Facility Layout Ross L. Fink

Facility Layout Types Classic Classic –Process (functional, departmental) –Product (assembly line) –Fixed Position Cellular Cellular

Process Layout

Product Layout

Advantages of Process Layout More product variety More product variety Less investment in equipment Less investment in equipment Can share equipment across products Can share equipment across products Redundant equipment Redundant equipment Training is easier Training is easier Maintenance is easier Maintenance is easier

Disadvantages of Process Layout More work-in-process (WIP) inventory More work-in-process (WIP) inventory More skilled workers More skilled workers More difficult Scheduling--workers and materials More difficult Scheduling--workers and materials Quality control more difficult Quality control more difficult Higher variable cost of production Higher variable cost of production

Advantages of Product Layout Lower variable cost of production Lower variable cost of production Easier scheduling--workers and materials Easier scheduling--workers and materials Higher quality--easier to manage quality Higher quality--easier to manage quality Lower work-in-process (WIP) inventory Lower work-in-process (WIP) inventory Can use less skilled workers Can use less skilled workers

Disadvantages of Product Layout Larger investment in equipment Larger investment in equipment Less flexibility in product offering Less flexibility in product offering Harder to develop workers Harder to develop workers Little sharing of equipment Little sharing of equipment Little or no backup equipment Little or no backup equipment Worker dissatisfaction with job Worker dissatisfaction with job

Fixed Position Layout Material, equipment, and workers brought to product Material, equipment, and workers brought to product Used for items that are difficult to move-- large items Used for items that are difficult to move-- large items

Changes to Classical Layout Types Process--arrangement of departments (minimize material flow) Process--arrangement of departments (minimize material flow) Product--use of general purpose equipment Product--use of general purpose equipment Mixed layouts-using different layout types for different products Mixed layouts-using different layout types for different products

Cellular Layouts Work cell--equipment and workers are arranged to produce a family of related products Work cell--equipment and workers are arranged to produce a family of related products Based on group technology Based on group technology