TYPES OF PLANT LAYOUT: PROCESS AND PRODUCT LAYOUT

• REVISION SERIES OPERATION MANAGEMENT
  TYPES OF PLANT LAYOUT
  PROCESS
  PRODUCT LAYOUT
  
  
• TYPES OF LAYOUT
• REFERS TO THE ARRANGING AND GROUPING OF MACHINES WHICH ARE MEANT TO PROCEDURE GOODS. GROUPING OF MACHINES IS DONE ON DIFFERENT LINES AND IS INFLUENCED BY VARIOUS FACTORS.
• TYPES OF PLANT LAYOUT:-

1. PROCESS OF LAYOUT
2. PRODUCT LAYOUT
3. FIXED POSITION LAYOUT
4. CELLULAR MANUFACTURING
5. COMBINATION LAYOUT

• PROCESS LAYOUT

1. ALSO CALLED THE FUNCTIONAL LAYOUT
2. LAYOUT FOR JOB LOT MANUFACTURE OR BATCH PRODUCTION
3. GROUPING TOGETHER OF LIKE MACHINES IN ONE DEPARTMENT
4. MACHINES PERFORMING SIMILAR FUNCTIONS ARE KEPT IN ONE DEPARTMENT
5. LIKE MACHINE PERFORMING DRILLING FUNCTION KEPT IN DRILLING DEPARTMENT
6. MATERIAL WOULD MOVE LONG DISTANCES AND ALONG CRISSCROSSING PATHS
7. AT ONE STAGE THE MATERIAL MAY BE TAKEN TO SEPARATE BUILDING FOR HEAT TREATMENT AND THEN BROUGHT BACK FOR GRINDING
8. MACHINES ARE CALLED GENERAL PURPOSE AND ALLOTMENT OF WORK IN SUCH A MANNER THAT NO MACHINE IS IDEAL
9. SUITABLE FOR INTERMITTENT TYPE OF PRODUCTION

• PRINCIPLES

1. THE DISTANCE BETWEEN DEPARTMENT NEEDS TO BE SHORT
2. LIKE MACHINES ARE GROUPED IN ONE DEPARTMENT,DEPARTMENT SHOULD BE LOCATED IN ACCORDANCE WITH THE PRINCIPLES OF SEQUENCE
3. CONVENIENCE FOR INSPECTION
4. CONVENIENCE FOR SUPERVISION
5. ADVANTAGES
6. REDUCED INVESTMENT OF MACHINES
7. GREATER FLEXIBILITY IN THE PRODUCTION
8. BETTER AND MORE EFFICIENT SUPERVISION
9. GREATER SCOPE FOR EXPANSION
10. BETTER UTILIZATION OF MEN AND MACHINES
11. EASIER TO HANDLE BREAKDOWN OF EQUIPMENT
12. FULL UTILIZATION OF EQUIPMENT
13. THE INVESTMENT OF EQUIPMENT WOULD BE LOW
14. GREATER INCENTIVE TO INDIVIDUAL WORKERS TO INCREASE HIS PERFORMANCE

• DISADVANTAGES

1. DIFFICULTY IN THE MOVEMENT OF MATERIALS
2. REQUIRE MORE FLOOR SPACE
3. DIFFICULTY IN PRODUCTION CONTROL
4. PRODUCTION TIME IS MORE AS WORK IN PROGRESS

• PRODUCT LAYOUT

1. STRAIGHT LINE LAYOUT/LAYOUT FOR SERIALIZED MANUFACTURE
2. A PRODUCT LAYOUT INVOLVES THE ARRANGEMENT OF MACHINES IN ONE LINE DEPENDING ON SEQUENCE OF OPERATIONS.
3. MATERIAL ARE FED INTO FIRST MACHINE AND FINISHED PRODUCT COME OUT OF THE LAST MACHINE
4. SPECIAL PURPOSE OF MACHINE. FOLLOWED IN STANDARDIZED PRODUCTS ON MASS SCALE CHEMICAL.PAPER,SUGAR ,RUBBER ETC
5. INVESTMENT IS HIGHER
6. GROUPING OF MACHINES ON THE BASIS OF PRODUCT LINE:
1. ALL THE MACHINES TOOLS OR OTHER EQUIPMENT MUST BE PLACED IN SEQUENCE
2. NO POINTS WHERE ONE LINE CROSSES ANOTHER LINE
3. MATERIALS MAY BE FED WHERE THEY ARE REQUIRED FOR ASSEMBLY
4. ALL THE OPERATIONS INCLUDING ASSEMBLY,TESTING AND PACKING SHOULD BE INCLUDED
5. LINE LAYOUT OR PRODUCT LAYOUT

• ADVANTAGES

1. REDUCTION IN MATERIAL HANDLING DUE TO MECHANIZATION
2. AVOIDS PRODUCTION OBSTACLES
3. BETTER PRODUCTION CONTROL
4. LESS FLOOR AREA PER UNIT OF PRODUCTION
5. WORK IN PROGRESS IS REDUCED
6. GREATER INCENTIVE TO RAISE THEIR LEVEL OF PERFORMANCE

• DISADVANTAGE

1. INFLEXIBILITY
2. EXPENSIVE
3. DIFFICULTY O SUPERVISION
4. DIFFICULTY IN EXPANSION
5. ANY BREAKDOWN WILL DISRUPT THE WHOLE SYSTEM

• COMPARISON
• PRODUCT LAYOUT

1. ONE OR FEW STANDARDIZED PRODUCT
2. HIGHLY AUTOMATION AND HUGE INVESTMENT
3. SPECIAL PURPOSE MACHINES
4. LESS FLEXIBILITY
5. REDUCTION IN MATERIAL HANDLING COST
6. LOW SPACE REQUIREMENT
7. TIMELY DETECTION OF DEFECTIVES
8. WORK IN PROGRESS IS LESS

• PROCESS LAYOUT

1. MANY PRODUCTS ARE PRODUCED IN SMALL QUANTITY
2. LESS AUTOMATION
3. MORE FLEXIBILITY
4. GENERAL PURPOSE MACHINES
5. MATERIAL HANDLING COST IS HIGH
6. MORE SPACE
7. MORE WIP
8. DELAYED DETECTION OF DEFECTIVE PRODUCTS