L3 Types of Plant Layout

Definition of Plant Layout:-

Plant layout means systematic arrangement of various departments, sections and all other
work facilities. This secures smooth operations of the machines, efficient working of the
employees and a steady flow of materials and plants.

Objectives of Plant Layout:-

1. The movement of the operators, the machines and the material should be reduced.
2. Plant layout must ensure that the machines and the workers get enough materials and
parts at the right time.
3. The layout must use the available floor space to the maximum and further, it should not
put forth excessive demand for the floor space.
4. The workers and the machines must be able to work conveniently.
5. The plant layout is necessary, to secure employee safety.
6. The capacity of man & machine should be used to the maximum.
7. The Plant Layout should not look only to the needs of the present. It should also consider
the possibilities of the gradual expense of the plant. Thus it must make responsible
provision of space for carrying out extension in future.
8. ‫ ﻻ ﯾﻨﺒﻐﻲ أن ﯾﺆدي إﻟﻰ‬،‫ وﻋﻼوة ﻋﻠﻰ ذﻟﻚ‬،‫ﯾﺠﺐ أن ﯾﺴﺘﺨﺪم اﻟﺘﺨﻄﯿﻂ اﻟﻤﺴﺎﺣﺔ اﻷرﺿﯿﺔ اﻟﻤﺘﺎﺣﺔ إﻟﻰ اﻟﺤﺪ اﻷﻗﺼﻰ‬
‫زﯾﺎدة اﻟﻄﻠﺐ ﻋﻠﻰ اﻟﻤﺴﺎﺣﺔ اﻷرﺿﯿﺔ‬.
9. ‫ﯾﺠﺐ أن ﯾﻜﻮن اﻟﻌﻤﺎل واﻵﻻت ﻗﺎدرﯾﻦ ﻋﻠﻰ اﻟﻌﻤﻞ ﺑﺸﻜﻞ ﻣﺮﯾﺢ‬.
10. ‫ﯾﻌﺪ ﺗﺨﻄﯿﻂ اﻟﻤﺼﻨﻊ ﺿﺮورﯾًﺎ ﻟﻀﻤﺎن ﺳﻼﻣﺔ اﻟﻤﻮظﻔﯿﻦ‬.
11. ‫ﯾﺠﺐ اﺳﺘﺨﺪام ﻗﺪرة اﻹﻧﺴﺎن واﻵﻟﺔ إﻟﻰ أﻗﺼﻰ ﺣﺪ‬.
12. ‫ وﯾﻨﺒﻐﻲ أﯾﻀﺎ اﻟﻨﻈﺮ ﻓﻲ إﻣﻜﺎﻧﯿﺎت اﻟﻨﻔﻘﺔ اﻟﺘﺪرﯾﺠﯿﺔ‬.‫ﻻ ﯾﻨﺒﻐﻲ ﻟﺘﺨﻄﯿﻂ اﻟﻤﺼﻨﻊ أن ﯾﻨﻈﺮ ﻓﻘﻂ إﻟﻰ اﺣﺘﯿﺎﺟﺎت اﻟﺤﺎﺿﺮ‬
‫ وﺑﺎﻟﺘﺎﻟﻲ ﯾﺠﺐ ﻋﻠﯿﮭﺎ ﺗﻮﻓﯿﺮ ﻣﺴﺎﺣﺔ ﻣﺴﺆوﻟﺔ ﻟﺘﻨﻔﯿﺬ اﻟﺘﻤﺪﯾﺪ ﻓﻲ اﻟﻤﺴﺘﻘﺒﻞ‬.‫ﻟﻠﻤﺼﻨﻊ‬.

