FACILITIES LAYOUT DESIGN

Presented by:
Dr.Anubha

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 Facilities Layout Design
• Facilities layout design refers to the
arrangement of all equipment, machinery, and
furnishings within a building envelope after
considering the various objectives of the
facility.
• The layout consists of production areas,
support areas, and the personnel areas in the
building

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 Need of Facilities Layout Design
• The need for facilities layout design arises both in
the process of designing a new layout and in
redesigning an existing layout.
• The need in the former case is obvious
• But in the latter case it is because of many
developments as well as many problems with in the
facility such as:
- change in the product design,
- obsolescence of existing facilities,
- change in demand,
- frequent accidents,
-more scrap and rework,
-market shift,
- introduction of a new product etc.
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 Objectives of Facilities Layout Design

(1) Overall integration and effective use of man,

machine, material, and supporting services,
(2) Minimization of material handling cost by suitably
placing the facilities in the best possible way,
(3) Better supervision and control,
(4) Employee's convenience, safety, improved morale
and better working environment,
(5) Higher flexibility and adaptability to changing
conditions and
(6) Waste minimization and higher productivity.

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 Types of Layout

The basic types of layouts are:

1.Product layout
2. Process layout
3. Fixed position layout
4. Cellular layout

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 Product layout

• This type of layout is generally used in systems

where a product has to be manufactured or
assembled in large quantities.
• In product layout the machinery and auxiliary
services are located according to the
processing sequence of the product without
any buffer storage within the line itself.

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 A pictorial representation of a product
layout

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 Advantages and Disadvantages of Product
Layout
ADVANTAGES DISADVANTAGES
•Low material handling cost per •Machine stoppage stops the
unit line
•Less work in process •Product design change or
•Total production time per unit process change causes the
is short layout to become obsolete
•Low unit cost due to high •Slowest station paces the line
volume •Higher equipment investment
•Less skill is required for usually results
personnel •Less machine utilization
•Smooth, simple, logical, and • Less flexible
direct flow
•Inspection can be reduced
•Delays
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•Effective supervision and control
 Process layout

• In a process layout, (also referred to as a job shop

layout) similar machines and services are located
together.
• Therefore, in a process type of layout all drills are
located in one area of the layout and all milling
machines are located in another area.
• A manufacturing example of a process layout is a
machine shop.
• Process layouts are also quite common in
non-manufacturing environments. Examples include
hospitals, colleges, banks, auto repair shops, and
public libraries

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 A pictorial representation of a process
layout.

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 Advantages and Disadvantages of
Process Layout
ADVANTAGES DISADVANTAGES
Better machine utilization •Increased material handling
Highly flexible in allocating •Increased work in process
personnel and equipment •Longer production lines
because general purpose •Critical delays can occur if the
machines are used. part obtained from previous
Diversity of tasks for personnel operation is faulty
Greater incentives to individual •Routing and scheduling pose
worker continual challenges
Change in Product design and
process design can be
incorporated easily
More continuity of production in
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unforeseen conditions like
 Fixed location layout

• In this type of layout, the product is kept at a fixed

position and all other material; components, tools,
machines, workers, etc. are brought and arranged
around it.
• Then assembly or fabrication is carried out.
• The layout of the fixed material location department
involves the sequencing and placement of
workstations around the material or product.
• It is used in aircraft assembly, shipbuilding, and most
construction projects.

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 A pictorial representation of a Fixed
Location layout

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 Advantages and Disadvantages of
Fixed Location Layout
ADVANTAGES DISADVANTAGES

•Material movement is reduced•May result in increase space

•Promotes pride and quality and greater work in process
because an individual can •Requires greater skill for
complete the whole job personnel
• Highly flexible; can •Personnel and equipment
accommodate changes in movement is increased
product design, product mix, •Requires close control and
and production volume coordination in production and
personnel scheduling

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 Cellular type layout
• This type of layout is based on the grouping of parts to form
product / part families.
• Similar parts may be grouped into families based on common
processing sequences, shapes, tooling requirements, and so
on.
• The processing equipment required for a particular product
family are grouped together and placed in a manufacturing
cell.
• The cells become, in effect, miniature versions of product
layouts. The cells may have movements of parts between
machines via conveyors or have a flow line connected by a
conveyor.
• This type of layout is used when various products have to be
produced in medium to large quantities.
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 A pictorial representation of a Cellular
layout

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 Advantages and Disadvantages of
Cellular Layout
Advantages Disadvantages
•Higher machine utilization •Greater labor skills required
•Smoother flow lines •Flow balance required in each cell
and shorter travel distances •Has some of the disadvantages of
are expected than for process product and process type of layout; it
layout is a compromise between the two
•Offers some benefits of
both product and process type
of layout because it is
a compromise between the two
•Encourages consideration of
general purpose equipment

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 Layout Selection
• The basis of selection of a layout is the volume-variety
analysis.
• Volume-variety analysis is based on the Pareto's principle,
which focuses on the fact that a majority of the resources
are consumed by a small fraction of the population. For
example 85% of the wealth of the world is held by 15% of
the people.
• This rule also applies to facilities design i.e. 85% of the
production volume is attributed to 15% of the product line.
• To decide a layout, a part-population analysis must first be
completed. A bar chart between the type of products and
the quantity to be produced is developed. This chart is also
called product-quantity chart

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 P-Q Chart

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 Decision regarding the type of layout
to be used--

• For the products lying in the area X -a product

type of layout is recommended and
• for the products lying in the area Y , a process
type of layout is recommended.
• In the middle (area between Xand Y ), a
combination of product and process type
layouts, is recommended

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 Types of Flow Patterns

• In the facilities layout problem, the decision

regarding placement of the machines is typically
made.
• Depending on the application and availability of
space, the machines are placed in one of the
following pattern:
1. Straight line pattern,
2. U-shaped pattern,
3. S-shaped pattern and
4. W- shaped pattern

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 Straight line pattern
• The straight-line pattern is normally used when
products are produced in large quantities and the
number of steps required for their production is few.
Moreover, the shipping and receiving sections are on
the opposite sides.
U-shaped pattern
• U-shaped patterns are often used when it is necessary
to keep the beginning (receiving) and end (shipping) of
the line at the same side and same end of the plant .
U-shaped patterns are also preferred in just-in-time
layouts. Workers are generally placed in the center of
the U. From there they can monitor more than one
machine at a time.
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 S-shaped pattern
• S-shaped patterns are used for long assembly
processes that have to fit in the same area as well
as when it is necessary to keep the receiving and
shipping ends on the opposite sides.
W-shaped pattern
• W-shaped pattern, like the S-shaped pattern is
also used for long assembly processes, which have
to fit in the same area. When it is also necessary
to keep the receiving and shipping ends on the
same side, the W-shaped pattern is preferred.

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 Layout Design Procedure
The major steps that needed to be followed in the layout
design are :
• Statement of the problem in terms of its objective, scope and
factors to be considered.
• Collection of basic data on sales forecast, production volume,
production schedules, part lists, operations to be performed
etc.
• Calculation of production rate and equipment requirements
• Data analysis and its presentation in the form of various
charts .
• Calculations of space requirements and allocation of activity
areas
• Development of block plan, plot plan, and detailed layout.
• Evaluation , selection , and installation of layout.
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