What type of layout is being used where the product remain stationary for the entire manufacturing cycle?

Layout planning is one of the most important aspects of Lean manufacturing. In some cases, it would be one of the solutions introduced in the Improve phase of DMAIC methodologies in lean six sigma projects. Layout planning directly or indirectly promotes product and service quality, provides flexibility to adapt to changing conditions, facilitates a smooth flow of work, material, and information and incorporate safety and security measures.

Different types of layout

Depending on the nature of the process. Different types of layouts can be used in a manufacturing or service process. These are the most common types of layout:

• Process Layout
• Product Layout
• Fixed Position Layout
• Cellular Layouts

Process Layout

It is also called functional, job shop or batch shop layout. It is very common to be a non-repetitive and intermittent process that can handle varied processing requirements. The machines are grouped according to the process they perform such as all x-ray machines in the same area. It causes low raw material and finished goods inventory but high Work In Process (WIP) inventory. It is not particularly vulnerable to equipment failures and general-purpose equipment is used which is often less costly than the specialised equipment.

As the disadvantages of process layout, we can refer to high WIP inventory cost, low machine utilization, slow and inefficient material handling and more complexity for routing, scheduling and supervision.

Product layout

Contrary to process layout, in product layout, workstations are arranged to produce a specific product as uses standardised processing operations to achieve smooth, rapid, high volume and repetitive flow which is appropriate for the standardised product, high production volume, and stable production quantities. Low unit cost regarding the high rate of output, high utilisation of labour and equipment and established routing and scheduling might be considered as the advantages of the product layout. On the other hand, creating dull and repetitive jobs with less flexibility to changes in volume or product/process design, being highly susceptible to equipment failures and high investment in justified equipment, largely raw material and finished goods inventory are disadvantages of this type of layout.

Fixed Position Layout

Layout in which the product or project remains stationary (cannot be moved), and workers, materials, and equipment are moved as needed. In this layout, highly skilled labour is needed. Fixed costs are low but variable costs are typically variable.

Cellular Layout

Cellular Layout captures advantages of both process and product layout and it is more common in lean manufacturing. A layout in which similar parts are identified and grouped together to take advantage of their similarities in design and production is typically called group technology (GT). Similarities among parts permit them to be classified into part families. In each part family, processing steps are similar.

The improvement is typically achieved by organising the production facilities into manufacturing cells that specialise in the production of certain part families.

Cellular manufacturing can be implemented by manual or automated methods. When automated, the term “flexible manufacturing system” is often applied.

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Option 3 : Fixed position layout

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Explanation:

Layout planning in manufacturing and service organisations involves the physical arrangement of various resources available in the system to improve the performance of the operating system, thereby providing better services in less time.

Layouts can be classified into the following four categories:

1. Process layout
2. Product layout
3. Group layout (Combination layout)
4. Fixed-position layout

PROCESS LAYOUT:

• It is also known as the functional layout and is characterized by keeping similar machines or similar operations at one location (place).
• In other words, all lathes will be in one place, all milling machines at another, and so on, that is machines have been arranged according to their functions.

Process Layout is employed where:

• low volume of production is required.
• similar jobs are manufactured on similar machines (Eg. Refining of crude oil).
• machined are arranges on functional basis.

Drawbacks of Process Layout:

• More floor space is required.
• Production control is more difficult and costly as it increases handling cost.

PRODUCT LAYOUT:

• It is also known as line layout. It implies that various operations on raw material are performed in a sequence and the machines are placed along the product flow line i.e. machines are arranged in the sequence in which the raw material will be operated upon.
• This type of layout is preferred for continuous production i.e. involving a continuous flow of in-process material towards the finished product stage.
• It is used for mass production of a product i.e. in automobile assembly.

Advantages of Product layout:

• Handling cost reduces.
• Less in-process inventory.
• Less supervision.
• Efficient space utilisation.
• Higher productivity i.e. cycle time is short.

Disadvantages:

• Lack of flexibility.
• Breakdown stops the entire process.
• Output quantity fixed, no alteration can be made.