Points To Be Consider While Preparing Layout:-

1. Proximity to raw material.
2. Proximity to a large market.
3. Availability of labour.
4. Efficiency of transport facility.
5. Steady power supply.
6. Supply of water
Signs Of
7. A Good
Proper Layout
climatic For Manufacturing And Back-Office Operations
conditions.
8. localization
1 Straight-line
9. Government
flow pattern
inducement.
(or adaptation).
2 Backtracking kept to a minimum.
3 Production time predictable.
4 Little interstage storage of materials.
5 Open plant floors so everyone can see what is happening.
6 Bottleneck operations under control.
7 Workstations close together.
8 Orderly handling and storage of materials.
9 No unnecessary rehandling of materials.
10 Easily adjustable to changing conditions.
‫وﻗﺖ اﻹﻧﺘﺎج ﯾﻤﻜﻦ اﻟﺘﻨﺒﺆ ﺑﮫ‬.
4 ‫ﺗﺧزﯾن ﻗﻠﯾل ﻟﻠﻣواد ﺑﯾن اﻟﻣراﺣل‬.
5 ‫أرﺿﯾﺎت ﻣﻔﺗوﺣﺔ ﻟﻠﻧﺑﺎﺗﺎت ﺣﺗﻰ ﯾﺗﻣﻛن اﻟﺟﻣﯾﻊ ﻣن رؤﯾﺔ ﻣﺎ ﯾﺣدث‬.
6 ‫ﻋﻣﻠﯾﺎت ﻋﻧﻖ اﻟزﺟﺎﺟﺔ ﺗﺣت اﻟﺳﯾطرة‬.
7 ‫ﻣﺣطﺎت ﻋﻣل ﻗرﯾﺑﺔ ﻣن ﺑﻌﺿﮭﺎ اﻟﺑﻌض‬.
8 ‫اﻟﺗﻌﺎﻣل ﻣﻊ اﻟﻣواد وﺗﺧزﯾﻧﮭﺎ ﺑﺷﻛل ﻣﻧظم‬. Page 1 of 14
9 ‫ﻋدم إﻋﺎدة اﻟﺗﻌﺎﻣل ﻣﻊ اﻟﻣواد ﻏﯾر اﻟﺿرورﯾﺔ‬.
10 ‫ﻗﺎﺑل ﻟﻠﺗﻌدﯾل ﺑﺳﮭوﻟﺔ ﻣﻊ اﻟظروف اﻟﻣﺗﻐﯾرة‬
 Signs of a Good Layout For Face-To-Face Services

1 Easily understood service flow pattern.

2 Adequate waiting facilities.
3 Easy communication with customers.
4 Easily maintained customer surveillance.
5 Clear exit and entry points with adequate checkout capabilities.
6 Departments and processes arranged so that customers see only what you want
them to see.
7 Balance between waiting areas and service areas.
8 Minimum walking and material movement.
9 Lack of clutter.
10 High sales volume per square foot of facility.

Volume
High
Product
Planning
Department

Medium Product
Layout Product
Family
Planning
Fixed Location Department Process
Low Layout Layout
Group Technology
Fixed Materials Layout Process
Location
Planning
Planning
Department
Department

Low Medium High Variety

Types Of Layout

(1) LINE OR PRODUCT LAYOUT:-

A product layout (also called a flow-shop layout) is one in which equipment or work
processes are arranged according to the progressive steps by which the product is made. The
path for each part is, in effect, a straight line. Production lines for shoes, chemical plants, and
car washes are all product layouts.
Product Layout (Product-oriented Layout): The organization of a factory or office so
that the position of the workstations is optimized to suit the product. Product layout ensures
that products follow an assembly line where the different operations are undertaken in a
logical sequence.

In line layout, the machines are arranged in a sequence. Such an arrangement helps
the raw materials to pass from operation to operation. This ensures the shortest & quickest
route for the material to pass from machine to machine until it is finished. The line that the
material follows may be straight, U-shaped, S-shaped, zigzag or a combination of any of
these. Line layout is also known as “Product Layout” because it continues the process till it is
transformed into a complete product.

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ADVANTAGES OF PRODUCT LAYOUT:

• Output. Product layouts can generate a large volume of products in a short time.
• Cost. Unit cost is low as a result of the high volume. Labour specialization results in
reduced training time and cost. A wider span of supervision also reduces labour costs.
Accounting, purchasing, and inventory control are routine. Because routing is fixed, less
attention is required.
• Utilization. There is a high degree of labour and equipment utilization.

