FACILITY

LAYOUT
 Facility
Facility Layout
Layout
 “Plant layout refers to the physical
arrangement of production facilities.”
 “Plant layout refers to the arrangement
of machinery, equipment and other
industrial facilities for achieving
quickest and smooth production.”
 Facility
Facility Layout
Layout
 “Arrangement of activities, processes, department,
work station, storage areas, within an existing and
proposed facility.”
 “Plant layout is a plan of an optimum arrangement
of facilities including personnel, operating
equipment, storage space, material handling
equipment and all other supporting services along
with the design of best structure to contain all
these facilities.”
 Objectives:
Objectives:Facility
Facility Layout
Layout
 To Make more efficient flow of materials through
the plant.
 To Facilitate the manufacturing process.
 To Maintain high turnover of in-process
inventory.
 To Minimize materials handling and cost.
 Effective utilization of men, equipment and space.
 Flexibility of manufacturing operations and
arrangements.
 To Provide convenience, safety and comfort for
employees.
 To Minimize investment in equipment.
 To Minimize overall production time.
Classification
ClassificationOf
OfFacility
Facility Layout
Layout

 Product layout
 Process layout
 Fixed position layout
 Cellular layout
 Product
Product Layout
Layout
 “Assembly line”
 “Machines and auxiliary services are located
according to the processing sequence of the
product.”
 “Arranging activities in a line according to the
sequence of operations for a particular product
or services.”
 Works for chemical, paper, sugar, refineries,
cement industries.
 Product
Product Layout
Layout
 If the volume of production of one or more products is
large, the facilities can be arranged to achieve efficient
flow of materials and lower cost per unit.
 Mass production and repetitive production
operations.
 Standard product and services
 High level of demand
 More automated than process layout
 Special purpose machines are used which perform
 Product
Product Layout
Layout

IN

OUT
Product
Product Layout
Layout
 Product
Product Layout
Layout

Racks containing
Racks containing Racks containing
Racks containing steering wheels
headlight sub-assembly backlight sub-assembly steering wheels
sub-assembly
sub-assembly
Workstation 3
Workstation 1 Workstation 2

Car 3 Car 2 Car 1

Conveyor
 Product
ProductLayout:
Layout: Advantages
Advantages
 The flow of product will be smooth and logical
 In-process inventory is less.
 Throughput time is less.
 Minimum material handling cost.
 Simplified production, planning and control
 Less space is occupied by work transit and for
temporary storage.
 Perfect line balancing which eliminates
bottlenecks and idle capacity.
 Manufacturing cycle is short due to
uninterrupted flow of materials.
 Product
ProductLayout
LayoutLimitations:
Limitations:
 A breakdown of one machine in a product line
may cause stoppages of machines in the
downstream of the line.
 A change in product design may require major
alterations in the layout.
 The line output is decided by the bottleneck
machine.
 Comparatively high investment in equipments
is required.
 Lack of flexibility
 Process
Process Layout
Layout
 “Functional Layout”
 Group similar activities together according to
the process or function they perform.
 Job shop and batch production system
 Used for low volume production
 General purpose machine are used
 For Example: In a machine shop, all drills
would be located in one work center, lathe in
another work center, and milling m/c in
another work center.
 Process
Process Layout
Layout
 “All machines performing similar type of operations are grouped at
one location in the process layout.”

B
Process
Process Layout
Layout
Process
Process Layout
Layout
 Process
Process Layout
Layout
Milling
Lathe Department Department Drilling Department
L L M M D D D D

L L M M D D D D

L L G G G P

L L G G G P

Grinding Painting Department

L L Department

Receiving and
A A A
Shipping Assembly
 Process Layout:
Process Layout:
Advantages
Advantages
 Machines are better utilized and fewer
machines are required.
 Flexibility of equipment and personnel.
 Lower investment.
 The diversity of tasks and variety of job makes
the job challenging and interesting.
 Supervisors will become highly knowledgeable
about the functions under their department.
 Process
ProcessLayout:
Layout:Disadvantages
Disadvantages
 Long movements may occur in the handling of
materials thus, this reduces material handling
efficiency.
 Material handling cannot be mechanized which adds to
cost.
 Prolonged Process time increases the in-process
inventory.
 Lowered productivity due to number of set-ups.
 Throughput (time gap between in and out in the
process) time is longer.

 PRODUCT LAYOUT PROCESS LAYOUT
Description Sequential arrangement of Functional grouping of activities
activates
Types of process Continuous, mass production, Intermittent, job and batch
mainly assembly
Product Standardized, made to stock Varied , made to order
Demand Stable Fluctuating
Volume High Low
Equipments Special purpose general purpose
Worker Limited skill Varied skill
Inventory Low in process and high High in process and low
finished finished
Storage space Small Large
Material handling Fixed path Variable path
Gangways Narrow Wide
(walkways)

