The literal meaning of “layout” is to arrange various things in a planned manner. In the context of the facility, especially concerning a manufacturing entrepreneur, it relates to the set-up of different machinery, equipment and other facilities incidental to the core manufacturing activity, viz., department for receiving (raw materials), department for dispatching (finished goods), tool rooms, maintenance department looking after the work relating to employees welfare, etc.
According to Keith and Gubellini, “Plant layout deals with the arrangement of the physical facilities and the manpower required to manufacture a product or perform a service”.
Top 9 Advantages of Facility Layout
Efficiency of a layout framework is of paramount importance, which may be judged from the following points:
1) The overall manufacturing cost will likely be reduced considerably due to efficient material management if the layout is appropriately structured.
2) A system of well-designed layout ensures efficient use of the available space, especially in urban and semi-urban areas.
3) It is possible to closely monitor the quality of a product or service as the quality control department is competent enough under an appropriately structured layout.
4) An efficient layout design ensures the balancing of the assembling line, wherein there is no waiting period for the job or the worker. It results in improved productivity.
5) As the well-designed layout reduces the space between two workstations, order execution becomes faster due to reduced cycle time.
6) The supervision job of managers/supervisors becomes smooth and hassle-free under a properly designed layout.
7) An efficient layout ensures the optimum utilisation of various inputs, including the workforce.
8) Higher productivity achieved through a better-designed layout increases the incentives employees and workers earn. It also improves their morale, encouraging them to perform better, further improving productivity. Thus, a virtuous cycle is created, which is good for the organisation as a whole.
9) A good layout design also takes care of the safety aspect. The number of accidents is drastically reduced due to this.
Top 4 Disadvantages of Facility Layout
The following are the main types of facility layout problems:
1) Re-layout for a Design Change
The layout designs must be changed in response to process design or production process changes. However, product layout may require only small changes.
2) Enlarged Department
In cases where the production of some parts or products is required to be increased, then the layout plan may also be required to be changed.
3) Reduced Departments
Change in the number of departments may impact the process flow and may require the facility layout change. If the plant’s production decreases, removing the extra departments and using that space for other work is advisable.
4) Addition of New Departments
The new departments may be required to be added to the production process, leading to facility layout change. Such changes are required as additional inputs require extra space for storage and placement, etc.