03 sisprod - layout types
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LAYOUT TYPESAYOUT TYPES
Presentasi KuliahTKI-313 Sistem Produksi
Jurusan Teknik Universitas Muhammadiyah Surakarta
Dosen : Much Djunaidi
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Product layouts
Process layouts
Basic Layout TypesBasic Layout Types
Fixed-Position layout
Combination layouts
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Product layout Layout that uses standardized processing
operations to achieve smooth, rapid, high-
volume flow
Basic Layout TypesBasic Layout Types
Layout that can handle varied processing
requirements
Fixed Position layout Layout in which the product or project
remains stationary, and workers, materials,and equipment are moved as needed
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Raw
materials
or customer
Finished
item
Station
2
Station
3
Station
4
Station
1
Product LayoutProduct Layout
6-4
Material
and/or
labor
Material
and/or
labor
Material
and/or
labor
Material
and/or
labor
Used for Repetitive or Continuous Processing
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High rate of output
Low unit cost
Labor specialization
Advantages of Product LayoutAdvantages of Product Layout
6-5
Low material handling cost
High utilization of labor and equipment
Established routing and scheduling
Routing accounting and purchasing
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Creates dull, repetitive jobs
Poorly skilled workers may not maintain
equipment or quality of output
Disadvantages of Product LayoutDisadvantages of Product Layout
6-6
Highly susceptible to shutdowns
Needs preventive maintenance Individual incentive plans are
impractical
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1 2 3 4
5
In
Figure 6.6
A UA U--Shaped Production LineShaped Production Line
6-7
6
78910Out
Workers
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Work
Station 1
Work
Station 2
Work
Station 3
Figure 6.7 (contd)
Product Layout(sequential)
Product LayoutProduct Layout
6-8
Used for Repetitive ProcessingRepetitive or Continuous Processes
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Dept. A Dept. C Dept. E
Process Layout(functional)
Figure 6.7
Process LayoutProcess Layout
6-9
Dept. B Dept. D Dept. F
Used for Intermittent processing
Job Shop or Batch Processes
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Can handle a variety of processingrequirements
Not particularly vulnerable to equipment
failures
Advantages of Process LayoutsAdvantages of Process Layouts
6-10
Equipment used is less costly
Possible to use individual incentive
plans
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In-process inventory costs can be high
Challenging routing and scheduling
Equipment utilization rates are low
Disadvantages of ProcessDisadvantages of Process
LayoutsLayouts
6-11
a er a an ng s ow an ne c en
Complexities often reduce span of
supervision Special attention for each product or
customer
Accounting and purchasing are more
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Fixed Position LayoutsFixed Position Layouts
Fixed Position Layout: Layout in which theproduct or project remains stationary, and
workers, materials, and equipment are
moved as needed.
6-12
Nature of the product dictates this type of
layout
Weight
Size
Bulk
Large construction projects
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Cellular Production
Layout in which machines are grouped into
a cell that can process items that have
similar processing requirements
Cellular LayoutsCellular Layouts
Group Technology
The grouping into part families of items with
similar design or manufacturingcharacteristics
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Dimension Functional Cellular
Number of moves
between departments
many few
Travel distances longer shorter
Travel paths variable fixed
Table 6.3
Functional vs. Cellular LayoutsFunctional vs. Cellular Layouts
o wa ng mes grea er s or er
Throughput time higher lower
Amount of work in
process
higher lower
Supervision difficulty higher lower
Scheduling complexity higher lower
Equipment utilization lower higher
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Warehouse and storage layouts Retail layouts
Office layouts
Service la outs must be aestheticall
Service LayoutsService Layouts
pleasing as well as functional
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Information Requirements:1. List of departments
2. Projection of work flows
Designing Process LayoutsDesigning Process Layouts
4. Amount of money to be invested
5. List of special considerations
6. Location of key utilities
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30
Example 3: Interdepartmental Work FlowsExample 3: Interdepartmental Work Flows
for Assigned Departmentsfor Assigned Departments
1 3 20
A B C
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Milling
Assembly
& Test Grinding
Process LayoutProcess Layout
Process Layout - work travels
to dedicated process centers
Drilling Plating
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Mill Drill Grind
222
444
222
111
444
222
3333
Functional LayoutFunctional Layout
Gear
cutting
LathesHeat
treat
111
333
111 333
111
444
111
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-1111 -1111
222222222 - 2222b
l
Lathe Mill
Mill
Drill
Drill
Heat
treat
Heat
treat
Gear
cut
Grind
Cellular Manufacturing LayoutCellular Manufacturing Layout
Asse
3333333333 - 3333
44444444444444 - 4444
Lathe Mill
Mill Drill
Heat
treat
Gear
cut
Grind