they do and
materials go to them.
 Cell Layout
Hybrid Layout that tries to take advantage of different
layouts types.
PROCESS LAYOUTS

Resources used are general

purpose
Facilities are less capital
intensive
Facilities are more labor
intensive
Resources have greater
flexibility
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Processing rates are slower
Material handling costs are
higher
Scheduling resources & work
flow is more complex
Space requirements are higher

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PRODUCT LAYOUTS
Resources are specialized

Facilities are capital intensive

Processing rates are faster

Material handling costs are lower

Space requirements for inventory

storage are lower
Flexibility is low relative to the
market
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 © Wiley 2010

PROCESS VS. PRODUCT LAYOUTS

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 Cellular Layouts
• Every cell contains a group of machines
which are dedicated to the production of a
family of parts.
• One of the problems is to identify a family
parts that require the same group of
machines.
• These layouts are also called as group
technology layouts.
 Cellular Layouts

Machines
Enter

Worker 2
Worker
3
Worker 1

Exit

Key: Product route

Worker route
 Cellular Layouts Example

Assembly

8 10 9 12

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4 Cell1 6 Cell 3
Cell 2
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2 1 3 5

Raw materials A C B

Each of A, B, C now visits only one area, minimizing jumping.

 © Wiley 2010

FIXED-POSITION LAYOUT
 Used when product is large
 Product is difficult or impossible to
move, i.e. very large or fixed
 All resources must be brought to
the site
 Scheduling of crews and resources
is a challenge
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OTHER FACILTY
LAYOUT
 Office Layout

main consideration
o technology that allows increasing
layout flexibility by moving information
electronically
o virtual companies that creates
dynamic needs for space and services
Retail Layout
-based on the idea that sales and
profitability vary directly with customer
exposure to products.

o locate high-draw items around the

periphery of the store
o use prominent locations for high-
impulse and high-margin items
o distribute items that may dominate a
purchasing trip
o use end isle locations because
they have a very high exposure
rate

o convey the mission of the store by

careful selection in the positioning
of the lead-off department
slotting fees – fees
manufacturers pay to get their
goods on the shelf in a retail
store or supermarket
servicescapes – the physical
surroundings in which a service takes
place and how they affect customers
and employees.
*ambient conditions
*spatial layout and functionality
*signs, symbols and artifacts
Warehouse and Storage
Layout
*cross-docking - processing the
materials as they arrived to avoid
placing them in the storage area
*random stocking – locate stock
wherever there is an open location
*customizing – adding value to the
product through component
modification, repair and packaging