1. Lower total material handling cost.

2. Less handling of material.
3. Lower total production time.
4. Less material in the process allows lower investment of material
5. Less floor area is required per unit of production.
6. More effective use of labour.
7. Production, planning & control become easy.
8. Since the layout corresponds to the sequence of operations, smooth
and logical flow lines result.
9. Since the work from one process is fed directly into the next, small in-
process inventories result.
10. Total production time per unit is short.
11. Since the machines are located to minimize distances between
consecutive operations, material handling is reduced.
12. Little skill is usually required by operators at the production line;
hence, training is simple, short, and inexpensive.
13. Simple production planning control systems are possible.
14. Less space is occupied by work in transit and for temporary storage.
15. ‫ ﻓﺈن ذﻟﻚ ﯾﺆدي إﻟﻰ وﺟﻮد ﻣﺨﺰوﻧﺎت ﺻﻐﯿﺮة‬،‫وﺑﻤﺎ أن اﻟﻌﻤﻞ ﻣﻦ إﺣﺪى اﻟﻌﻤﻠﯿﺎت ﯾﺘﻢ ﺗﻐﺬﯾﺘﮫ ﻣﺒﺎﺷﺮة إﻟﻰ اﻟﻌﻤﻠﯿﺔ اﻟﺘﺎﻟﯿﺔ‬
‫ﻗﯿﺪ اﻟﺘﺸﻐﯿﻞ‬.
16. ‫إﺟﻣﺎﻟﻲ وﺣدة ﺗوﻗﯾت اﻹﻧﺗﺎج ﻗﺻﯾر‬.
17. ‫ ﯾﺗم ﺗﻘﻠﯾل اﻟﺗﻌﺎﻣل ﻣﻊ اﻟﻣواد‬،‫وﺑﻣﺎ أن اﻵﻻت ﻣوﺟودة ﻟﺗﻘﻠﯾل اﻟﻣﺳﺎﻓﺎت ﺑﯾن اﻟﻌﻣﻠﯾﺎت اﻟﻣﺗﺗﺎﻟﯾﺔ‬.
18. ‫ ﯾﻛون اﻟﺗدرﯾب ﺑﺳﯾطًﺎ وﻗﺻﯾرًا وﻏﯾر ﻣﻛﻠف‬،‫ﯾﺗطﻠب اﻟﻣﺷﻐﻠون ﻓﻲ ﺧط اﻹﻧﺗﺎج اﻟﻘﻠﯾل ﻣن اﻟﻣﮭﺎرات؛ وﺑﺎﻟﺗﺎﻟﻲ‬
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‫ﻋﺎد‬.
19. ‫أﻧظﻣﺔ اﻟﺗﺣﻛم ﻓﻲ ﺗﺧطﯾط اﻹﻧﺗﺎج اﻟﺑﺳﯾطﺔ ﻣﻣﻛﻧﺔ‬.
20. ‫ﯾﺗم ﺷﻐل ﻣﺳﺎﺣﺔ أﻗل ﻣن ﺧﻼل ﻧﻘل اﻟﻌﻣل واﻟﺗﺧزﯾن اﻟﻣؤﻗت‬.
DISADVANTAGES OF PRODUCT LAYOUT:
• Motivation. The system's inherent division of labour can result in dull, repetitive jobs that
can prove to be quite stressful. Also, assembly-line layouts make it very hard to administer
individual incentive plans.
• Flexibility. Product layouts are inflexible and cannot easily respond to required system
changes—especially changes in product or process design.
‫ ﯾﻤﻜﻦ أن ﯾﺆدي ﺗﻘﺴﯿﻢ اﻟﻌﻤﻞ اﻟﻤﺘﺄﺻﻞ ﻓﻲ اﻟﻨﻈﺎم إﻟﻰ وظﺎﺋﻒ ﻣﻤﻠﺔ وﻣﺘﻜﺮرة‬.‫ﺗﺤﻔﯿﺰ‬
‫ ﻛﻤﺎ أن ﺗﺨﻄﯿﻄﺎت ﺧﻂ اﻟﺘﺠﻤﯿﻊ ﺗﺠﻌﻞ ﻣﻦ اﻟﺼﻌﺐ ﺟﺪًا إدارﺗﮭﺎ‬.‫ﯾﻤﻜﻦ أن ﯾﻜﻮن ﻣﺮھﻘًﺎ ﺟﺪًا‬
‫ﺧﻄﻂ اﻟﺤﻮاﻓﺰ اﻟﻔﺮدﯾﺔ‬.
• ‫ ﺗﺨﻄﯿﻄﺎت اﻟﻤﻨﺘﺞ ﻏﯿﺮ ﻣﺮﻧﺔ وﻻ ﯾﻤﻜﻨﮭﺎ اﻻﺳﺘﺠﺎﺑﺔ ﺑﺴﮭﻮﻟﺔ ﻟﻠﻨﻈﺎم اﻟﻤﻄﻠﻮب‬.‫اﻟﻤﺮوﻧﺔ‬
‫ وﺧﺎﺻﺔ اﻟﺘﻐﯿﯿﺮات ﻓﻲ ﺗﺼﻤﯿﻢ اﻟﻤﻨﺘﺞ أو اﻟﻌﻤﻠﯿﺔ‬- ‫اﻟﺘﻐﯿﯿﺮات‬.
• System protection. The system is at risk of equipment breakdown, absenteeism, and
downtime due to preventive maintenance.
1.Duplication of equipment leads to higher capital investment.
2.A single machine breaking down may shut a whole production time.
3.Poor machine utilization
4.Difficult to production schedule.
5.No specification.
6.A breakdown of one machine may lead to a complete stoppage of the line that follows that machine.
7.Since the layout is determined by the product, a change in product design may require major
alterations in the layout.
8.The “pace” of production is determined by the slowest machine.
9.Supervision is general, rather than specialized.
10. Comparatively high investment is required, as identical machines
(a few not fully utilized) are sometimes distributed along the line.

