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Facility Layout
Refers to the specific arrangement of physical facilities
Facility layout studies are necessary whenever…
(1) A new facility Is constructed (2) there is a significant change in demand or through put volume (3) A new good or service is introduced to the customer benefit package (4) different processes, equipment, and/or technology are installed
Objective of layout studies
Minimize delays in materials handling and customer movement, maintain flexibility, use labor, and space, effectively, promote high morale and customer satisfaction, minimize energy, using an environmental impact, provide for good housekeeping and maintenance, and enhance sales as appropriate and manufacturing service facilities.
Product Layout
An arrangement based on the sequence of operations that is performed during the manufacturing of a good or delivery of a service
Examples of product layout
Subway, chipotle, credit card processing, paper manufacturing, insurance policy, processing, and automobile assembly
Advantages of product layout
Higher output rates, lower work in process, inventories, less materials handling, higher labor, and equipment, utilization, and simple planning and control systems.
Disadvantages of product layout
A breakdown of one piece of equipment can cause the entire process to shut down, a change in product design, or the introduction of a new product may require a major changes in the layout, flexibility can be limited, expensive to change, may provide little job satisfaction.
Process layout
Consists of a functional grouping of equipment or activities that do similar work
Examples of process layout
Job shops are an example of facilities that use this layout because they typically handleable wide variety of customized orders. Legal offices, shoe manufacturing, jet, engine, turbine, blades, and hospitals also use this process.
Advantages of process layout
Provide more flexibility and generally require a lower investment equipment. If a piece of equipment fails, it generally does not affect the entire system.
Disadvantages of process layout
Low equipment, utilization, high materials, handling costs, more complicated, planning, and control systems, entire worker skill requirements.
Cellular Layout
The design is not according to the functional characteristics of equipment, but rather is based on self-contained groups of equipment (called cells) Needed for producing a particular set of goods or services. Was developed at the Toyota motor company.
Cellular layout: operator
Responsible for loading the parts on the individual machine, performing the processing operation, unloading the parts, and moving them to the next operation. Working in parallel, they increase the output from the cell.
Group technology
The procedure of classifying parts and two such families. This layout facilitates the processing of families of parts with similar processing requirements.
Advantages of cellular layout
Workflow is standardized and centrally located, materials handling requirements are reduced, workers are able to concentrate on production rather than moving parts between machines. Workers have greater responsibility in this type of system therefore, they become more aware of their contribution to the product and this increases their morale and satisfaction.
Fixed-position layout
Consolidate the resources necessary to manufacture, a good or deliver a service, such as people, materials, and equipment, and one physical location.
Examples of fixed-position layout
The production of large items, such as heavy machine, tools, airplanes, buildings, locomotives, and ships. Require a high level of planning and control compared with other types of layouts
Product layout characteristics
Demand volume is high, equipment utilization is high, automation potential is high, set up/changeover requirements are high, flexibility is low, and type of equipment is highly specialized.
Process layout characteristics
Demand volume is low, equipment utilization is low, automation potential is moderate, set up/changeover requirements are moderate, flexibility is high, and type of equipment is general purpose.
Cellular layout characteristics
Demand volume is moderate, equipment utilization is high, automation potential is high, set up/changeover requirements are low, flexibility is moderate, and type of equipment is moderate specialization.
Fixed-position layout characteristics
Demand volume is very low, equipment utilization is moderate, automation potential is moderate, set up/change of requirements are high, flexibility is moderate, and type of equipment is moderate specialization
specialization; flexibilty
In service organizations, the basic trade-off between product and process layouts concerns the degree of ____ versus ____
process layout.
Those that need the ability to provide a wide variety of services to customers with different requirements usually use a ___
product layout.
Service organizations that provide highly standardized services tend to use ___
