PRODUCT

LAYOUT

THAH


A
 Product layout
• A product layout involves the
arrangement of machines in one
line depending on the sequence of
operations.
• Also called as straight line layout or
layout for serialised manufacture.
•
•
•
•
• The output of one machine become
the input of the another .


• In product layout , there are more

than one line of production,
because of many lines of machines.
•
 1.All the machines tools or
The

items of equipment must
grouping be placed at the point
of demanded by the
machines sequence of operations.
should be 2.There should be no point
where one line crosses
done ,on another line
product 3.Materials may be fed where
line , they are required for
keeping in assembly ,but not
mind the necessarily all at one
point.
following
4.All the operations
principles: ,including assembly

 Advantages
•
• There is mechanism of materials
handling and consequently
reduction in materials handling
cost.
• This type of layout avoids production
bottlenecks.
• There is economy in manufacturing
time.
• This type of layout facilities better
production control.
• This type of layout requires less floor
area per unit of production.
• Work -in-progress is reduced and
investment thereon is minimised.
• Early detection of mistakes or badly
produced item is possible.
• The greater incentive to a group of
workers to raise their level of
performance.
 Disadvantages
• Product layout is known for its
flexibility.
• This type of layout is also expensive.
• There is difficulty of supervision.
• Expansion is also difficult.
• Any breakdown of equipment along a
production line can disrupt the
whole system.
Relative merits
of product and
process layouts
Product layout
 Process layout


 
• Mechanization of • Reduction in the
materials handling and investments on
consequent reduction machines as they are
in materials handling general purpose
cost. machines.
• Avoidance of bottlenecks. • Greater flexibility in
• Economy in production.
manufacturing time. • Better and more efficient
• Better production control. supervision possible
through specialisation.
• Less floor area required
per unit of production. • Better scope for
expansion.
• Minimum investment in
work-in-progress. • Better utilisation of men,
machines, plant etc.
• Early detection of
mistakes or badly • Easier to handle break
produced items. downs of equipments
• Greater incentive to a by transferring work to
another machine.
 Fixed position layout
• It implies that the movement of men
and machines to the product which
remains stationary.


• The movement of men and material

to the product is advisable because
the cost of moving them would be
less than the cost of moving
product which is very bulky.

 Circumstances when
product & process

layout
Product layout can
• One or few standard products.
be
Process

used
layout
• Emphasis on special orders.
• Large volume of production of • Relatively low volume of
each item over a considerable production of individual
period of time. items.
• Minimum inspection required • Many inspections required
during the sequence of during the sequence of
operations. operations.
• Materials and products permit • Materials or products too bulky
bulk or continuous handling to permit bulk or continuous
by mechanical means. handling by mechanical
• Little or no occasion to use the means.
same machine or work • Frequent need for using the
station for more than one same machine or work
operation. station for two or more
 Fixed position or
static layout
Raw material

Finished product
Machine & equipment

A ircra ft a sse m b ly
labour
•
•
• This method is followed in the
manufacture of bulky and heavy
products ,such as locomotives,
ships ,boilers, aircraft and
generators.
•

 Advantages
• Men and machines can be used for a
wide variety of operations
producing different products.
• The investment on layout is very
small.
• The worker identifies himself with the
product and takes pride in it when
the work is complete.
• The high cost of ,and difficulty in
transporting bulky products are
avoided.
 Cellular manufacturing
(CM)layout
• In cellular manufacturing
(CM),machines are grouped into
cells, and the cells function
somewhat like a product layout
within a larger shop or process
layout.
• Each cell in the CM layout is formed
to produce a single parts family-a
few parts ,all with common
characteristics ,which means that
they require the same machines
and have similar machine settings.
 Cell#1 cell#2

Papart D
1 2 1 2 3

3
5 4
Part X
2
1

Part A 1 2
3 Cell#3
Part 4 Cell#4
B

Production operation product or material

flow
• Advantages :
• Lower work-in-process inventories,
reduced materials handling costs
,shorter flow times in production,
simplified production planning,
increased operator responsibilities,
improved visual control, and fewer
tooling changes which facilitating
quicker setups.
• Quality also tends to improve.
• Overall performance increases by
lowering production costs and
• Disadvantages
Reduced manufacturing flexibility

and potentially increased

machine –down time .
 Combined layout
• The combination of product and
process layout, with an emphasis in
the most industrial establishments.
• Plans are never laid out in pure form.
• If the products manufactured are
somewhat similar and not
complex ,then it is possible for a
combined layout.
• For eg: In plants involving the
fabrication of parts and assembling,
fabrication tends to employ the
process layout, while the assembly
areas often employ the product
layout.
• To extend the logic of the combined
layout , we may refer to the
application of the fixed location
principle in every industrial
establishment.
 PRODUCT
LAYOUT

F.P. G.C.
G.G. FINISHED
RAW PRODUCT
MATERIAL ( GEARS )
H.T
H.T
G .G
F.P. G.C.
Proces
layout

G.C.
s

F . P .= FORGING PRESS G . C = GEAR CUTTING MACHINE

H . T = HEAT TREATMENT FURNANCE G . G = GEAR GRINDING
MACHINE