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Product, Process,
Fixed and Group
Layouts

BY,

AJEESH KUMAR B K (9)

AJITH ANTONY (10)

AKASH ANAND (11)

AKASH UNNIKRISHNAN (12)

Contents
Introduction
Classification

of layout

Process

layout

Product

layout

Group
Fixed

layout

position layout

Reference

Introduction

Plan layout is a floor plan of the physical facilities which are used in
production.

Layout planning refers to the generation of several possible plans for

the spatial arrangement of physical facilities and select the one which
minimises the distance between the department.

Objectives include :
1.

Minimising investment, production time and material handling constants.

2.

Facilitate the manufacturing process and organisational structure

3.

Utilise existing space more effectively

Classification of layout

Process layout

Product layout

Group layout

Fixed position layout

Process layout

Machines and services are grouped on a functional and operational

basis. For example, all welding work is carried out at one place and all
turnings in another.

This layout is normally used where

Expensive machinery is required

Production involves a large variety of items having limited volume in each

type

Operations are not balanced in time.

When demand is small and intermittent.

Advantages

Lower initial capital investment in machines and equipments. There is

high degree of machine utilization, as a machine is not blocked for a
single product

The overhead costs are relatively low

Change in output design and volume can be more easily adapted to the
output of variety of products

Supervision can be more effective and specialized

There is a greater flexibility of scope for expansion.

Disadvantages

Material handling costs are high due to backtracking

More skilled labor is required resulting in higher cost.

Time gap or lag in production is higher

Work in progress inventory is high needing greater storage space

More frequent inspection is needed which results in costly supervision

Product Layout

Machines are laid out in sequence of operation along the flow lines

Used when

machines and auxiliary services are located according to the processing

sequences of the product.

The volume of production is very high

Nature of work is standardised

Process operation are balanced in time

Continuity of materials can be maintained

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Advantages

Low cost of material handling, due to straight and short route and
absence of backtracking

Smooth and uninterrupted operations

Continuous flow of work

Lesser investment in inventory and work in progress

Optimum use of floor space

Shorter processing time or quicker output

Less congestion of work in the process

Simple and effective inspection of work and simplified production control

Lower cost of manufacturing per unit

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Disadvantages

High initial capital investment in special purpose machine

Heavy overhead charges

Breakdown of one machine will hamper the whole production process

Lesser flexibility as specially laid out for particular product.

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Group Layout

It is a combination of product and process layout. It combines the

advantages of both layout systems.

It is used when the same item is being manufactured in different types

of sizes.

In this, the machines are arranged in the process layout but process
grouping is arranged in a sequence.

The sequence of operation with each of the product variety however

remains the same.

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Advantages

Improved utilisation of labour and employee morale.

Reduced in-process inventory

Reduced set-up time and manufacturing costs.

Reduced material handling

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Disadvantages

Reduced shop flexibility

Possible reduced machine utilization

Possible extended job flow times

Possible increased job tardiness

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Fixed Position Layout

This type of layout is suitable when one or a few identical heavy items
are to be manufactured.

The materials are kept fixed because the cost of transportation of

material is very high.

The ship building industry commonly employs this layout.

In this type of layout,

the material or the major component remain fixed and

the tools, machinery, men and other materials move around it.

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Advantages

It saves time and cost involved on the movement of work from one
workstation to another.

The layout is flexible as change in job design and operation sequence

can be easily incorporated.

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Disadvantages

Production period being very long, capital investment is very heavy

Very large space is required for storage of material and equipment near
the product.

As several operations are often carried out simultaneously, there is

possibility of confusion and conflicts among different workgroups.

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Comparison between process and product layout

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References

Production and Operations Management- R. Pannerselvam