Facilities Planning - Unit
Layout Types: Manufacturing
04
Hierarchy of Facility Planning
Layout Design
Facility
Location
Facility
Planning
Facility
Design
Source for Figure: Tompkins and White,
Facilities Planning, 2nd edition, Wiley
Structural Design
Layout
Design
Handling System
Design
Layout Types: Manufacturing - 2
Layout Design
 Facility layout means planning:
 for the location of all machines, utilities, employee
workstations, customer service areas, material
storage areas, aisles, restrooms, lunchrooms,
internal walls, offices, and computer rooms
 for the flow patterns of materials and people
around, into, and within buildings
Layout Types: Manufacturing - 3
Layout Design
Planning for required Spaces and Areas








Equipment
Work stations
Material storage
Rest/break areas
Utilities
Eating areas
Aisles
Offices
Layout Types: Manufacturing - 4
Layout Design – Introduction
Characteristics of the Facility Layout Decision
 Location of these various areas impacts the flow
through the system.
 The layout can affect productivity and costs
generated by the system.
 Layout alternatives are limited by
 the amount and type of space required for the
various areas
 the amount and type of space available
 the operations strategy
Layout Types: Manufacturing - 5
Basic Layout Types




Product Layouts
Process Layouts
Fixed-position layouts
Cellular/Group technology layouts
Layout Types: Manufacturing - 6
Basic Layout Types
Product Volume vs. Product Variety
High
Product
Planning
Department
Volume
Product Layout
Medium
Fixed Location Layout
Fixed Materials
Location Planning
Department
Product Family
Planning
Department
Group Technology Layout
Process Layout
Process
Planning
Department
Low
Low
Medium
High
Variety
Layout Types: Manufacturing - 7
Types of Layout
Fixed Position Layout
Lathe
Press
Grind
W
a
r
e
h
o
u
s
e
S
t
o
r
a
g
e
Weld
Paint
Assembly
Layout Types: Manufacturing - 8
Types of Layout
Fixed Position Layout
Layout in which the product or project remains stationary, and
workers, materials, and equipment are moved as needed.
Examples:

Large construction projects (buildings, power plants, dams)

Shipbuilding, production of large aircraft

Rockets used to launch space missions
Layout Types: Manufacturing - 9
Types of Layout
Fixed Position Layout: Advantages
 Material movement is reduced.
 Promotes job enlargement by allowing
individuals or teams to perform the
“whole job”.
 Continuity of operations and
responsibility results from team.
 Highly flexible; can accommodate
changes in product design, product mix,
and product volume.
 Independence of production centers
allowing scheduling to achieve minimum
total production time.
Layout Types: Manufacturing - 10
Types of Layout
Fixed Position Layout: Limitations
 Increased movement of personnel and
equipment.
 Equipment duplication may occur.
 Higher skill requirements for personnel.
 General supervision required.
 Cumbersome and costly positioning of
material and machinery.
 Low equipment utilization.
Layout Types: Manufacturing - 11
Types of Layout
Product Type Layout
Lathe
S
t
o
r
a
g
e
Drill
Press
Bend
Mill
Drill
Lathe
Lathe
Grind
Drill
Drill
A
s
s
e
m
b
l
y
W
a
r
e
h
o
u
s
e
Drill
Layout Types: Manufacturing - 12
Types of Layout
Product Type Layout - Requirements




