03
LAYOUT TYPES
Dosen : Much Djunaidi
Presentasi Kuliah
TKI-313 Sistem Produksi
Jurusan Teknik Universitas Muhammadiyah Surakarta
Basic Layout Types
 Product layouts
 Process layouts
 Fixed-Position layout
 Combination layouts
Basic Layout Types
 Product layout

Layout that uses standardized processing
operations to achieve smooth, rapid, highvolume flow
 Process layout

Layout that can handle varied processing
requirements
 Fixed Position layout

Layout in which the product or project
remains stationary, and workers, materials,
and equipment are moved as needed
Product Layout
Raw
materials
or customer
Material
and/or
labor
Station
1
Material
and/or
labor
Station
Station
Station
2
3
4
Material
and/or
labor
Finished
item
Material
and/or
labor
Used for Repetitive or Continuous Processing
6-4
Advantages of Product Layout







High rate of output
Low unit cost
Labor specialization
Low material handling cost
High utilization of labor and equipment
Established routing and scheduling
Routing accounting and purchasing
6-5
Disadvantages of Product Layout
 Creates dull, repetitive jobs
 Poorly skilled workers may not maintain
equipment or quality of output
 Fairly inflexible to changes in volume
 Highly susceptible to shutdowns
 Needs preventive maintenance
 Individual incentive plans are
impractical
6-6
A UU-Shaped Production Line
Figure 6.6
In
1
2
3
4
5
Workers
6
Out
10
9
8
7
6-7
Product Layout
Figure 6.7 (cont’d)
Product Layout
(sequential)
Work
Station 1
Work
Station 2
Work
Station 3
Used for Repetitive Processing
Repetitive or Continuous Processes
6-8
Process Layout
Figure 6.7
Process Layout
(functional)
Dept. A
Dept. C
Dept. E
Dept. B
Dept. D
Dept. F
Used for Intermittent processing
Job Shop or Batch Processes
6-9
Advantages of Process Layouts
 Can handle a variety of processing
requirements
 Not particularly vulnerable to equipment
failures
 Equipment used is less costly
 Possible to use individual incentive
plans
6-10
Disadvantages of Process
Layouts
In-process inventory costs can be high
Challenging routing and scheduling
Equipment utilization rates are low
Material handling slow and inefficient
Complexities often reduce span of
supervision
 Special attention for each product or
customer
 Accounting and purchasing are more
involved





6-11
Fixed Position Layouts
 Fixed Position Layout: Layout in which the
product or project remains stationary, and
workers, materials, and equipment are
moved as needed.
 Nature of the product dictates this type of
layout
 Weight
 Size
 Bulk
 Large construction projects
6-12
Cellular Layouts
 Cellular Production

Layout in which machines are grouped into
a cell that can process items that have
similar processing requirements
 Group Technology

The grouping into part families of items with
similar design or manufacturing
characteristics
Functional vs. Cellular Layouts
Table 6.3
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
Service Layouts




Warehouse and storage layouts
Retail layouts
Office layouts
Service layouts must be aesthetically
pleasing as well as functional
Designing Process Layouts
Information Requirements:
1. List of departments
2. Projection of work flows
3. Distance between locations
4. Amount of money to be invested
5. List of special considerations
6. Location of key utilities
Example 3: Interdepartmental Work Flows
for Assigned Departments
30
1
A
170
B
3
10
0
C
2
Process Layout
Milling
Assembly
& Test
Grinding
Drilling
Plating
Process Layout - work travels
to dedicated process centers
Functional Layout
222
444
Mill
111 333
111
333
Lathes
222
111
444
222
Drill
Grind
3333
1111 2222
Heat
treat
Assembly
111
Gear
cutting
111
444
-1111
Lathe
222222222
3333333333
Mill
Mill
Drill
Drill
Lathe Mill
44444444444444
Mill
Heat
treat
Gear
-1111
cut
Heat
treat
Grind - 2222
Heat
treat
Grind - 3333
Drill
Gear - 4444
cut
Assembly
Cellular Manufacturing Layout