(2) FUNCTIONAL OR PROCESS LAYOUT:-

A process layout (also called a job shop or functional layout) is a format in which
similar equipment or functions are grouped, such as all lathes in one area and all stamping
machines in another. A part being worked on then travels, according to the established
sequence of operations, from area to area, where the proper machines are located for each
operation. This type of layout is typical of hospitals, for example, where areas are dedicated
to particular types of medical care, such as maternity wards and intensive care units.

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Layout (Layout
Grind by Function):
Assembly a type of office or plantlayout
that groups stations or equipment that undertake similar processes. Within a process
layout organization, the finished product moves from process to process and each batch may
follow a different route.
In this layout, the machines are arranged on a functional basis. This means that a machine of
the same type is grouped. Each machine forms a department.
Department Carries one particular function and not the whole production. It is also
called “Process Layout” because

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in every department only one process is carried out. In this type of layout, the material in the
process does not flow continuously.

PROCESS TYPE LAYOUT FOR TWO PRODUCTS A& B.

Figure shows the movement of the material from the incoming store to the finished
part stores for two components A&B. The operations carried out on this component are as
follows:
OPERATION COMPONENT—A COMPONENT—B
1 Turning Turning
2 Milling Drilling
3 Drilling Welding
4 Heat treatment Grinding
5 Grinding Plating
6 Inspection Inspection
Advantages:‫ ﯾﻤﻜﻦ ﻟﻠﺸﺮﻛﺔ اﻟﺘﻌﺎﻣﻞ ﻣﻊ ﻣﺠﻤﻮﻋﺔ ﻣﺘﻨﻮﻋﺔ ﻣﻦ ﻣﺘﻄﻠﺒﺎت اﻟﻤﻌﺎﻟﺠﺔ‬.‫اﻟﻤﺮوﻧﺔ‬.
• ‫ ﻗﺪ ﺗﻜﻮن اﻟﻤﻌﺪات ذات اﻷﻏﺮاض اﻟﻌﺎﻣﺔ اﻟﻤﺴﺘﺨﺪﻣﺔ أﻗﻞ ﺗﻜﻠﻔﺔ ﻟﻠﺸﺮاء‬،‫ ﻓﻲ ﺑﻌﺾ اﻷﺣﯿﺎن‬.‫ﯾﻜﻠﻒ‬
‫وأﻗﻞ ﺗﻜﻠﻔﺔ وأﺳﮭﻞ ﻓﻲ اﻟﺼﯿﺎﻧﺔ ﻣﻦ اﻟﻤﻌﺪات اﻟﻤﺘﺨﺼﺼﺔ‬.
• Flexibility. The firm can handle a variety of processing requirements.
• Cost. Sometimes, the general-purpose equipment utilized may be less costly to purchase
and less costly and easier to maintain than specialized equipment.
• Motivation. Employees in this type of layout will probably be able to perform a variety
of tasks on multiple machines, as opposed to the boredom of performing a repetitive task
on an assembly line. A process layout also allows the employer to use some type of
individual incentive system.
• System protection. Since there are multiple machines available, process layouts are not
particularly vulnerable to equipment failures.

1. Less expensive
2. Flexible.
3. The machine broken has not affected to whole unit.
4. Better efficient supervision is possible through specialization
5. Better utilization of machines can result; consequently, fewer machines are required.
6. A high degree of flexibility exists relative to equipment or manpower allocation for
specific tasks.
7. Comparatively low investment in machines is required.
8. The diversity of tasks offers a more interesting and satisfying occupation for the operator.
9. Specialized supervision is possible.

DISADVANTAGES:‫ إن ﺗﻐﯿﯿﺮ اﻟﺠﺪاول اﻟﺰﻣﻨﯿﺔ واﻟﻤﺴﺎرات ﺑﺎﺳﺘﻤﺮار ﯾﺠﻌﻞ ﻣﺘﻄﻠﺒﺎت ﻋﻤﻠﯿﺔ اﻟﺘﻮﻓﯿﻖ أﻛﺜﺮ‬.‫ارﺗﺒﺎك‬

• Utilization. Equipment utilization rates in process layout are frequently very low
because machine usage is dependent upon a variety of output requirements.
• Cost. If batch processing is used, in-process inventory costs could be high. Lower
volume means higher per-unit costs. More specialized attention is necessary for both
products and customers. Setups are more frequent, hence higher setup costs. Material
handling is slower and more inefficient. The span of supervision is small due to job
complexities (routing, setups, etc.), so supervisory costs are higher. Additionally, in
this type of layout accounting, inventory control, and purchasing usually are highly
involved.
• Confusion. Constantly changing schedules and routings make juggling process
requirements more difficult.

