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Chapter 7 – Layout design

Figure 7.1 Process layout

The process layout is most common when the same operation must intermittently produce

many different products or serve many different customers. Process arrangement is

typical of a job shop in that it provides high flexibility in the type of products that can be

made. In addition, the diversity of jobs offers more satisfaction to workers. However,

handling and transportation costs are high, since the products must be moved frequently

between departments. There is often high in-process inventory, and scheduling of both

production and movement is more difficult.

Many service organizations use a process arrangement. Libraries have such items

as reference materials, serials, and microfilms grouped in separate areas. Insurance

companies have office layouts in which claims, underwriting, filing, and so on are

grouped as individual departments. Nearly all office layouts are process layouts.
Product layout

Continuous-flow, mass-production, and batch-processing arrangements are usually

organized by product layout. Equipment arrangement is based on the sequence of

operations performed in production, and products move in a continuous path from one
department to the next. An example of a product layout is winemaking, which uses a

layout of the type shown in Figure 7.2. Product arrangements allow for continuity of
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Chapter 7 – Layout design
production and the use of specialized handling equipment, since all products move in the
same directions.
Station 1
Station 2
Station 3
Station 4

Figure 7.2 Product layout

Although product layouts often follow a straight line, a straight line is not always best,

and layouts may take an L, O, S, or U shape. A product layout often is called a

production line or an assembly line. The difference between the two is that an assembly

line is limited to assembly processes, whereas a production line can be used to perform

other processes such as machining.

Hybrid layout (Group technology or cellular layout)

In hybrid layout some portions of the facility are arranged in a process layout and others

are arranged in a product layout. Hybrid layouts are used in facilities having both

fabrication and assembly operations. Fabrication operations – in which components are

made from raw materials – have a jumbled flow, whereas assembly operations – in which

components are assembled into finished products – have a line flow.

A retail store is an example of a hybrid layout in a nonmanufacturing setting. The

manage may group similar merchandise, enabling customers to find desired items easily

(a process layout). At the same time, the layout often leads customers along
predetermined paths, such as up and down aisles (a product layout). The intent is to

maximize exposure to the full array of goods, thereby stimulating sales.

Fixed-position layout
The construction of large items, such as heavy machine tools, airplanes, locomotives, and
so on, is usually accomplished in one place. Rather than move the item from one work
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Chapter 7 – Layout design

center to another, tools and components are brought to one place for assembly. Many

project processes have this arrangement. A fixed-position layout minimizes the number

of times that the product must be moved and often is the only feasible solution.
With that, we have come to the end of today’s discussions. I hope it has been an
enriching and satisfying experience. See you around in the next lecture.
Points to ponder