CBMEC 1
OPERATIONS MANAGEMENT WITH TQM
MODULE 13
Monday
FACILITY LAYOUT
Facility layout is an arrangement of different aspects of manufacturing in an
appropriate manner as to achieve desired production results.
o Facility layout considers available space, final product, safety of users and
facility and convenience of operations.
An effective facility layout ensures that there is a smooth and steady flow of
production material, equipment and manpower at minimum cost.
o Facility layout looks at physical allocation of space for economic activity in
the plant.
o Therefore, main objective of the facility layout planning is to design
effective workflow as to make equipment and workers more productive.
Facility Layout Objective
1. To provide optimum space to organize equipment and facilitate movement of
goods and to create safe and comfortable work environment.
2. To promote order in production towards a single objective
3. To reduce movement of workers, raw material and equipment
4. To promote safety of plant as well as its workers
5. To facilitate extension or change in the layout to accommodate new product line
or technology upgrade
6. To increase production capacity of the organization
An organization can achieve the above-mentioned objective by ensuring the following:
1. Better training of the workers and supervisors.
2. Creating awareness about of health hazard and safety standards
3. Optimum utilization of workforce and equipment
4. Encouraging empowerment and reducing administrative and other indirect work
Factors affecting Facility Layout
1. The design of the facility layout should consider overall objectives set by the
organization.
2. Optimum space needs to be allocated for process and technology.
3. A proper safety measure as to avoid mishaps.
Sources:
https://www.managementstudyguide.com/facility-layout.htm
https://courses.lumenlearning.com/wm-introductiontobusiness/chapter/facility-location-and-layout/
4. Overall management policies and future direction of the organization
Design of Facility Layout
Flexibility - facility layout should provide flexibility for expansion or modification.
Space utilization - optimum space utilization reduces the time in material and
people movement and promotes safety.
Capital - capital investment should be minimal when finalizing different models of
facility layout.
Design Layout Techniques
Two or three dimensional templates - this technique utilizes development of a
scaled-down model based on approved drawings.
Sequence analysis - this technique utilizes computer technology in designing the
facility layout by sequencing out all activities and then arranging them in circular
or in a straight line.
Line balancing - this kind of technique is used for assembly line.
Types of Facility Layout
Process layout
The process layout arranges workflow around the production process.
All workers performing similar tasks are grouped together.
Products pass from one workstation to another (but not necessarily to every
workstation).
o or example, all grinding would be done in one area, all assembling in
another, and all inspection in yet another.
The process layout is best for firms that produce small numbers of a wide variety
of products, typically using general-purpose machines that can be changed
rapidly to new operations for different product designs.
o For example, a manufacturer of custom machinery would use a process
layout.
Sources:
https://www.managementstudyguide.com/facility-layout.htm
https://courses.lumenlearning.com/wm-introductiontobusiness/chapter/facility-location-and-layout/
Product or assembly-line layout
Products that require a continuous or repetitive production process use the
product (or assembly-line) layout.
When large quantities of a product must be processed on an ongoing basis, the
workstations or departments are arranged in a line with products moving along
the line.
Automobile and appliance manufacturers, as well as food-processing plants,
usually use a product layout.
Service companies may also use a product layout for routine processing
operations.
Fixed-position layout
Some products cannot be put on an assembly line or moved about in a plant.
A fixed-position layout lets the product stay in one place while workers and
machinery move to it as needed.
Sources:
https://www.managementstudyguide.com/facility-layout.htm
https://courses.lumenlearning.com/wm-introductiontobusiness/chapter/facility-location-and-layout/
Products that are impossible to move—ships, airplanes, and construction
projects—are typically produced using a fixed-position layout.
Limited space at the project site often means that parts of the product must be
assembled at other sites, transported to the fixed site, and then assembled.
The fixed-position layout is also common for on-site services such as
housecleaning services, pest control, and landscaping.
Cellular layouts
Cellular layouts combine some aspects of both product and fixed-position
layouts.
Work cells are small, self-contained production units that include several
machines and workers arranged in a compact, sequential order.
Each work cell performs all or most of the tasks necessary to complete a
manufacturing order.
There are usually five to 10 workers in a cell, and they are trained to be able to
do any of the steps in the production process.
The goal is to create a team environment wherein team members are involved in
production from beginning to end.
Sources:
https://www.managementstudyguide.com/facility-layout.htm
https://courses.lumenlearning.com/wm-introductiontobusiness/chapter/facility-location-and-layout/
Sources:
https://www.managementstudyguide.com/facility-layout.htm
https://courses.lumenlearning.com/wm-introductiontobusiness/chapter/facility-location-and-layout/
