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Faizan
A process layout is a plant or factory layout in which machines and equipment integral to a workflow are grouped together by function. This layout is designed to facilitate the most effective workflow between departments.
Process Layout vs Product Layout
A process layout is different than a product layout, though both are common layouts used in manufacturing facilities. The process layout arranges workstations by functionality and is largely used for customized goods. The product layout, typically referred to as an assembly line, uses a sequential structure and is used to create one product line. When choosing which to use, a facility must determine whether it will be creating many different products or a few specific products.
Movement Analysis
One widely used tool for the analysis of a process layout is the "from-to chart," which is created using a grid. Each department, workstation or machine is listed and the correlating boxes filled in with the number of times movement occurs from one workstation to another -- say, from the cutting workstation to the painting workstation, or from the office to the shipping department. This tool helps a manufacturing facility determine the amount of travel between each department or area. Areas that report a high amount of movement should be located closer together to ensure efficient time management and inventory movement.
Need Analysis
The relationship chart is another tool for assessing the layout in a facility. This model determines which departments have a need for proximity, beyond the number of movements between each area. This analysis determines which departments have a high, medium or low need for proximity, then compares that to the results from the from-to chart.
Other Considerations
A process layout incorporates a few other considerations. Long-term planning has an effect on process layout, as the ease of expansion and change of equipment could affect the layout design. The flow of movement between workstations also needs to be considered so employees can move easily and quickly from one station to another. This includes proper materials handling between stations, best use of space and appropriate storage, especially in food manufacturing facilities. The ability of large vehicles to maneuver in and out of the shipping and receiving areas determines where they fit in the layout. There are software programs designed to assist with process layouts, but these should be reviewed with an analytical eye toward all the elements that comprise the layout. Even without high tech software, a designer can create a highly effective, productive and safe layout for the successful operation of any manufacturing facility.
Process Layout vs Product LayoutA process layout is different than a product layout, though both are common layouts used in manufacturing facilities. The process layout arranges workstations by functionality and is largely used for customized goods. The product layout, typically referred to as an assembly line, uses a sequential structure and is used to create one product line. When choosing which to use, a facility must determine whether it will be creating many different products or a few specific products.
Movement Analysis
One widely used tool for the analysis of a process layout is the "from-to chart," which is created using a grid. Each department, workstation or machine is listed and the correlating boxes filled in with the number of times movement occurs from one workstation to another -- say, from the cutting workstation to the painting workstation, or from the office to the shipping department. This tool helps a manufacturing facility determine the amount of travel between each department or area. Areas that report a high amount of movement should be located closer together to ensure efficient time management and inventory movement.
Need Analysis
The relationship chart is another tool for assessing the layout in a facility. This model determines which departments have a need for proximity, beyond the number of movements between each area. This analysis determines which departments have a high, medium or low need for proximity, then compares that to the results from the from-to chart.
Other Considerations
A process layout incorporates a few other considerations. Long-term planning has an effect on process layout, as the ease of expansion and change of equipment could affect the layout design. The flow of movement between workstations also needs to be considered so employees can move easily and quickly from one station to another. This includes proper materials handling between stations, best use of space and appropriate storage, especially in food manufacturing facilities. The ability of large vehicles to maneuver in and out of the shipping and receiving areas determines where they fit in the layout. There are software programs designed to assist with process layouts, but these should be reviewed with an analytical eye toward all the elements that comprise the layout. Even without high tech software, a designer can create a highly effective, productive and safe layout for the successful operation of any manufacturing facility.
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