Facility Layout - Objectives, Design and Factors Affecting the
Layout
Introduction
For an organization to have an effective and efficient manufacturing unit,
it is important that special attention is given to facility layout. Facility
layout is an arrangement of different aspects of manufacturing in an
appropriate manner as to achieve desired production results. Facility
layout considers available space, final product, safety of users and
facility and convenience of operations.
An effective facility layout ensures that there is a smooth and steady flow
of production material, equipment and manpower at minimum cost.
Facility layout looks at physical allocation of space for economic activity
in the plant. Therefore, main objective of the facility layout planning is to
design effective workflow as to make equipment and workers more
productive.
Facility Layout Objective
A model facility layout should be able to provide an ideal relationship
between raw material, equipment, manpower and final product at
minimal cost under safe and comfortable environment. An efficient and
effective facility layout can cover following objectives:
To provide optimum space to organize equipment and facilitate
movement of goods and to create safe and comfortable work
environment.
To promote order in production towards a single objective
To reduce movement of workers, raw material and equipment
To promote safety of plant as well as its workers
To facilitate extension or change in the layout to accommodate new
product line or technology upgradation
To increase production capacity of the organization
An organization can achieve the above-mentioned objective by ensuring
the following:
Better training of the workers and supervisors.
Creating awareness about of health hazard and safety standards
Optimum utilization of workforce and equipment
Encouraging empowerment and reducing administrative and other
indirect work
Factors affecting Facility Layout
Facility layout designing and implementation is influenced by various
factors. These factors vary from industry to industry but influence facility
layout. These factors are as follows:
The design of the facility layout should consider overall objectives
set by the organization.
Optimum space needs to be allocated for process and technology.
A proper safety measure as to avoid mishaps.
Overall management policies and future direction of the organization
Design of Facility Layout
Principles which drive design of the facility layout need to take into the
consideration objective of facility layout, factors influencing facility layout
and constraints of facility layout. These principles are as follows:
Flexibility: Facility layout should provide flexibility for expansion or
modification.
Space Utilization: Optimum space utilization reduces the time in
material and people movement and promotes safety.
Capital: Capital investment should be minimal when finalizing
different models of facility layout.
Design Layout Techniques
There are three techniques of design layout, and they are as follows:
1. Two or Three Dimensional Templates: This technique utilizes
development of a scaled-down model based on approved drawings.
2. Sequence Analysis: This technique utilizes computer technology in
designing the facility layout by sequencing out all activities and then
arranging them in circular or in a straight line.
3. Line Balancing: This kind of technique is used for assembly line.
Types of Facility Layout
There are six types of facility layout, and they are as follows:
Line Layout -Product or line layout refers to the arrangement of
productive machines and equipment in the order of manufacturing
operations.
Functional Layout -In a process layout or functional layout similar
machines and equipment of the same functional type are arranged in
one department. The processes are segregated and the machines of
each process are kept together while each process is kept
separately.
For example all the milling equipment would be arranged in the
milling department, all the grinding machines in the grinding
department and welding machines in the welding department. It
requires large amount of specially designed plant operated by a
small workforce.
Fixed Position Layout -A production technique used to assemble
products that are too large, bulky, or fragile to safely or effectively
move to a location for completion. In a fixed position layout,
personnel, supplies, and equipment are brought to the site where the
product will be assembled, rather than the product being moved
through an assembly line or set of assembly stations.
Combined Layout - Many situations call for a mixture of the three
main layout types. These mixtures are commonly called combination
or hybrid layouts. For example, one firm may utilize a process layout
for the majority of its process along with an assembly in one area.
Alternatively, a firm may utilize a fixed-position layout for the
assembly of its final product, but use assembly lines to produce the
components and subassemblies that make up the final product (e.g.,
aircraft).
Cellular Technology Layout -Cellular manufacturing is a type of
layout where machines are grouped according to the process
requirements for a set of similar items (part families) that require
similar processing. These groups are called cells. Therefore, a
cellular layout is an equipment layout configured to support cellular
manufacturing.
Computerized Relative Allocation of Facility Technique
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