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 1. Multiple handling of material leads to higher material handling costs.
2. More space is required.
3. The large amount of work in progress.
4. Low rate of production.
5. Uneconomical inspection
6. Production, Planning & Control becomes difficult.
7. Limitations
8. Since longer flow lines usually exist, material handling is more expensive.
9. Production planning and control systems are more involved.
10. Total production time is usually longer.
11. Comparatively large amounts of in-process inventory result.
12. Space and capital are tied up by work in process.
13. Because of the diversity of the jobs in specialized departments, higher grades of skill
are required.

(3). FIXED TYPE LAYOUT:-

In a fixed-position layout, the product (by its bulk or weight) remains at one location.
Manufacturing equipment is moved to the product rather than vice versa. Construction sites
and movie lots are examples of this format
Under special circumstances fixed position layout is used. In this type of layout, the
machine and process equipment are transported to one fixed position. They are taken away
when work is over. Here large components are kept at a convenient place from beginning to
end and for small parts machines and equipment are brought to the contract place when work
is over.

Example: -
1. Shipbuilding.
2. Fabrication of a very large vessel.
3. Manufacturing of the Aero-planes

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Advantages. ‫"ﯾﻌﺰز ﺗﻮﺳﯿﻊ اﻟﻮظﯿﻔﺔ ﻣﻦ ﺧﻼل اﻟﺴﻤﺎح ﻟﻸﻓﺮاد أو اﻟﻔﺮق ﺑﺄداء "اﻟﻤﮭﻤﺔ ﺑﺄﻛﻤﻠﮭﺎ‬.
3. ‫اﺳﺘﻤﺮارﯾﺔ اﻟﻌﻤﻠﯿﺎت وﻣﺴﺆوﻟﯿﺔ اﻟﻨﺘﺎﺋﺞ ﻣﻦ اﻟﻔﺮﯾﻖ‬.

1. Material movement is reduced.

2. Promotes job enlargement by allowing individuals or teams to perform the “whole job”.
3. Continuity of operations and responsibility results from the team.

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4. Highly flexible; can accommodate changes in product design, product mix, and product
volume.
Independence of production centers allowing scheduling to achieve minimum total
production time.

Limitations‫ ﻗﺪ ﺗﻜﻮن ﻣﻨﻄﻘﺔ اﻟﻌﻤﻞ ﻣﺰدﺣﻤﺔ ﺑﻤﺴﺎﺣﺔ‬،‫ ﺑﺎﻟﻨﺴﺒﺔ ﻟﻠﻌﺪﯾﺪ ﻣﻦ اﻟﺘﺨﻄﯿﻄﺎت ذات اﻟﻤﻮﺿﻊ اﻟﺜﺎﺑﺖ‬.‫ﻓﻀﺎء‬
‫ﺗﺨﺰﯾﻦ ﻗﻠﯿﻠﺔ‬

‫ وھﺬا ﯾﻤﻜﻦ أن ﯾﺴﺒﺐ أﯾﻀًﺎ ﻣﺸﺎﻛﻞ ﻓﻲ اﻟﺘﻌﺎﻣﻞ ﻣﻊ اﻟﻤﻮاد‬.‫اﻟﻤﺴﺎﺣﺔ ﻣﺘﺎﺣﺔ‬.

8. ‫ ﯾﻜﻮن اﻟﻌﺐء اﻹداري أﻋﻠﻰ ﺑﺎﻟﻨﺴﺒﺔ ﻟﺘﺨﻄﯿﻄﺎت اﻟﻤﻮﺿﻊ اﻟﺜﺎﺑﺖ‬،‫ ﻓﻲ ﻛﺜﯿﺮ ﻣﻦ اﻷﺣﯿﺎن‬.‫اﻹدارة‬.

‫ ھﻨﺎ اﻟﺴﻔﯿﻨﺔ اﻟﻜﺒﯿﺮة‬.‫ وﯾﻜﻮن اﻟﺘﻨﺴﯿﻖ ﺻﻌﺒًﺎ‬،‫ﯾﻤﻜﻦ أن ﯾﻜﻮن ﻧﻄﺎق اﻟﺴﯿﻄﺮة ﺿﯿﻘًﺎ‬

‫ ﺗﺜﺒﯿﺖ اﻷﺟﺰاء ﻣﺜﻞ اﻟﻔﻮھﺎت واﻟﻤﻠﻔﺎت‬.‫ ﯾﺘﻢ اﻟﻠﺤﺎم ﻋﻠﻰ ﺟﺎﻧﺐ واﺣﺪ‬.‫ﺗﺼﻨﯿﻊ ﻓﻲ ﻣﻜﺎن واﺣﺪ‬

‫ ھﺬا‬.‫ ﺗﺘﻢ أﻋﻤﺎل اﻟﺮﺳﻢ أﯾﻀًﺎ ﻋﻠﻰ اﻟﺠﺎﻧﺐ اﻵﺧﺮ‬.‫وﻣﺎ إﻟﻰ ذﻟﻚ ﺗﺘﻢ أﯾﻀًﺎ ﻋﻠﻰ اﻟﺠﺎﻧﺐ اﻵﺧﺮ‬

