Facilities Layout

Dr. Suhas Rane

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Disclaimer : This PPT is prepared from multiple

books, papers & internet down-loading.
credit goes to those authors.

The

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Introduction
Facility layout means planning:
for placing of machines, utilities, employee
workstations, customer service areas, material
storage areas, aisles, restrooms, lunchrooms, internal
walls, offices, and computer rooms
for the convenient flow patterns of materials and
people around, into, and within buildings
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Locate All Areas

Equipment
Work stations
Material storage
Rest/break areas
Utilities
Eating areas
Aisles
Offices
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Major Objectives of an ideal layout

Providing enough production capacity
Reduction in materials Handling cost.
Efficient and effective utilization of space
Safe working conditions (accident free)
Easy supervision
Ease of maintenance with high
machine/equipment utilization.
Efficient labor utilization & increased
employee morale.
Improvement in productivity

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Types of Layout
Manufacuring

Fixed position (or Static) layout

Process Focussed (or Functional layout)
Product Focused (or Flowline layout)
Cellular Mfg. (or Group Technology layout)
Hybrid (or Combination layout

Service Industry
Office layout
Retail Layout
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Various Types of Material Flows

1

Straight Line
Weld

Weld

Grid

U Shape

Paint

L Shape

Serpentine
shape or
Convoluted
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Sub assembly C

Mill

Sub assembly B

Cut

Sub assembly A

Step

Slide
Main assembly
line

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Fixed-Position Layouts
Typical of projects
Job is Stationary,
Eqpt., workers, materials,
other resources brought
to the Job site
Highly skilled labor

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Process Focused Layout - Mfg.

(Similar m/cs grouped in process centers)
Grinding

G1

G2

Forging

Turning

F1

T1
T2

F2
G3
G4

Inspection

G5

i2

i1

Polishing
/ Lapping

i3

L2

W1

Drilling

D1

D2

D3

Welding

L1

T3

Painting

W2

P1

W3
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P2

Process 1
F2 T3 D1
G4 i1
Process 2
D2 T1 G2
W1 i2
Process 3
W3 G1 L1
P1 i3
9

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Product Focused Assy. Line

Product 1

Product 2

Product 3

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10

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Group Technology / Cellular Mfg.

( Dis-similar M/cs grouped together)
Whole lay-out consists of multiple Cells
A cell consists of dissimilar machines.
Each cell produces -range of similar products.
(e.g. Gear Shop within Machining Shop)

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11

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Cellular Manufacturing layout

Cell # 1

Cell # 2
1

Part D

2
3

Part X

4
1

Part A

Part Y

2
3

Part B

Cell # 4
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Cell # 3
12

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Group Technology
Dis-similar m/cs grouped to produced
SAME Family Products ( Gears)

Machine
2

Machine
1

Machine
3

Materials in

Finished
goods out

Machine
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5

13

Machine
4

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Process Layout - Hospital

Similar facilities are located in respective centers
E.R.Triage
room

Patient A broken leg

Patient B - erratic
pacemaker

Hallway

E.R. beds

Pharmacy

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Billing/exit
14

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Before : Process Layout

Jumbled flows in a job shop without GT
cells
Lathing

Milling

Drilling

M
Grinding

Receiving and
shipping

Assembly
A

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G
15

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After : Group Technology

L

Assembly
area
A

Cell 2

Cell 1
Receiving

Cell 3
L

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Shipping

16

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17

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Mfg Processes at diff. Stages

of PLC
Product
Focused
To stock
( Batch)

Process
focused
to Order
( job Shop)

Product
Focused
To Stock
(Continuous)

Process
focused
to Order
( Batch)

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18

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Hybrid Layout or Combined Layout

A combination of the Product & Process
Layouts
Product Layout
F.P.

G.C.

Raw
Materials

F.P.

G.C.

Process
layout

Raw
Materials

H.T.
H.T.

G.G.

Finished
Product
(Gears)

G.G.

G.C.

F.P. = Forging Press

G.C. = Gear Cutting Machine
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19
H.T. = Heat Treatment Furnace G.G. = Gear Grinding machine

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Flexible Manufacturing Systems

(FMS)
FMS consists of numerous programmable machine tools
connected by an automated material handling system
and controlled by a common computer network
FMS combines flexibility with efficiency
FMS layouts differ based on
variety of parts that the system can process
size of parts processed
average processing time required for part completion
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20

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Full-Blown FMS

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Service Facility Layout

Objectives are to maximize
Customer satisfaction
Utilization of space, equipment, & people
Efficient flow of information, material, &
people
Employee morale & safety

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22

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Lay-out Innovations at McDonald

(3 out of 4 decisions are layout related)
Indoor seating (1950s)
Drive-through window (1970s)
Adding breakfast to the menu (1980s)
Adding play areas (1990s)
Next ???
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23

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Office Layout
Design positions of people, equipment, & offices
for maximum information flow
Arranged by process (which itself is a product)
Example: Payroll dept. is by process
Relationship chart used
Examples
Insurance company
Software company
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1995
Corel Corp.

24

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Designing Retail Layouts

Must be both attractive and functional
Types
Free flow layouts
encourage browsing, increase impulse purchasing, are flexible and
visually appealing

Grid layouts
encourage customer familiarity, are low cost, easy to clean and
secure, and good for repeat customers

Loop and Spine layouts

both increase customer sightlines and exposure to products, while
encouraging customer to circulate through the entire store
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25

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Types of Retail Store Layouts

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New Trends in Manufacturing Layouts

Designed for quality and flexibility
Simultaneous Product Flexibility & Volume Flex.
Cellular layout within larger process layouts
Automated material handling
U-shaped production lines
More open work areas, fewer partitions/ obstacles
Smaller and more compact factory layouts
Less space for Inv. storage throughout the layout
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Wrap-Up: World-Class Practice

Strive for flexibility in layouts
Multi-job training of workers
Sophisticated preventive-maintenance
programs
Flexible machines
Empowered workers trained in problem
solving
Layouts small and compact
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