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20. Types of layout. Compare product layout and process layout.

Layout is the arrangement of work space, equipment, products, and so on in a place of business. In a well planed factory layout everything is arranged so that the product and workers move in an orderly manner and with the least possible confusion. An efficient layout helps to increase workers productivity and keep costs down by reducing walking distances for employees and keeping supervisors and maintenance personnel close to their areas of responsibility.

Two general types of factory layout are associated with two basic methods of production. The continuous production method, which is used for petroleum, chemicals, and mass produced items such as automobiles and airplanes, uses what is called a product layout. Intermittent production, used for example in a furniture factory, employs [uses] a process or functional layout. With product layout the factory is set up to suit the particular product being manufactured. Employees and machines perform their operations on the product as it moves along an assembly line from start to finish. In intermittent type of layout, machines, materials, and workers are grouped according to the particular process each performs. In a furniture factory, for example, the cutting, gluing, and painting would all be done in different areas using different tools.

Let’s compare product layout and process layout by considering their advantages and disadvantages.

An advantage of product layout is that the use of assembly lines usually has lower unit costs than other methods have. The unit cost is the cost for producing one individual item. Another advantage is that by controlling and coordinating the use of machines, scheduling and routing are simplified so that bottlenecks are eliminated. Also, control and supervision are simplified by using product layout since each worker has a specific assignment on the line.

A disadvantage of product layout is that a breakdown at any point on the assembly line usually results in a total shutdown of the line. Then, employee attitude and workmanship can suffer because assembly line work is generally routine and boring.

An advantage of process layout is that there is flexibility in the types of products manufactured, the assignments of workers, and the uses of the machines. Machines operate independently of each other, and a breakdown of the machine would not result in a total line shutdown and, therefore, a complete halt in production. Different jobs are done in different areas; in this way interference is reduced. Furniture finishing, for example, must be done in a dust-free environment away from the saws and sanders. An advantage for workers is that they each have a specific job which they can identify with and take pride in.

A disadvantage of process layout is that there is no definite line in which materials move; therefore, they tend to move less efficiently. Special routing and cost analysis are necessary for each job order. Generally, there is slower productivity with process layout, and production volume us restricted.