‫ﯾﺼﺒﺢ ﺿﺮورﯾًﺎ ﻷن اﻟﻤﮭﻤﺔ ﺳﺘﻜﻮن ﺛﻘﯿﻠﺔ ﺟﺪًا ﺑﺤﯿﺚ ﻻ ﯾﻤﻜﻦ ﻧﻘﻠﮭﺎ‬

1. Increased movement of personnel and equipment.

2. Equipment duplication may occur.
3. Higher skill requirements for personnel.
4. General supervision required.
5. Cumbersome and costly positioning of material and machinery.
6. Low equipment utilization.
7. Space. For many fixed-position layouts, the work area may be crowded so little storage
space is available. This also can cause material handling problems.
8. Administration. Oftentimes, the administrative burden is higher for fixed-position layouts.
The span of control can be narrow, and coordination is difficult. Here the large vessel is
fabrication in one place. Welding is done on one side. Fixing of the parts like nozzles, coils
etc. are also done on the other side. Painting work is also done on the other side. This
becomes necessary because the job will be too heavy to be transported.

(3) Hybrid Layout: MIXED TYPE LAYOUT (COMBINATION LAYOUTS):-

Many manufacturing facilities present a combination of two layout types. For example,a
given production area may be laid out by process, while another area may be laid out by
product. It is also common to find an entire plant arranged according to product layout— for
example, a parts fabrication area followed by a subassembly area, with a final assembly area
at the end of the process. Different types of layouts may be used in each area, with a process
layout used in fabrication, group technology in subassembly, and a product layout used in
final assembly.‫ ﻗﺪ ﯾﺘﻢ ﺗﺨﻄﯿﻂ ﻣﻨﻄﻘﺔ‬،‫ ﻋﻠﻰ ﺳﺒﯿﻞ اﻟﻤﺜﺎل‬.‫ﺗﻘﺪم اﻟﻌﺪﯾﺪ ﻣﻦ ﻣﺮاﻓﻖ اﻟﺘﺼﻨﯿﻊ ﻣﺰﯾﺠًﺎ ﻣﻦ ﻧﻮﻋﯿﻦ ﻣﻦ اﻟﺘﺨﻄﯿﻂ‬
‫ وﻣﻦ اﻟﺸﺎﺋﻊ أﯾﻀًﺎ اﻟﻌﺜﻮر ﻋﻠﻰ ﻣﺼﻨﻊ ﻛﺎﻣﻞ‬.‫ ﺑﯿﻨﻤﺎ ﻗﺪ ﯾﺘﻢ ﺗﺨﻄﯿﻂ ﻣﻨﻄﻘﺔ أﺧﺮى ﺣﺴﺐ اﻟﻤﻨﺘﺞ‬،‫إﻧﺘﺎج ﻣﻌﯿﻨﺔ ﺣﺴﺐ اﻟﻌﻤﻠﯿﺔ‬
‫ ﻣﻊ ﻣﻨﻄﻘﺔ اﻟﺘﺠﻤﯿﻊ‬،‫ ﻣﻨﻄﻘﺔ ﺗﺼﻨﯿﻊ اﻷﺟﺰاء ﺗﻠﯿﮭﺎ ﻣﻨﻄﻘﺔ اﻟﺘﺠﻤﯿﻊ اﻟﻔﺮﻋﻲ‬،‫ ﻋﻠﻰ ﺳﺒﯿﻞ اﻟﻤﺜﺎل‬- ‫ﻣﺮﺗﺐ وﻓﻘًﺎ ﻟﺘﺨﻄﯿﻂ اﻟﻤﻨﺘﺞ‬
‫ ﻣﻊ ﺗﺨﻄﯿﻂ اﻟﻌﻤﻠﯿﺔ اﻟﻤﺴﺘﺨﺪم ﻓﻲ‬،‫ ﯾﻤﻜﻦ اﺳﺘﺨﺪام أﻧﻮاع ﻣﺨﺘﻠﻔﺔ ﻣﻦ اﻟﺘﺨﻄﯿﻄﺎت ﻓﻲ ﻛﻞ ﻣﻨﻄﻘﺔ‬.‫اﻟﻨﮭﺎﺋﯿﺔ ﻓﻲ ﻧﮭﺎﯾﺔ اﻟﻌﻤﻠﯿﺔ‬
‫ وﺗﺨﻄﯿﻂ اﻟﻤﻨﺘﺞ اﻟﻤﺴﺘﺨﺪم ﻓﻲ اﻟﺘﺠﻤﯿﻊ اﻟﻨﮭﺎﺋﻲ‬،‫ وﺗﻜﻨﻮﻟﻮﺟﯿﺎ اﻟﻤﺠﻤﻮﻋﺔ ﻓﻲ اﻟﺘﺠﻤﯿﻊ اﻟﻔﺮﻋﻲ‬،‫اﻟﺘﺼﻨﯿﻊ‬.