Scheduling Easy Varied and dynamic

Layout decision Line balancing Machine location
Goal Equalized work at each station Minimize material handling cost
Advantage Efficiency Flexibility
 Cellular
CellularLayout
Layout
 A combination of process and product layouts
combines the advantages of both types of layouts.
 Here machinery is arranged in a process layout but
the process grouping is then arranged in a sequence
to manufacture various types and sizes of products.
 It is to be noted that the sequence of operations
remains same with the variety of products and sizes
 Identification of similar groups of items requiring
similar design (features: size, shape, use) is known

as Group Technology (GT)

 Typical
Typical Process
Processlayout
layout
111
Lathe 222
111 Fitting shop 222 Paint shop
Machines 222
333 333

111

333

11

111
11

1
222

333 333
222 Drilling Welding
Foundry
444
Machines Shop
444 444 444
 Cellular
CellularLayout
Layout
Manufacturing Cell 1
111 Lathe Drilling Fitting Welding Paint 111

Manufacturing Cell 2
222 Foundry Lathe Fitting Paint 222

Manufacturing Cell 3

Lathe Fitting Drilling Welding 333

333

Manufacturing Cell 4
444 Foundry Drilling Welding 444
 Cellular
CellularLayout
Layout
 Advantages of Group Technology Layout:
 Reduce material handling and transit time
 Reduce set up time
 Reduce work in progress
 Better use of human resource
 Easier to control
 Easier to automate

 Disadvantages of Group Technology Layout:

 Identification of similar groups of items may be difficult
 Line balancing is difficult
 Increased capital investment
 Expanded training and scheduling of worker
 Fixed
FixedPosition
PositionLayout
Layout
 Fixed position layout used for project in which
the product cannot be moved.
 Product remain stationary for the entire
manufacturing cycle and equipment, Material,
workers and other resources are brought to
production site.
 Product too bulky, heavy to move: Ship,
House, aircraft….
Fixed
FixedPosition
PositionLayout
Layout
Fixed
FixedPosition
PositionLayout
Layout
 Fixed
FixedPosition
PositionLayout
Layout
 Advantages:
 The workers identify themselves with a product in
which they take interest and pride in doing the job.
 Greater flexibility with this type of layout.
 Unique product

 Limitations:
 High variable cost (wages and other cost)
 Too much movement of tools, worker, machines,
etc….
 Individualized project so cost increases
 Production volume is less
 Designing Product Layout
Designing Product Layout
 Arranges machines and workers in a line according to the
operation.
 Product layout objective is balance the line:
 Line balancing is used to group work elements (task
activities) into each workstations (often the work area of a
single worker) so that all workers in each workstation are
active about the same amount of time.
 The process of that tries to equalized the amount of work
at each workstation is called as LINE BALANCING:
 Line Balancing:
Line Balancing:
 Line balancing operate under two conditions:
 Precedence requirements:
 Physical restriction on order in which operations
are performed.

Loading Process Unloading Packing

 Cycle time:
 The maximum amount of time a product is allowed
to spend at each workstation.
 Calculated: Production time available / desired
units of output
 Line Balancing:
Line Balancing:
 Suppose company wants to produce 120 units 8/hour
a day.
 Cycle time = Production time available / desired
units of output
 Cycle time = (8*60)/120 = 4 minutes.
Loading Process Unloading Packing

4 4 4 4

 Cycle time = 4 minutes

 Flow time: the time required to complete an item.
 (FT= 16 Minutes)
Line
Line Balancing:
Balancing:
 Line
Line Balancing:
Balancing: Steps
Steps
A trial-and-error method of line balancing uses the following steps to
arrive at a solution:

Draw and label a precedence diagram.

Calculate the desired cycle time required for the line.

Calculate the theoretical minimum number of workstations.

Group elements into workstations, recognizing cycle time and precedence

constraints.

Calculate the efficiency of the line

Determine if the theoretical minimum number of workstations or an

acceptable efficiency level has been reached. If not, go back to step.
 Line
Line Balancing:
Balancing:
• Real fruit need to produce 6000 fruit strip every 40 hour week.
• Real fruit need to produce 6000 fruit strip every 40 hour week.
• design an assembly line with fewest number of workstations.
• design an assembly line with fewest number of workstations.

Work Element Precedence Time (min)

A Press out sheet of fruit - 0.1

B Cut into strips A 0.2

C Outline fun shapes A 0.4

D Roll up and pack B,C 0.3

1.
1.Draw
Drawand
andlabel
labelaaprecedence
precedencediagram
diagram
Work Element Precedence Time (min)
A Press out sheet of fruit - 0.1
B Cut into strips A 0.2
C Outline fun shapes A 0.4
D Roll up and pack B,C 0.3
 Step 2 and 3:
0.2
 Cd = 40*60/6000 = 0.4 Min.
0.1 B

A D 0.3
 N= 0.1+0.2+0.3+0.4/.04 = 2.5

C  N=3

0.4
 Line
Line Balancing:
Balancing:
 4. Group elements into workstations, recognizing cycle time
and precedence constraints. (cycle time = 0.4 Min at each
work station)
 Assembly line operation:

wc 1 wc 2 wc 3

A,B C D

0.3 min 0.4 min 0.3 min

 Step 6: E = ti/n*Cd
 = 0.3+0.4+0.3/3*0.4 = 83.333%
 Balance delay = 1- efficiency