Standardized product
High production volume
Stable production quantities
Uniform quality of raw materials & components
Layout Types: Manufacturing - 13
Types of Layout
Product Type Layout - Assumptions
 Volume is adequate for high equipment utilization
 Product demand is stable enough to justify high
investment in specialized equipment
 Product is standardized or approaching a phase of its
life cycle that justifies investment in specialized
equipment
 Supplies of raw materials and components are
adequate and of uniform quality ensure they will work
with specialized equipment
Layout Types: Manufacturing - 14
Types of Layout
Product Type Layout - Advantages
 Since the layout corresponds to the sequence of
operations, smooth and logical flow lines result.
 Since the work from one process is fed directly
into the next, small in-process inventories result.
 Total production time per unit is short.
 Since the machines are located so as to minimize
distances between consecutive operations,
material handling is reduced.
 Little skill is usually required by operators at the
production line; hence, training is simple, short,
and inexpensive.
 Simple production planning control systems are
possible.
 Less space is occupied by work in transit and for
temporary storage.
Layout Types: Manufacturing - 15
Types of Layout
Product Type Layout - Limitations
 A breakdown of one machine may lead to a
complete stoppage of the line that follows that
machine.
 Since the layout is determined by the product, a
change in product design may require major
alternations in the layout.
 The “pace” of production is determined by the
slowest machine.
 Supervision is general, rather than specialized.
 Comparatively high investment is required, as
identical machines (a few not fully utilized) are
sometimes distributed along the line.
Layout Types: Manufacturing - 16
Types of Layout
Process Type Layout
Lathe
S
t
o
r
a
g
e
Lathe
Drill
Weld
Lathe
Lathe
Drill
Paint
Mill
Mill
Grind
Assembly
Mill
Mill
Grind
Assembly
Weld
Paint
W
a
r
e
h
o
u
s
e
Layout Types: Manufacturing - 17
Types of Layout
Process Type Layout
 Process type layouts can handle varied processing
requirements
 The layouts feature departments or other functional groupings
in which similar kinds of activities are performed
 Examples: Machine shops usually have separate departments
for milling, grinding, drilling, and so on
 Different products may present quite different processing
requirements and sequences of operations
Layout Types: Manufacturing - 18
Types of Layout
Process Type Layout
Milling
Assembly Test
Drilling
Grinding
Plating
Process Layout - work travels to dedicated process centers
Layout Types: Manufacturing - 19
Types of Layout
Process Type Layout - Advantages
 A high degree of flexibility exists relative
to equipment or manpower allocation for
specific tasks.
 Comparatively low investment in
machines is required.
 The diversity of tasks offers a more
interesting and satisfying occupation for
the operator.
Layout Types: Manufacturing - 20
Types of Layout
Process Type Layout - Limitations
 Since longer flow lines usually exist, material
handling is more expensive.
 Production planning and control systems are
more involved.
 Total production time is usually longer.
 Comparatively large amounts of in-process
inventory result.
 Space and capital are tied up by work in
process.
 Because of the diversity of the jobs in
specialized departments, higher grades of
skill are required.
Layout Types: Manufacturing - 21
Types of Layout
Process Layout vs. Product Layout
Layout Types: Manufacturing - 22
Types of Layout
Group Technology/Cellular/Product Family Layout
Lathe
S
t
o
r
a
g
e
Drill
Grind
Assembly
Mill
Assembly
Weld
Paint
Press
Lathe
Drill
Press
Assembly
Grind
Drill
Assembly
Drill
Grind
W
a
r
e
h
o
u
s
e
Layout Types: Manufacturing - 23
Types of Layout
Group Technology vs. Cellular Manufacturing
 Group Technology (GT) is a management philosophy that
attempts to group products with similar design or
manufacturing characteristics, or both.
 Cellular Manufacturing (CM) is an application of GT that
involves grouping machines based on the parts
manufactured by them.
 The main objective of CM is to identify machine cells and
part families simultaneously, and to allocate part families
to machine cells in a way that minimizes the intercellular
movement of parts.
Layout Types: Manufacturing - 24
Types of Layout
Group Technology/Cellular Layout – Example A (page 1)
Original Process Layout
Assembly
4
6
7
8
5
2
A
B
12
10
3
1
9
C
11
Raw materials
Layout Types: Manufacturing - 25
Types of Layout
Group Technology/Cellular Layout – Example A (page 2)
Original Part Routing Matrix
Parts
1
2
A
B
C
D
E
F
G
H
x
x
3
Machines
4 5 6 7
8
x
x
x
x
x
x
x
x
10 11 12
x
x
x
x
x
x
x
9
x
x
x
x
x
x
x
x
x
x
x
x
x
Layout Types: Manufacturing - 26
Types of Layout
Group Technology/Cellular Layout – Example A (page 3)
Reordered Part Routing Matrix
Parts
1
2
4
Machines
8 10 3 6
A
D
F
C
G
B
H
E
x
x
x
x
x
x
x
x
x
x
x
9
5
7
11 12
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Layout Types: Manufacturing - 27
Types of Layout
Group Technology/Cellular Layout – Example A (page 4)
Revised Cellular Layout
Assembly
8
10
9
12
11
4
Cell 2 6
Cell 1
Cell 3
7
2
1
3
5
A B C
Raw materials
Layout Types: Manufacturing - 28
Types of Layout
Group Technology/Cellular Layout – Example B (page 1)
Unorganized Parts
Layout Types: Manufacturing - 29
Types of Layout
Group Technology/Cellular Layout – Example B (page 2)
Process Flows before the Use of GT Cells
Layout Types: Manufacturing - 30
Types of Layout
Group Technology/Cellular Layout – Example B (page 3)
Transition from Process Layout
1.
Grouping parts into families that follow a common
sequence of steps.
2.
Identifying dominant flow patterns of parts families
as a basis for location or relocation of processes.
3.
Physically grouping machines and processes into
cells.
Layout Types: Manufacturing - 31
Types of Layout
Group Technology/Cellular Layout – Example B (page 4)
Grouping parts into families
Layout Types: Manufacturing - 32
Types of Layout
Group Technology/Cellular Layout – Example B (page 5)
Process flows after the Use of GT Cells
Layout Types: Manufacturing - 33
Types of Layout
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Lathe
Mill
Drill
Heat
treat
Gear
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cut
BBBBBBBBB
Mill
Drill
Heat
treat
Grind BBBB
CCCCCCCCCC
Lathe
Mill
Heat
treat
Grind CCCC
Drill
Gear DDDD
cut
DDDDDDDDDDDDDD
Mill
Assembly
Group Technology/Cellular Layout
Related topic: Mixed model Assembly/manufacturing
Layout Types: Manufacturing - 34
Types of Layout
Group Technology/Cellular Layout
Grouping parts into families
A family of similar parts
A family of related grocery items
Layout Types: Manufacturing - 35
Types of Layout
Group Technology vs. Cellular Manufacturing
Potential benefits of CM
 Setup time reduction
 Work-in-process (WIP)
reduction
 Material handling cost reduction
 Direct/indirect labor cost
reduction
 Improvement in quality
 Improvement in material flow
 Improvement in machine
utilization
 Improvement in space utilization
 Improvement in employee moral
Layout Types: Manufacturing - 36
Basic Layout Types
Product Volume vs. Product Variety
High
Product
Planning
Department
Volume
Product Layout
Medium
Fixed Location Layout
Fixed Materials
Location Planning
Department
Product Family
Planning
Department
Group Technology Layout
Process Layout
Process
Planning
Department
Low
Low
Medium
High
Variety
Layout Types: Manufacturing - 37
Types of Layout
Process (Functional) Layout vs. Cellular Layout
Dimension
Functional
Cellular
Number of moves between departments
Many
Few
Travel distances
Longer
Shorter
Travel paths
Variable
Fixed
Job waiting times
Greater
Shorter
Throughput time
Higher
Lower
Amount of work in process
Higher
Lower
Supervision difficulty
Higher
Lower
Scheduling complexity
Higher
Lower
Equipment utilization
Lower
Higher
Layout Types: Manufacturing - 38
Types of Layout - Example
Direction of part movement within cell
A Manufacturing Cell
with Worker Paths
HM
VM
Worker 3
VM
L
Paths of three
workers moving
within cell
Worker 2
Material
movement
G
L
Key:
S
= Saw
L
= Lathe
HM = Horizontal milling
machine
VM = Vertical milling machine
G
= Grinder
Final
inspection
S
Worker 1
In
Finished
part
Out
Layout
Types:Manufacturing
Manufacturing-- 39
39
Layout
Types:
Types of Layout - Example
Manufacturing Cell
Animated Picture
Layout Types: Manufacturing - 40
Types of Layout - Example
Manufacturing Cell
An example of a hybrid layout
Layout Types: Manufacturing - 41
Types of Layout - Example
Automated Manufacturing Cell
An example of a hybrid layout
Layout Types: Manufacturing - 42
Types of Layout - Example
Flexible Manufacturing Cell
An example of a hybrid layout
Layout Types: Manufacturing - 43
Types of Layout
Work Cell, Focused Work Center, and Focused Factory
Work Cell
Assembly or Production line-oriented arrangement of
machines and personnel in what is ordinarily a processoriented facility. Cells can be formed on a temporary basis.
Example: job shop with rearranged machinery and
personnel to produce 30 unique control panels
Focused Work
Center
A permanent assembly-line-oriented arrangement of
machines and personnel in what is ordinarily a processoriented facility
Example: manufacturing of pipe brackets at a shipyard
Focused Factory A permanent facility to produce a product or component in
a product-oriented facility
Example: a plant to produce window mechanisms for
automobiles
Layout Types: Manufacturing - 44
Principles of a Good Layout
Manufacturing









