TYPES OF LAYOUT

A layout essentially refers to the arranging & grouping

of machines which are meant to produce goods.
The methods of grouping or types of layout are:
1. Process layout, functional layout or job shop
layout.
2. Product layout, line processing layout or flow line
layout.
3. Fixed position layout or static layout.
4. Cellular manufacturing layout or hybrid layout.
5. Combination layout or Hybrid layout.
 PROCESS LAYOUT

It involves grouping together like machines in one

department based upon their operational
characteristics.
E.g.. Machines performing drilling operations are
installed in the drilling dept, machines performing
casting operations are grouped in casting dept,
and so on..
Machines in each dept attend to any product that is
taken to them. These machines are therefore
called as ‘General purpose machines’.
Work has to e allotted in each department in such
a way that no machines in any dept should be
ideal.
In a batch production layout machines are
chosen
to do as many different as jobs possible.
While grouping the machines according to the
process type, certain principals have to be
fallowed:
> the distance b/w depts must be shorter so as
to avoid long distance movement of materials.
> The departments should be locted in
accordance with the serious of operations.
> Convenience for inspection.
> Convenience for supervision.
 PROCESS LAYOUT FOR MEDICAL CLINIC

neurology gynecology Labarotary test

Rest room Patient waiting

hall X-ray

Reception
room Plastic &
Reconstructive
surgery

pediatrics

pediatrics

pharmacy Patient entrance clinic

Patient exit clinic

 ADVANTAGES

• Reduced investments on machines as they are

general purpose machines.
• Greater flexibility in the production.
• Better & more efficient supervision is possible
through specialization.
• There are greater scope for expansion as the
capacities of different lines can be easily
increased.
• This type of layout results in better utilization of
men & machines.
• It is easier to handle breakdown of equipment by
transferring work to another machines.
• There is full utilization of equipment.
• The investment on equipment would be
comparatively lower.
• There is greater incentive to te individual worker
to increase his performance.
DISADVANTAGES:
• There is difficulty in the in movement of
materials.
• This type of layout requires more floor space.
• There is difficulty in production control.
• Production time is more as WIP has to
travel from place to place in search of
machines.
• There is accumulation of WIP at differt
places.
 PRODUCT LAYOUT

It involves the arrangements of machines in one

line, depending upon sequence of operations. In
product layout, if there is a more than one line of
production, there are as many lines of machines.
The emphasis here, therfore,is on special purpose
machines in contrast to the general purpose
machines which are installed in the process layout.
The investment on straight line layout is higher than
in the functional layout.
The product layout is followed in plants manufacturing
standardized products on a mass scale such as
chemical, paper, sugar, rubber, refineries & cement
industries.
 STARTS DRILL
PRODUCTION LATHE PRESS
#2

PACKAGING
MACHINE

DRILL
PRESS PAINTING
#1 MACINE
FINISH
PRODUCTION

PRODUCT LAYOUT IN MANUFACTURING PRODUCT

 The grouping of m/c’s should be done by
keeping in mind the fallowing principals:

• All the m/c tools or other items of equipment

must be placed at a point demanded by the
sequence of operations.
• There should be no points where one line
crosses another line.
• Materials may be fed where they are required for
assembly, but not necessarily all at one point.
• All the operations should be included in the line.
 ADVANTAGES
• There is mechanization of materials handling a &
consequently reduction in materials handling
cost.
• This type of layout avoids production
bottlenecks.
• There is economy in manufacturing time.
• The layout facilitates better production control.
• It requires less floor area per unit of production.
• WIP is reduced & investment thereon,
minimized.
• Early detection of mistakes.
• There is greater incentives to a group of workers
to raise their level of performance.
 DISADVANTAGES

• Product layout is known for its inflexibility.

• This type of layout is also expensive.
• There is difficulty of supervision.
• Expansion is also difficult.
• Any breakdown of equipment along the
production line can be disturpt the whole system.
 FIXED LAYOUT
Fixed position layout involves the movement of men
& machines to the product which remains
stationary. In this type of layout, the materials or
major components remains in a fixed ocation, &
tools, machinery & men as well as other pieces of
material are brought to this location.
The movement of men & machines is advisable as
the cost of moving them would be lesser.
This is fallowed in manufacturing of bulky & heavy
products, such as, construction of buildings,
locomotives, ships, boilers, aircraft & generators.
 FIXED POSITION LAYOUT

Raw materials

m/c’s & equipments AR CRAFT ASSEMBLY Finished product

(air craft)

labour
 ADVANTAGES
• Men & machines can be used for a wide
varity of operations producing different types
of products.
• The investment on lyout is very small
• The worker identifies himself with the
products & takes pride in it when the work is
complete.
• The high cost of & difficulty in transporting a
bulky product is avoided.
 CELLULR MANUFACTURING (CM)
LAYOUT
In CM, machines are grouped in to a cells &
cells function somewhat like product layout
within a larger shop or process layout.

Each cell in the CM layout is formed to

produce a single part family- a few partsm all
with a common charectrestics, which usually
means that they require the same machines
& have similar machine settings.
 ADVANTAGES
• Lower WIP inventories.
• Reduced materials handling cost.
• Shorter flow times in production.
• Simplified production planning ( mtrls & labour).
• Increased operators responsibilities.
• Improved visual control & fewer tooling changes,
therefore facilitating quicker set ups.
• Overall performance often increases by lowering
production costs & improving on time delivery.
• Quality also tends to improve.
 DISADVANTAGES
• Reduced manufacturing flexibility &
potentially increased machine- down time
( since machines are contained to cells & may
not be used all the time) & finally dublicate
pieces of equipment may be needed so that
parts need not be transported b/w cells.
 COMBINED LAYOUT
A combination of process & product layout is known
as combined layout.
It is possible to have both types of layout in an
efficiently combined form if the products
manufactured are some what similar & not
complex.
E.g.. In soap mfg plant, the machinery mfg soap is
arranged on the product line principle; but ancillary
services, such as heating, the mfg of glycerin, the
power house, the water treatment plant are
arranged on a functional basis.