The document discusses facility layout and describes different types of layouts. It begins by defining facility layout as the allocation of space and arrangement of equipment to minimize operating costs. The objectives of a good layout are then outlined, such as reducing costs, improving efficiency, and increasing productivity. Key factors that influence layout decisions are also identified, including materials, products, workers, and machinery. The main types of layouts - process, product, and combination - are then described and their advantages and disadvantages compared. Specific examples of process and product layouts are provided.

1. Material & Operation Management
Topic : Facility Layout
BY: PRANIT SHEREKAR
PM-2014-408
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2.  In the words of James Lundy, 'Plant layout
identically involves the allocation of space
and the arrangement of equipments in
such a manner that overall operating cost
are minimized.’’
 The disposition of the various parts of a
plant along with all the equipments used is
known as Plant Layout. It should be
designed that the plant functions most
effectively.
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3. Objectives of a good
Layout
 Provide enough production
capacity.
 Reduces handling costs.
 Reduces congestion.
 Reduces hazards to personnel.
 Utilizes labour efficiently.
 Increase employee morale.
 Reduce accidents.
 Utilizes available space efficiently
and effectively.
 Provide for volume and product
facility.
 Provide ease for supervision.
 Facilitate co-ordination
communication.
 Provide safety and health.
 Allow ease of maintenance.
 Allow high machine/equipment
utilization.
 Improve productivity.
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4. FACTORS INFLUENCING FACILITY
LAYOUT
 MATERIALS (Type of raw materials and availability)
 PRODUCT (Type of product and its position)
 WORKER (Type , position and requirements)
 MACHINERY(Product, volume and process)
 INDUSTRY (Type of industry: Synthetic, Analytical,
Conditioning and Extractive)
 LOCATION (Factor of production)
 MANAGERIAL POLICIES ( volume, provision for expansion,
automation, making or buying decisions, desire for rapid
delivery, purchasing policy and personnel policies)
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5. Principles of Layout
 Principle of minimum travel
 Principle of sequences
 Principle of usage
 Principle of compactness
 Principle of safety and satisfaction
 Principle of flexibility
 Principle of minimum investment.
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6. Types of layout
 Process layout or functional or job shop
layout.
 Product layout or line processing layout.
 Fixed position layout or static layout.
 Cellular manufacturing layout or Group
Technology layout .
 Combination layout or Hybrid layout.
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7. Process layout
 The distance between departments should
be as short as possible.
 Machines should be grouped in accordance
with the principle of sequence of operation.
 Convenience for inspection.
 Convenience for supervision.
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9. Advantages of Process
layout
 Reduced investment of machine.
 Greater flexibility.
 Better and efficient supervision.
 Scope for expansion as the capacity can be
easily increased.
 Better utilisation of men and machine.
 Easier to handle breakdown of equipment.
 Full utilisation of equipments.
 Investment of equipment would be
comparatively lower.
 Greater incentive to individual worker .
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10. Disadvantages of Process
Layout.
 Difficulty in the movement of material.
 Requires more space.
 Difficult in production control.
 More production time as work in progress has to travel
from place to place.
 Accumulation of work in progress at different places.
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11. Product Layout (Straight
Line)
 All the machine tool and equipment must be placed at
the point demanded by the sequences of operations.
 There should be no points where one line crosses
another line.
 Materials may be fed where they are required for
assembly but not necessarily all at one point.
 All the operations , including assembly, testing and
packing should be included in the line.
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12. Recei
ving
Raw Materials
stores
Fabrication line for part
C
Fabrication for part B
Packing
and
shipping
Raw Material
Fabrication line for
Part A
Finishing
t goods
store
WC-1
WC-2
WC-3
TEST
Assembly line for the product
Finishedgoods
Line Layout or Product Layout
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13. Product Layout
(advantages)
 Reduction in material handling cost due to mechanization.
 Avoid production bottleneck.
 Economy in manufacturing time.
 Better production control.
 Require less floor area per unit of production.
 Work-in-progress is reduced and so on investment.
 Early detection of mistakes.
 Greater incentive to a group of workers to raise their level
of performance.
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14. Product Layout
(disadvantages)
 Product layout is known for its inflexibility.
 This is an expensive layout
 Difficulty in supervision.
 Expansion is also difficult.
 Breakdown can disrupt the whole system.
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16.  Fifth major innovation
 Sandwiches assembled in order
 Elimination of some steps, shortening of
others
 No food prepared ahead except patty
 New bun toasting machine and new
bun formulation
 Repositioning condiment containers
 Savings of $100,000,000 per year in food
costs
Mc Donald’s new kitchen layout
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