Many situations call for a mixture of the three main layout types. These mixtures are
commonly called combination or hybrid layouts. For example, one firm may utilize a process
layout for the majority of its process along with an assembly in one area. Alternatively, a firm
may utilize a fixed-position layout for the assembly of its final product, but use assembly
lines to produce the components and subassemblies that make up the final product (e.g.,
aircraft).‫ ﺗُﺴﻤﻰ ھﺬه اﻟﺨﻼﺋﻂ ﻋﺎدةً ﺑﺎﻟﺘﺨﻄﯿﻄﺎت‬.‫ ﻣﻦ اﻟﻤﻮاﻗﻒ ﻣﺰﯾﺠًﺎ ﻣﻦ أﻧﻮاع اﻟﺘﺨﻄﯿﻂ اﻟﺮﺋﯿﺴﯿﺔ اﻟﺜﻼﺛﺔ‬Page‫اﻟﻌﺪﯾﺪ‬7‫ﺗﺘﻄﻠﺐ‬
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‫ ﻗﺪ ﺗﺴﺘﺨﺪم إﺣﺪى اﻟﺸﺮﻛﺎت ﺗﺨﻄﯿﻂ اﻟﻌﻤﻠﯿﺔ ﻟﻐﺎﻟﺒﯿﺔ ﻋﻤﻠﯿﺎﺗﮭﺎ ﺑﺎﻹﺿﺎﻓﺔ إﻟﻰ اﻟﺘﺠﻤﯿﻊ ﻓﻲ‬،‫ ﻋﻠﻰ ﺳﺒﯿﻞ اﻟﻤﺜﺎل‬.‫اﻟﻤﺮﻛﺒﺔ أو اﻟﮭﺠﯿﻨﺔ‬
‫ ﺷﺮﻛﺔ‬،‫ وﺑﺪﻻ ﻣﻦ ذﻟﻚ‬.‫ﻣﻨﻄﻘﺔ واﺣﺪة‬
 Functional layout Cellular layout
Cellular manufacturing is a type of layout where machines are grouped according to the
process requirements for a set of similar items (part families) that require similar processing.
These groups are called cells. Therefore, a cellular layout is an equipment layout configured
to support cellular manufacturing.

Processes are grouped into cells using a technique known as group technology (GT). Group
technology involves identifying parts with similar design characteristics (size, shape, and
function) and similar process characteristics (type of processing required, available
machinery that performs this type of process, and processing sequence).

Workers in cellular layouts are cross-trained so that they can operate all the equipment within
the cell and take responsibility for its output. Sometimes the cells feed into an assembly line
that produces the final product. In some cases, a cell is formed by dedicating certain
equipment to the production of a family of parts without actually moving the equipment into
a physical cell (these are called virtual or nominal cells). In this way, the firm avoids the
burden of rearranging its current layout. However, physical cells are more common.
‫ ﯾﺘﻢ ﺗﺸﻜﯿﻞ اﻟﺨﻠﯿﺔ ﻋﻦ طﺮﯾﻖ ﺗﻜﺮﯾﺲ ﻣﻌﯿﻦ‬،‫وﻓﻲ ﺑﻌﺾ اﻟﺤﺎﻻت‬
‫)اﻟﻤﻌﺪات ﻹﻧﺘﺎج ﻣﺠﻤﻮﻋﺔ ﻣﻦ اﻷﺟﺰاء دون ﻧﻘﻞ اﻟﻤﻌﺪات ﻓﻌﻠﯿًﺎ إﻟﻰ ﺧﻠﯿﺔ ﻣﺎدﯾﺔ )وﺗﺴﻤﻰ ھﺬه اﻟﺨﻼﯾﺎ اﻻﻓﺘﺮاﺿﯿﺔ أو اﻻﺳﻤﯿﺔ‬.
An automated version of cellular manufacturing is the flexible manufacturing system (FMS).
With an FMS, a computer controls the transfer of parts to various processes, enabling
manufacturers to achieve some of the benefits of product layouts while maintaining the
flexibility of small-batch production.
Some of the advantages of cellular manufacturing include:
[1] Cost. Cellular manufacturing provides for faster processing time, less material
handling, less work-in-process inventory, and reduced setup time, all of which reduce
costs.
[2] Flexibility. Cellular manufacturing allows for the production of small batches, which
provides some degree of increased flexibility. This aspect is greatly enhanced with
FMSs.
[3] Motivation. Since workers are cross-trained to run every machine in the cell, boredom
is less of a factor. Also, since workers are responsible for their cells' output, more
autonomy and job ownership are present.

