Process layout

From CEOpedia | Management online

Process layout is a type of product layout that arranges machines and equipment in a straight line, or flow, according to the sequence of operations needed to produce a product. It is designed to reduce the time and cost of production by having all the necessary resources available in a single line. This type of layout is most commonly used in industries such as food processing, printing, and clothing manufacturing.

Example of Process layout

Process layout is illustrated in the following example. In a T-shirt manufacturing factory, the machines and equipment are arranged in a straight line according to the sequence of operations needed to produce the product. The first machine in the line is the sewing machine, followed by the cutting machine, and then the ironing machine. Lastly, the finished product is packaged and sent to the warehouse.

This example shows how process layout can be used to streamline the production process. By having all the machines and equipment in one place, the manufacturing process can be completed in an efficient and cost-effective manner.

When to use Process layout

Process layout is most useful in industries that require large amounts of resources to produce a product. Examples of industries where process layout is often used include food processing, printing, and clothing manufacturing. Process layout can be beneficial in these industries because it allows for increased efficiency, improved quality, and flexibility. Additionally, this type of layout can help to reduce costs associated with production.

Types of layouts

  • Fixed-Position Layout: This type of layout is used when the product itself is not moved during production, such as in the construction of large ships or aircraft.
  • Line Layout: This type of layout is used when the product moves from one station to another in a linear fashion, such as in the assembly of vehicles or electronics.
  • Cellular Layout: This type of layout is used when the product moves between several different stations in a circuitous path, such as in the assembly of furniture.

Steps of Process layout

Process layout involves the following steps:

  • Define the process: The first step is to define the process, which includes determining the sequence of operations that need to be completed in order to produce a product.
  • Identify resources: The second step is to identify the resources needed to complete the process, such as machines, equipment, and materials.
  • Develop layout: The third step is to develop the layout, which includes arranging the resources in a straight line according to the sequence of operations.
  • Implement the layout: The fourth step is to implement the layout, which includes setting up the machines and equipment in the designated locations.

Advantages of Process layout

Process layout has several advantages that make it an attractive option for many types of industries. These advantages include:

  • Improved efficiency: Process layout allows for improved efficiency, as machines and equipment are located in one location, which makes it easier to manage and track the process.
  • Improved quality: The close proximity of machines and equipment in one location makes it easier to ensure quality standards are met.
  • Flexibility: Process layout is highly flexible, as it can easily be modified to accommodate changes in production needs.

Limitations of Process layout

Along with its advantages, process layout also has several disadvantages that should be taken into consideration. These disadvantages include:

  • Limited space: As all machines and equipment are located in one location, it can be difficult to find enough space to accommodate them.
  • Maintenance problems: As all machines and equipment are located in one location, it can be difficult to keep them properly maintained.
  • High initial cost: The initial cost of setting up a process layout may be high, as it requires purchasing or leasing a space for the machines and equipment.

Process layout has several limitations that can make it difficult to use in certain situations. These include:

  • Inability to handle high volumes: As the machines and equipment are arranged in a line, it can be difficult to handle high volumes of production.
  • Poor utilization of space: As the machines and equipment are arranged in a straight line, there may be a lack of efficient use of space.
  • Complexity of operations: As the machines and equipment are arranged in one line, it can be difficult to keep track of all the operations that need to be carried out.

In conclusion, process layout can be a useful tool in many industries, but it also has several limitations such as its inability to handle high volumes, poor utilization of space, and complexity of operations. These limitations should be taken into consideration when deciding whether process layout is the right choice for a particular application.

Other approaches related to Process layout

Other approaches related to process layout include job shop layout, cellular layout, and fixed-position layout.

Job shop layout is a type of layout in which machines and equipment are grouped by function. This type of layout is used in industries such as metalworking, where production orders are relatively small and require a variety of machines for completion. Advantages of job shop layout include increased flexibility, as it allows for quick changes in production needs, and improved quality, as it allows for efficient quality control. Disadvantages include limited space and high initial cost.

Cellular layout is a type of layout in which machines and equipment are arranged in cells, or groups, according to the type of product being produced. This type of layout is used in industries such as electronics manufacturing, where the same products are produced in large quantities. Advantages of cellular layout include increased efficiency, as it reduces the amount of time and cost associated with production, and improved quality, as it allows for efficient quality control. Disadvantages include limited space and high initial cost.

Fixed-position layout is a type of layout in which machines and equipment are arranged around a single product. This type of layout is used in industries such as aerospace manufacturing, where the product is too large to move from one place to another. Advantages of fixed-position layout include increased efficiency, as it allows for efficient production, and improved quality, as it allows for efficient quality control. Disadvantages include limited space and high initial cost.

In conclusion, process layout is one of several approaches related to product layout. Other approaches include job shop layout, cellular layout, and fixed-position layout. Each type of layout has its own advantages and disadvantages, but all require a high initial cost and limited space.


Process layout — recommended articles
Production batch — Production system — Production line — Serial production — Production rhythm — Intermediate goods — Optimization of the production run-length — Structural programming — Computer integrated manufacturing

References

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