Straight-line Flow Pattern when possible
Backtracking kept to a Minimum
Predictable Production Time
Little In-process materials storage
Open Floor plans so everyone can see what is going on
Bottlenecks under control
Workstations close together
Minimum of material handling
Easy adjustment to changing conditions
Layout Types: Manufacturing - 45
New Trends in Manufacturing Layouts
 Designed for quality and flexibility
 Ability to quickly shift to different product models or to
different production rates
 Cellular layout within larger process layouts
 Automated material handling
 U-shaped production lines use to better accomplish flow control
 More open work areas with fewer walls, partitions, or
other obstacles
 Smaller and more compact factory layouts
 Less space provided for storage of inventories
throughout the layout
Layout Types: Manufacturing - 46
Wrap-Up
World-Class Practices
 Strive for flexibility in layouts
 Multi-job training of workers
 Sophisticated preventive-maintenance programs
 Flexible machines
 Empowered workers trained in problem solving
 Layouts small and compact
 Services follow the above practices plus incorporate
customer needs in design
Layout Types: Manufacturing - 47
Wrap-up
Attaining Lean Production









Focus on inventory reduction
Build systems that help employees
Reduce space requirements
Develop close relationships with suppliers
Educate suppliers
Eliminate all but value-added activities
Develop the workforce
Make jobs more challenging
Set sights on perfection!
Layout Types: Manufacturing - 48