Facility
Layout
• Analyze the common types
of manufacturing layouts.
• Illustrate layouts used in
service settings
Facility Layout
• Facility – Place where goods are produced, or services are
provided.
• Layout – How materials/parts/jobs/machines/workforce, etc.
are arranged.
Guess the Facility!!
FACILITY LAYOUT
• Facility layout refers to the specific
ARRANGEMENT of
• Machinery
• Equipment, etc.
for achieving QUICK PRODUCTION at least COST.
What Decisions should be taken in Facility Layout ?
Determine placement of departments, work
groups within departments, workstations,
machines, and stock-holding points within a
production facility.
What is the main objective of Facility Layout?
To arrange all the elements (departments,
workstations, machines, etc.) in a way that ensures
smooth workflow (in a factory or in a service
organization)
OBJECTIVES OF GOOD LAYOUT
1. Material Handling Costs
2. Movement of people and material
3. Hazards to personnel
4. Accidents
1. Production Capacity
2. Labour Efficiency
3. Space Utilization
4. Ease of Supervision and Maintenance
Principles for Ideal Layout
• Minimum Travel
• Sequence
Ideal
Layout • Usage & Flexibility
• Safety & Satisfaction
• Compactness & Minimum Investment
When a Facility Layout is Necessary??
✓ A new facility is constructed.
✓ There is a change in demand or throughput rate.
✓ A new product or service is introduced.
✓ Different processes, equipment, technology are
installed.
Why A Good Facility Layout is
Necessary?
Effective use of available area
Minimization of production delays
Improved quality control
Better supervision
Improved utilization of labour
Avoidance of unnecessary and costly changes
What are the Inputs Required for Facility Layout?
• Specification of objectives and corresponding criteria to be used to evaluate design.
• Amount of space required and distance that must be traveled between elements in
the layout are common basic criteria.
• Estimates of product or service demand on the system.
• Processing requirements in terms of number of operations and amount of flow between
the elements in the layout.
• Space requirements for the elements in the layout.
• Space availability within the facility itself or, if this is a new facility, possible building
configurations.
Types of Layout
Process/Workcentre/Job-shop/Functional Layout
Product/Assembly Line/flow-shop Layout
Manufacturing Cell/Cellular Layout
Fixed Position/Project Layout
Service Facility Layout
Type-1
Process/Workcenter/Job-shop/Functional
Layout
• Similar equipment or functions are grouped together.
• A part being worked on travels, according to the established
sequence of operations, from area to area, where the proper
machines are located for each operation.
• Example: All lathe machines kept in one area and all drilling
machines in another area in a factory.
Type-2
Product/Assembly Line/flow-shop Layout
• Equipment or work processes are arranged according to the
progressive steps by which the product is made.
• The path for each part is, in effect, a straight line.
• Example: Assembly lines for shoes, chemical plants, and car
washes are all product layouts.
Type-3
Manufacturing Cell/Cellular Layout
• Groups dissimilar machines to work
on products that have similar shapes
and processing requirements.
• Example: metal fabricating, computer
chip manufacture
Type-4
Fixed Position/Project Layout
• The product (by virtue of its bulk or weight) remains
at one location.
• Manufacturing equipment is moved to the product rather
than vice versa.
• Example: Construction sites
Combination of Layout Types
• Many manufacturing facilities present a combination of two or more
layout types.
Example:
• A given production area may be organized as a workcenter, while another
area may be an assembly line.
• Different types of layouts may be used in each area, with workcenters used
in fabrication, manufacturing cells in subassembly, and an assembly line
used in final assembly.
Guess the layouts!!!!
Guess the layout!!!!
Process Layout for a Machine Shop
Guess the layout!!!!
Process Layout for a Departmental Store
Guess the layout!!!!
Product Layout for Wine Manufacturing
Guess the layout!!!!
Cellular Layout
Guess the layout!!!!
Fixed Position/Project Layout
True of False?
Manufacturing facilities can have
combination of multiple layout types.
True of False?
Manufacturing cell is similar to a process
layout in that cells are designed to perform
a specific set of processes.
True of False?
Manufacturing cell is similar to a product
layout in that the cells are dedicated to a
limited range of products.
Guess the Type of Layout
Sequence depends on product request
General purpose machines
Guess the Type of Layout
Sequence depends on product request
General purpose machines
Guess the Type of Layout
Pre-defined sequence of machines
Dedicated machines
Guess the Type of Layout
Pre-defined sequence of machines
Dedicated machines
Guess the Type of Layout
In hospitals, areas are dedicated to
particular types of medical care, such as
maternity wards and intensive care
units.
Guess the Type of Layout
In hospitals, areas are dedicated to
particular types of medical care, such as
maternity wards and intensive care
units.
Guess the Type of Layout
Product is not moving;
instead manpower and machine move to
the product
Guess the Type of Layout
Product is not moving;
instead manpower and machine move to
the product
Guess the Type of Layout
Guess the Type of Layout
Guess the Type of Layout
Movement of worker & machine;
not product
Bulky product
Portable machines
Guess the Type of Layout
Movement of worker & machine;
not product
Bulky product
Portable machines
Which Type of Layout??
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T T T
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T T T SG SG M M T
D D M D
M M D D D
SG CG CG D
M M SG
D D D
Resources to produce similar
Similar resources placed
products placed together
together
A B
Which Type of Layout??
T T T CG CG
T T T
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T T T SG SG M M T
D D M D
M M D D D
SG CG CG D
M M SG
D D D
Resources to produce similar
Similar resources placed
products placed together
together
A B
Process Layout Product Layout
Guess the Type of Layout
Guess the Type of Layout
Guess the Type of Layout
Product
Guess the Type of Layout
Product
Service Facility Layout
• Service-oriented industries
• Retails, Warehouses, etc.
Retail Layout Pattern
Retail Layout Pattern
Layout of Warehouse
Zones Zones Control station
Shipping doors
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Tractor trailer
Tractor trailer
Feeder lines Feeder lines
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