Process Layout Is Recommended For Batch Production
Process Layout Is Recommended For Batch Production
Process Layout Is Recommended For Batch Production
All machines performing similar type of operations are grouped at one location in the process layout
e.g., all lathes, milling machines, etc. are grouped in the shop will be clustered in like groups based on
function.
The flow paths of material through the facilities from one functional area to another vary from product
to product.
Process layout is normally used when the production volume is not sufficient to justify a product
layout.
Typically, job shops employ process layouts due to the variety of products manufactured and their low
production volumes.
Advantages
1. In process layout machines are better utilized and fewer machines are required.
2. Flexibility of equipment and personnel is possible in process layout.
3. Lower investment on account of comparatively less number of machines and lower cost of general
purpose machines.
4. A high degree of flexibility with regards to work distribution to machineries and workers.
5. The diversity of tasks and variety of job makes the job challenging and interesting.
Limitations
1. Backtracking and long movements may occur in the handling of materials thus, reducing material
handling efficiency.
2. Material handling cannot be mechanized which adds to cost.
3. Process time is prolonged which reduce the inventory turnover and increases the in process
inventory.
4. Lowered productivity due to number of set-ups.
Product Layout
If the volume of production of one or more products is large, the facilities can be arranged to achieve
efficient flow of materials and lower cost per unit.
Special purpose machines are used which perform the required function quickly and reliably.
The product layout is selected when the volume of production of a product is high such that a separate
production line to manufacture it can be justified.
In a strict product layout, machines are not shared by different products.
Therefore, the production volume must be sufficient to achieve satisfactory utilisation of the
equipment.
Advantages
1. The flow of product will be smooth and logical in flow lines.
2. In-process inventory is less.
3. Minimum material handling cost.
4. Simplified production, planning and control systems are possible.
5. Less space is occupied by work transit and for temporary storage.
6. Reduced material handling cost due to mechanized handling systems and straight flow.
Limitations
1. A breakdown of one machine in a product line may cause stoppages of machines in the downstream
of the line.
2. A change in product design may require major alterations in the layout.
3. The line output is decided by the bottleneck machine.
4. Comparatively high investment in equipments is required.
5. Lack of flexibility. A change in product may require the facility modification.