FIXED PRODUCT LAYOUT:

• It is also known as a static product layout.
• In other types of layouts earlier, the product moves post stationary production equipment, whereas in this case, the reverse applies men and equipment are moved to the material which is very large in size i.e. remains at one place and the product is completed at that place.
• It is used in shipbuilding; aircraft manufactured big pressure vessel fabrication.

UNIT PRODUCT LAYOUT:

It is similar to fixed product layout but here the quantity also reduced to unity eg. launch of a satellite.

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Plant layout is a plan of optimum management of facilities which include; personnel, operating equipment, storage space, material handling equipment, and all other support services

It includes the arrangement and location of work centres and various service centres like inspection, storage, and shipping within the manufacturing/factory building.

Plant Layout identically involves the allocation of space and the arrangement of equipment in such a manner that overall operating cost is minimised.[James Lundy]

It begins with plant location and continues through three categories, namely:

• The layout of departments within the site
• The layout of items within the department(s).
• Layout of individual workplaces.

Stages of the procedure of Plant Layout

1. Objectives
2. Information gathering
3. Production and flow analysis
4. Compilation of overall plan
5. Support services
6. Implementation and evaluation.

Plant Layout Procedure

Phase 1 - Information gathering

• Determine what will be produced
• Determine how many products will be produced
• Determine what components will be made or purchased
• Determine required operations
• Determine the sequence of operations
• Set time standards for each operation

Phase 2 Production and Flow Analysis

• Determine the number of machines
• Balance production lines
• Study the flow requirements
• Determine activity relationships
• Layout each workstation

Phase 3 - Support Services

• Identify the needs for personal and plant services
• Identify office needs
• Develop total space requirements
• Select material handling equipment
• Develop plot plan and building shape

Phase 4 - Implementation and Evaluation

• Construct master plan
• Seek input and adjustment
• Seek approvals
• Install
• Start up
• Follow up

Principles of Plant Layout:

• Integration
• Minimum distance
• Maximum space utilisation
• Process Flow
• Maximum flexibility
• Safety, security and satisfaction
• Minimum material handling

Layout evaluation:

Objectives of a Good Plant Layout:

The main objectives are revealed through the attainment of the following facts;

• Congestion reduction
• Elimination of unnecessary occupied areas
• Reduction of administrative and indirect work
• Improvement on control and supervision
• Better adjustment of changing directions
• Better utilisation of the workforce, equipment and services
• Reduction of material handling activities and stock in process
• Reduction on parts and quality risks
• Reduction on health risks and increase on workers safety
• Ensuring that workers satisfaction is increased
• Reduction on delays and manufacturing time as well as production capacity

These factors above cannot be reached simultaneously.

Factors influencing Facility Layout:

1. Management/Managerial Policy and Decisions
2. Nature of plant location
3. Type of machinery used
4. Nature of product to be manufactured or produced
5. Method of production
6. Minimum movement
7. The arrangement of materials handling equipment.
8. Continuance
9. Availability of total floor area
10. Type of industry
11. Possibility of future expansion
12. Flexibility

Principles of Layout

• The principle of minimum travel (from suppliers, to the airport, to customers, etc)
• The principle of sequence
• Effective use of available space
• The principle of usage
• The principle of safety
• Maximum visibility
• The principle of flexibility
• The principle of minimum investment
• Maximum accessibility
• Overall integration of factors

A good layout is one that integrates men, materials, machines and supporting activities and others in a way that the best compromise is obtained. no layout can satisfy each and every principle of a good layout.

A good layout is one that permits the minimum movement between the operations. The plant and machinery in case of product layout and departments in case of process layout should be arranged as per sequence of operations of most of the products.

A straight line is the shortest distance between any two points. men and materials should be made to move along the straight path.

A good layout is one that makes the materials move only in the forward direction, towards the completion stage.

When a straight line flow is not possible, other flows like a U-shaped flow, circular or zig-zag flow may be adopted but the layout must ensure that materials move in a forward direction.

