1. Basic Layout Types Product layouts Process layouts
Fixed-Position layout
Hybrid/Combination layouts

2. Basic Layout Types Product/Service layout Process layout
Layout that uses standardized processing operations to achieve smooth, rapid, high-volume 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
HYBRID/COMBINATION
Layout that makes use of the combination of
Product, Process or Fixed Position Layout.

3. Product Layout Characteristics
Product layouts are used to achieve a smooth and rapid flow of large volumes of goods and customers through a system.
The work is divided into a series of standardized tasks, permitting specialization of both labor and equipment.
The large volumes handled by these systems make it pertinent and necessary to invest in equipment and job design.

4. Product Layout Characteristics
Layouts should be arranged to make the best use of technological processing abilities to fulfill the requirements of both product and services.

5. Product Layout Characteristics
In manufacturing environments the lines are referred to as production lines or assembly lines, depending on the type of activity involved.
In services side, the word line may or may not be used like Healthcare/Hospital Services line ,Carwash (absence of word line here) or Cafeteria Line.
Without standardization, many of the benefits of the repetitive processing are lost.

6. Product Layout Characteristics
Product Layouts achieve a high degree of labor and equipment utilization, which tends to offset their high equipment costs.
Operations are so closely tied up that a mechanical failure or high absenteeism ( rains) would increase vulnerability of the Systems.
We can prevent breakdowns if we religiously follow preventive maintenance schedules, inspection and replacement of worn parts.

7. 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.

8. Disadvantages of Product Layout
Creates dull, repetitive jobs.
Poorly skilled workers may not maintain equipment or quality of output of service.
Fairly inflexible to changes in volume.
Highly susceptible to shutdowns.
Needs preventive maintenance.
Individual incentive plans are impractical.

9. A U-Shaped Production Line
Figure 6.6 1 2 3 4 5 6 7 8 9 10 In
Out
Workers

10. A U-Shaped Production Line
Straight Line designs are often not practical because of space constraints.
U shape Production Line is more compact, and requires often half the length of a Straight Production Line.
U shaped Layouts are a must for teamwork where communication is necessary.
U shaped Layouts allow flexibility in work assignments as workers can handle adjacent stations as well as stations on opposite ends.

11. A U-Shaped Production Line
Sometimes U shaped production line interferes with the cross travel/movement of workers, mobile equipment.

12. A U-Shaped Production Line
Highly automated processes do not require teamwork or communication, noise or contamination factors then U shaped Production Lines are not required.

13. Used for Intermittent processing
Process Layout
Figure 6.7
Process Layout
(functional)
Dept. A
Dept. B
Dept. D
Dept. C
Dept. F
Dept. E
Used for Intermittent processing
Job Shop or Batch

14. Used for Repetitive Processing Repetitive or Continuous
Product Layout
Figure 6.7 (cont’d)
Product Layout
(sequential)
Work
Station 1
Station 2
Station 3
Used for Repetitive Processing
Repetitive or Continuous

15. 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.

16. 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.