Types of Plant layouts?

A layout essentially refers to the arranging and grouping of machine of machines which are meant to produce goods. Grouping is done on different lines. The choice of a particular line depends on several actions. The method of grouping and types of layout are:


  1. Process layout, functional layout or job layout;
  2. Product layout, line processing layout or flow line layout;
  3. Fixed position layout and static layout;
  4. Cellular manufacturing (CM) layout or Group Technology layout;
  5. Combination layout or hybrid layout.

(1) Process Layout



  • Also called the Functional layout, layout for job lot manufacturing or batch production layout, the process layout involves a grouping together of like machines in one department.
  • For example: machines performing drilling operations are installed in the drilling departments; machines performing casting operations are grouped in the casting department and so on. In this way, there would be a heating department, painting department, a lathe department and the like, where similar machines are installed in the plants which flow the process layout.

    Process Layout
  • A Quality of raw materials is issued to a machine which performs the first operation. This machine may be situated anywhere in the factory. For the next operations, a different machine may be required, which may be situated in another part of the factory. The material should be transported to this other machine for department.
  • Machines in each department attend to any product that is taken to them. These machines are, therefore, called general purpose machines. Work has to be allotted to each department in such a way that no machine in any department is idle.

  1. While grouping machines according to process type, certain principles must be kept in mind. They are:
  2. The distance between departments needs to be as short as possible with a view to avoiding ling-distance movement of materials.
  3. Though like machines are grouped in one department. The departments themselves be located in accordance with the principle of sequence of operations. For example, in a steel plant, the operations are melting, casting, rolling, twisting, These different departments may be arranged in that order to avoid crossovers and back-tracking of materials.
  4. Convenience for inspection.
  5. Convenience for supervision. Process layout may be advantageously used in light and heavy engineering industries, made-to-order furniture industries and the like.

Advantages
  • Reduced investment on machines as they are general purpose machines.
  • Greater flexibility in operations i.e. product differentiation is possible.
  • Better and more efficient supervision is possible through specialization.
  • There is greater scope for expansion as the capacities of different lines can be easily increased.
  • This type of layout results in better utilization of men and machines.
  • It is easier to handle breakdown of equipment by transferring work to another machine or station.
  • There is greater incentive to the individual worker to increase his performance.

Disadvantages

  • There is difficulty in the movement of materials. Mechanical devices for handling materials cannot be conveniently used.
  • This type of layout requires more floor space per unit of production.
  • There is difficulty in production control.
  • Production time is more as work-in-progress has to travel from place to place in search of machines.
  • There is accumulation of work-in-progress at different places.

(2) Product Layout

  • Also called the straight-line or layout for serialized manufacture. Product layout involves the arrangement of machines in one line, depending upon the sequence of operations.
  • Materials are fed into the first machine and finished products come out at the last machine. In between, partly finished goods travel automatically, from machine to machine; the output of one machine becomes the input for the next machine.
  • It is a feast for the eyes to watch the way sugarcane, fed at one of the mill, comes out as sugar at the other end. Similarly, in paper mill, bamboos are fed into machine at one end and paper comes out at the other. In product layout, if there is more than one line of production, there are as many lines of machines.
  • Product Layout

  • The grouping of machines should be done, on product line, keeping in mind the following principles:

  1. All the machines tools or other items of equipments must be placed at the point demanded by the sequence of operations.
  2. There should be no points where one line crosses another line;
  3. Materials may be fed where they are required for assembly, but, not necessarily all at one point; and
  4. All the operations, including assembly, testing and packaging should be included in the line. The product layout may be advantageously followed in plants manufacturing standardized products on a mass scale as chemical, paper, sugar, refineries and cement industries.

Advantages

  1. There is mechanization of materials handling and consequently reduction in materials handling cost.
  2. This type of layout avoids production bottlenecks.
  3. There is economy in manufacturing time i. e. production time will be less.
  4. The layout facilitates better production control.
  5. It requires less floor area per unit of production.
  6. Work-in-production is reduced and investment thereon is minimized.
  7. Early detection of mistakes or badly produced items is possible.
  8. There are greater incentives to a group of workers to raise their level of performance.

Disadvantages

  1. Product layout is know for its inflexibility.
  2. This type of layout is also expensive.
  3. There is difficulty of supervision.
  4. Expansion is also difficult.
  5. Any breakdown of equipments along the production line disrupts the whole system.

Comparison of product layout and process layout

  • Mechanization of materials handling and consequently reduction in materials handling cost.
  1. Reduction in the investment on machines as they are general purpose machines.
  • Avoidance of bottlenecks.
  1. Greater flexibility in production.
  • Economy in manufacturing time.
  1. Better and efficient supervision possible through specialization.
  • Better production control.
  1. Better scope of expansion.
  • Less floor area required per unit of production.
  1. Better utilization of men and materials.
  • Minimum investment in work-in-progress.
  1. Easier to handle breakdowns of equipments by transferring work to another machine or station.
  • Early detection of mistakes or badly produced items.
  1. Full utilization of the plant capacity.
  • Greater incentives to a group of workers to raise their performance.
  1. Greater incentives to individual workers to raise the level of their performance.

(3) Fixed position layout
  • As the term implies, fixed position layout involves the movement of man and machines to the product which remains stationary.
  • In this type of layout, the material or major component in fixed location, and tools, machinery and men as well as other pieces of material are brought to this 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 is very bulky.
  • Also called the fixed location layout, this is followed in the manufacturing of bulky and heavy products, such as locomotives, ships, boilers, aircraft, and generators.
  • The constructions of a building require a fixed location layout because men, cement, sand, bricks, steel, wood and other are taken to the site of the construction.
  • Another example is that of a hospital, where doctors and nurses (workers) and medicines and other paraphernalia (materials) are taken to the patient (product).
    Fixed Position layout

(4) Cellular Manufacturing (CM) Layout
Cellular Manufacturing (CM) Layout
  • In cellular manufacturing (CM), Machines are grouped into cells and each cell functions some what like a product layout within a larger shop or process layout.
  • The figure shown above is an illustration of CM layout. Each cell in CM layout is formed to produce a single parts family_a few parts, all with common characteristics, which usually means that they require the same machines and have similar machine settings

Advantages

  • Lower work-in-process inventories
  • Reduced materials handling costs
  • Shorter flow times in production 
  • Overall performance often increases by lowering production costs and improving on time delivery.
  • Quality also tends to improve.

Disadvantages
  • Reduced manufacturing flexibility
  • Potentially increased machine-down time (since machines are contained to cells and may not be used all the time)
  • Duplication of equipments may be there so that parts need not be transported between cells.

(5) Combined layout

  • The application of principle of product layout, process layout or fixed location layout in their strict meanings is difficult to come across. A combination of product and process layouts, with an emphasis on either, is noticed in most industrial establishments. Plants are never laid out in either pure from. It is possible to have both types of layout in an efficiently combined from if the products manufactured are somewhat similar and not complex.


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