• Effective use of available space

A good layout is one that makes effective use of available space both horizontal and vertical

Backtracking and duplicated movements consume more time, involve unnecessary materials handling, add to costs and lead to inefficiency.

Raw materials, work-in-progress and finished goods should be piled vertically one above another rather than being strewn on the floor.

Pallets or equivalent should be made use of to pile up several layers one above another.

A good layout is one that makes men, machines and materials ready and observable at all times

All departments should be integrated, convenient to service and easy to supervise

Enclosures, cupboards, offices, partitions should be avoided except when their utility is established beyond doubt.

A good layout is one that makes all servicing and maintenance points readily accessible

Machines should be kept sufficiently apart and with reasonable clearance from the wall so that lubrication, adjustment, replacement of belts, removal of parts at times of repair can be done conveniently by the maintenance staff

The area of electrical panels and fire extinguishers should be kept free from obstructions.

Types of Plant Layout:

1. Product layout or line processing layout or flow-line layout
2. Process layout or functional layout or job shop layout
3. Fixed position layout or static layout
4. Cellular manufacturing (CM) layout or Group Technology layout
5. Combination layout or Hybrid layout or Mixed layout
6. Service Facility Layout

Product Layout:

• It involves the arrangement of machines in one line depending on the sequence of operations.
• The material is fed into the first machine and finished products come out of the last machine. e.g. Sugarcane to sugar, Bamboo to paper, plastic to plastic smart cards production
• Emphasis is on special purpose machines so high investment is needed.

Advantages of a good, well planned and designed Layout:

1. Labour costs

• Increase in productivity with more units being produced per man hour.
• Reduction in the number of workers.
• Minimal movement between operations.

2. Production control

• Increased production rate.
• Provision of convenient and adequate storage points.
• Improved ability of forecasting manufacturing time and delivery.

3. Supervision

• Lesser requirement of supervision.
• Reduction in time spent on inspection.
• Reduction in cost of inspection.

4. Other manufacturing costs

• Reduced consumption of power.
• Minimisation of scrap and defective products.
• Better quality due to reduced handling.
• Reduced costs of maintenance.
• Improved utilisation of materials.

5. Workers

• Reduction in the number of those handling production related paraphernalia.
• Reduced effort, stress and strain.
• Better safety and less chance of accidents.
• Improved productivity leading to higher wages.
• Increased morale and motivation.
• Improved health and welfare.

Process Layout:

Involves the arrangement of similar machines in a group in one department/one area according to the functions performed in the department e.g. welding machines.

Advantages of a Good Process Layout:

1. Reduced investment in machines if they are general purpose machines.
2. Flexibility in production
3. Better and more efficient supervision is possible through specialisation
4. Better utilisation of men and machines
5. Full and efficient utilisation of equipment

Disadvantages a Bad Process Layout:

1. Difficulty in the movement of materials
2. If more floor space is needed
3. Difficulty in production control
4. More production time

Fixed position layout:

• Major components remain in a fixed location.
• The movement of men and machines to the product is advisable because the cost of moving them would be less than the cost of moving the product which is very bulky.
• For example construction of buildings or bridges, ship-building etc.

Cellular Manufacturing(CM) Layout:

Machines are grouped into cells, and each group makes a family of parts which require similar operation and service. It lies in between process layout and line layout.

Importance of Cellular Plant Layout:

1. Economies in Handling
2. Effective use of available area
3. Minimisation of production delays
4. Improved quality control
5. Better production control
6. Better supervision
7. Improved utilisation of labour
8. Improved employee morale

Why Layout problems exist

• Enlargement or contraction of existing departments
• Movement of a department due to changes in the design of the product.
• Addition of a/some new department(s)
• Replacement or addition of a facility/machinery.

1. Nature of the product: The nature of the product to be manufactured has a significant influence on plant layout. Small and light products can be moved from one machine to another with minimum effort and time and therefore line layout would be more suitable. Stationary layout would be suitable for heavy and bulky products. In case of production of large variety of non-standardized products, process layout is ideal.

