Product layout
Process layout
1. Investment
Needs high investment in machine/equipment
Comparatively low investment needed
2. Duration of Production
Needs less manufacturing times as the economy in
time can be planned in the beginning
Production time can not be economized due to
frequent movement of men and material.
3. Immobilization due to Breakdown
Break down of any unit/component immobilises the Breakdown of any machine does not immobilize the
whole system
whole system
4. Adjustability to changes
Inflexible as each machine can perform predesigned operation only
Flexible as different section can adjust ht operation
according to operation
5. Floor space
Requires less space.
Require more space.
6. Men/Equipment Utilization
Not to full capacity
Comparatively better utilization
Lesser amount of material handling and
comparatively lesser time, money and efforts
Involves greater handling of material requiring
more time, money and efforts.
7. material handling
Lesser amount of material handling and
comparatively lesser time, money and efforts
Involves greater handling of material requiring
more time, money and efforts.
8. Demand and supply relationship
Proper co-ordination between demand and as these Co-ordination between demand and supply is likely
are made to stock
to be difficulty as these made to order.
9. Control and Inspection
Specialized and expertise control is required thus
increasing supervision costs
Comparatively lesser efforts on control are needed.
Product layout
This type of layout is generally used in systems where a product has to be manufactured or assembled in
large quantities. In product layout the machinery and auxiliary services are located according to the
processing sequence of the product without any buffer storage within the line itself. A pictorial
representation of a product type of layout is given in Figure 1. The advantages and disadvantages are
given in Table 1.
Figure: A Pictorial Representation of Product Type of Layout
ADVANTAGES
Low material handling cost per unit
Less work in process
Total production time per unit is short
Product design change or process
change causes the layout to become
obsolete
Low unit cost due to high volume
Slowest station paces the line
Less skill is required for personnel
Smooth, simple, logical, and direct flow
Higher equipment investment usually
results
Inspection can be reduced
Less machine utilization
Delays are reduced
Effective supervision and control
DISADVANTAGES
Machine stoppage stops the line
Less flexible
Process layout
In a process layout, (also referred to as a job shop layout) similar machines and services are located
together. Therefore, in a process type of layout all drills are located in one area of the layout and all
milling machines are located in another area. A manufacturing example of a process layout is a machine
shop. Process layouts are also quite common in non-manufacturing environments. Examples include
hospitals, colleges, banks, auto repair shops, and public libraries ( Muther, R, Systematic Layout
Planning, Second Edition , CBI Publishing Company, Inc. Boston, 1973 ).
A pictorial representation of a process type of layout is given in Figure 2. The advantages and
disadvantages are given in Table 2.
Fig: A Pictorial Representation of Process Type of Layout
DISADVANTAGES
Increased material handling
Highly flexible in allocating personnel and
equipment because general purpose
machines are used.
Increased work in process
Longer production lines
Diversity of tasks for personnel
Critical delays can occur if the part
obtained from previous operation is faulty
Greater incentives to individual worker
Change in Product design and process
design can be incorporated easily
Routing and scheduling pose continual
challenges
More continuity of production in unforeseen
conditions like breakdown, shortages,
absenteeism
ADVANTAGES
Better machine utilization
Fixed location layout
In this type of layout, the product is kept at a fixed position and all other material; components, tools,
machines, workers, etc. are brought and arranged around it. Then assembly or fabrication is carried out.
The layout of the fixed material location department involves the sequencing and placement of
workstations around the material or product. It is used in aircraft assembly, shipbuilding, and most
construction projects. A pictorial representation of a fixed location type of layout is given in Figure 3. The
advantages and disadvantages are detailed in Table 3.
Figure 3: A Pictorial Representation of Fixed Location Type of Layout
ADVANTAGES
Material movement is reduced
Promotes pride and quality because an
individual can complete the whole job
DISADVANTAGES
May result in increase space and greater
work in process
Requires greater skill for personnel
Personnel and equipment movement
is increased
Requires close control and coordination
in production and personnel scheduling
Highly flexible; can accommodate changes
in product design, product mix, and
production volume
