TYPES OF LAYOUTSThere are four basic layout types: process, product, hybrid, and fixed position. In this section we look at the basic characteristics of each of these types. Then we examine the details of designing some of the main types. Show
Layouts that group resources based on similar processes or functions. Process layouts arrange items by type as seen in this grocery store. Process LayoutsProcess layouts are layouts that group resources based on similar processes or functions. This type of layout is seen in companies with intermittent processing systems. You would see a process layout in environments in which a large variety of items are produced in a low volume. Since many different items are produced, each with unique processing requirements, it is not possible to dedicate an entire facility to each item. It is more efficient to group resources based on their function. The products are then moved from one resource to another, based on their unique needs. The challenge in process layouts is to arrange resources to maximize efficiency and minimize waste of movement. If the process layout has not been designed properly, many products will have to be moved long distances, often on a daily basis. This type of movement adds nothing to the value of the product and contributes ... Classification and Advantages of Plant LayoutLayouts can be classified into the following five categories:
Process Layout Thus, in process layout the arrangement of facilities are grouped together according to their functions. A typical process layout is shown in the following figure. The flow paths of material through the facilities from one functional area to another vary from product to product. Usually the paths are long and there will be possibility of backtracking. Process layout is normally used when the production volume is not sufficient to justify a product layout. Typically, job shops employ process layouts due to the variety of products manufactured and their low production volumes. Process layout Advantages
Limitations
Product Layout The product layout is selected when the volume of production of a product is high such that a separate production line to manufacture it can be justified. In a strict product layout, machines are not shared by different products. Therefore, the production volume must be sufficient to achieve satisfactory utilization of the equipment. A typical product layout is shown in the following figure. Product layout Advantages
Limitations
Combination Layout Advantages and DisadvantagesCombination Layout Combination layout for making different types and sizes of gears Fixed Position Layout Fixed position layout Advantages
Group Layout (or Cellular Layout) Group technology layout in Operation ManagementGroup technology (GT) is the analysis and comparisons of items to group them into families with similar characteristics. GT can be used to develop a hybrid between pure process layout and pure flow line (product) layout. This technique is very useful for companies that produce variety of parts in small batches to enable them to take advantage and economics of flow line layout. The application of group technology involves two basic steps; first step is to determine component families or groups. The second step in applying group technology is to arrange the plants equipment used to process a particular family of components. This represents small plants within the plants. The group technology reduces production planning time for jobs. It reduces the set-up time. Thus group layout is a combination of the product layout and process layout. It combines the advantages of both layout systems. If there are m-machines and n-components, in a group layout (Group-Technology Layout), the M -machines and n -components will be divided into number of machine-component cells (group) such that all the components assigned to a cell are almost processed within that cell itself. Here, the objective is to minimize the intercell movements. The basic aim of a group technology layout is to identify families of components that require similar of satisfying all the requirements of the machines are grouped into cells. Each cell is capable of satisfying all the requirements of the component family assigned to it. The layout design process considers mostly a single objective while designing layouts. In process layout, the objective is to minimize the total cost of materials handling. Because of the nature of the layout, the cost of equipments will be the minimum in this type of layout. In product layout, the cost of materials handling will be at the absolute minimum. But the cost of equipments would not be at the minimum if the equipments are not fully utilized. In-group technology layout, the objective is to minimize the sum of the cost of transportation and the cost of equipments. So, this is called as multi-objective layout. A typical process layout is shown . Group layout or Cellular layout Advantages of Group Technology
Layout
It can decrease the
Limitations of Group Technology Layout Which of the following basic types of facility layouts is the one where similar equipment or functions are grouped together?Answer and Explanation: Process layout can be defined as the process where machines are set up in various locations for production of various goods. The job shop layout involves process which deals with grouping similar functions and equipment.
In which layout format equipment or work processes are arranged according to the progressive steps?Product layout is also called a flow-shop layout. It is one in which equipment or work processes are arranged according to the progressive steps by which the product is made.
Which of these is not a basic type of manufacturing process layout?The correct option is: b.
Explanation: The Assembly line, manufacturing cell, work center and continuous process all are the types of process structure except the product-process matrix.
Which of the following would you expect to see in a manufacturing cell layout?Correct answer is Option c. In a manufacturing cell layout, there are a specific number of workers and machines required to complete a task.
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