Page 8 of 14
Limitations of cellular layout:
[1] Rapid obsolescence
[2] Workload unbalances
[3] Limited flexibility
[4] Resource duplication

A sample hybrid layout that has characteristics of group, process and product layout is
shown in the following figure.

TM DM TM TM

BM TM TM

A combination of group layouts in manufacturing cells, product layouts in the

assembly area, and process layouts in the general machining and finishing section is used.

Group Layout:

A group technology (cellular) layout groups dissimilar machines into work centres (or cells)
to work on products that have similar shapes and processing requirements. A group
technology (GT) layout is similar to a process layout in that cells are designed to perform a
specific set of processes, and it is similar to a product layout in that the cells are dedicated to
a limited range of products. (Group technology also refers to the parts classification and
coding system used to specify machine types that go into a cell.)

Lathe Drill Grind Assembly

W
S a
t Mill Assembly Weld Paint r
o e
r h
a o
g Press Lathe Drill Press Assembly u
e s
e
Grind Drill Assembly Drill Grind

Page 9 of 14
Advantages
1. Increased machine utilization.
2. Team attitude and job enlargement tend to occur.
3. Compromise between product layout and process layout, with associated advantages.
4. Supports the use of general-purpose equipment.
Shorter travel distances and smoother flow lines than for process layout.

Limitations
1. General supervision required.
2. Higher skill levels are required of employees than for product layout.
3. Compromise between product layout and process layout, with associated limitations.
4. Depends on balanced material flow through the cell; otherwise, buffers and work-in-
process storage are required.
5. Lower machine utilization than for process layout.

Flexible Manufacturing System :

(FMS) “allows them (Japanese manufacturers) to build up to eight different models on a

single assembly line. In the United States, most assembly lines and some entire plants are
dedicated to a single model. If the model isn’t selling, the line shuts down. US auto
executives must plan only models that can sell at least 200,000 units. In contrast, the Mazda
Miata can sell 20,000 units in the United States without taking a financial bath.[Bateman and
Zeithaml.1993]

Page 10 of 14
 Computer
control
room
Tools

Conveyor
Machine Machine

Pallet

Load Unload
Parts Finished
Terminal
goods

U Shaped Layout:
A better layout is to have machines that perform successive operations located close to one
another so that the products can flow easily from one to another. A linear arrangement of
machines traditionally common to facilities (Earlier all machines were driven by a central
drive shaft) accommodates the product flow well but is not suited to workers who tend to
multiple machines because they must walk too far from machine to machine. To facilitate
material flow and reduce the walking time the Japanese have tended toward U- shaped lines
or cells as shown in Fig.
U-shaped manufacturing cells in a variety of production environments, to the point
where cellular manufacturing has become much more prevalent than the JIT system

Page 11 of 14
 In 1 2 3 4

Workers

Ou 1 9 8 7

The advantages of U-shaped cells are as follows:

1) One worker can see and attend all the machines with a minimum of walking.
2) They are flexible in the number of workers they can accommodate, allowing adjustments
to respond to changes in production requirements.
3) A single worker can monitor work entering and leaving the cell to ensure that it remains
constant thereby facilitating just-in-time flow.
4) Workers can conveniently cooperate to smooth out unbalanced operations and address
other problems as they surface.

FLOW PATTERN:

One of the most important in designing and developing Plant Layout is the flow analysis
which considers the operation, transportation, inspection delays, and storage required as part
of moves from receiving to shipping in a plant. The goals of flow analysis are to minimize
distance travelled, backtracking, cross-traffic, and production costs. Eliminate unnecessary
steps or combine steps in the process. Techniques used for plant flow analysis are process
charts, flow diagrams, operations charts and process charts.

In plant layout, there are about five (5) flow patterns which could be considered.
These are the Straight Flow, L flow, U flow, Circular or O flow and serpentine flow.
Depending on the nature of the product and the type of manufacturing (low volume versus
high volume, product mix etc.) being performed, plant layouts are categorized as follows:
Static Product, Product or Production line layout, Group or Cellular layout and the Process
Lay-out.

Flow patterns can be divided as (i) Flow patterns - production line and (ii) Flow patterns -
assembly line
The function of the flow pattern is to:
1. Minimize material handling
2. Maximum floor space utilization.
3. Minimum of backtracking‫اﻟﺤﺪ اﻷدﻧﻰ ﻣﻦ اﻟﺘﺮاﺟﻊ‬

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Page 13 of 14
Apart from this, one can combine these basic flows to get various combinations like (S + L) and
(O + U), and so on.

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