2. Production volume: Line layout should be preferred if standardized commodities are manufactured on a large scale. Functional layout is suitable if production is based on customers orders. It is better suited for low volume job production.

3. Location of the site: The topology and size of the site influences the choice of a particular layout. The idea is to maximise the utilisation of space. Layout should also suit the factory building. The positioning of elevators, stairways, parking lots and storage points also influence the layout.

4. Type of machines: Stationary layout is preferable if machines are heavy and emit more noise. Such heavy machinery can be fitted on the floor. Adequate space should be provided for the location of machines and also there should be sufficient space between them to avoid accidents.

5. Climate: Temperature, illumination, ventilation should be considered while deciding on the type of layout. These factors should be considered in order to improve the health and welfare of employees.

6. Service facilities: The layout should provide for the comforts and welfare of the employees. It should have adequate provision for rest rooms, drinking water, lavatory. There should be sufficient space for free movement of workers.

7. Safety of employees: While deciding on a particular type of layout, the safety of employees should be given importance. The layout should provide for obstruction free floors, non-slippery floors, protection against dangerous fumes, excess heat, strong odours etc.

8. Type of production: Layout plans differ according to the type of production. In case of job orders, production of non-standardised products are undertaken, and therefore functional or process outlet is suitable. Line layout would be suitable when there is mass production of standardized goods.

9. Type of process: In the case of intermittent type of production (bi-cycle manufacturing, electronics), functional layout is suitable. For synthetic type of Production (cement and automobile industries), line layout is preferable.

10. Management policies: Policies of the management relating to type of product, quality, scale of production, level of plant integration, type of production, possibility of future expansion etc., influence the type of layout to be adopted.

Characteristics of an Efficient Layout

The designing of a plant layout should be such that it should maximise the return and minimise the cost of production.

The following are the characteristics of a plant layout:

1. Smooth flow of production

Plant layout should be in such a way that there must be a smooth flow of production. Raw materials and workers must have access to each machine without any difficulty and delay.

2. Maximum utilisation of available space

An efficient plant layout must be such that may utilize the maximum of the space available.

3. Facilitating the movement of men, materials and machines, etc.

There must be sufficient space left in between different machines so that raw materials, workers and machines move very easily from one place to another, without the fear of accident.

4. Involves minimum handling

The various machines in a good layout must be arranged in such a manner that the product of one operation may pass on to the next operation with a minimum of handling. It will reduce wastage of raw materials and labour hours.

5. Provides better working conditions

A good plant layout must have facilities such as water, ventilation, retiring room, etc., in the plant. It should also safeguard the health of the workers.

6. Flexibility

A good layout must be flexible enough so as to incorporate any change in the management policies. It must be capable of incorporating, without major change, new equipment to meet technological changes and or progress, or increased production requirements or to eliminate waste.

7. Location of stores

The stores/storage in a plant must be located in such a place from where raw materials, tools, equipment and other materials may be supplied to the departments concerned easily, without any delay.

8. Facilitates supervision and control

The position of workers must be arranged in such a way that it facilitates supervision, coordination and control.

9. Provision of safety

There must be complete safety for workers engaged on a machine(s). Necessary instructions must be given to them about the risks involved while working on certain types of machines. The Provisions of Factories Act must be followed at all times.

10. Co-ordination and integration

If the plant layout is efficient enough, it is possible to achieve maximum with coordination and integration among men, machines and materials.

A decision to manufacture some new or modified products may necessitate a reorganisation of the existing plant or provision of additional facilities. The reasons for change are due to variation in the level of demand, change in the location of product markets, change in style and obsolescence or failure of existing equipment.

Thus, development of a proper layout for a plant calls for careful planning. Such planning involves considerations of the technical aspects of the machinery and equipment and processes of manufacture, etc. Company related Management executives can benefit considerably by involving a highly qualified engineer(s) and or maybe management consultants while designing a plant layout. In this way, plant layout is a joint product of both the disciplines, namely, engineering and management.

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