03 03

LAYOUT TYPES LAYOUT TYPES

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