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Process and Material Flow Analysis
Published in Sunderesh S. Heragu, Facilities Design, 2022
The product layout is known by names such as flow-line layout, production-line layout, assembly line layout, and layout by product. In a product layout, the machines and workstations are arranged along the product route in a sequence that corresponds to the sequence of operations the product undergoes. If a product undergoes milling, drilling, assembly, and packing operations in sequence, the vertical milling machines, drilling machines, assembly equipment, and packing equipment must be arranged one after another in a line. Typically, the product layout is used by companies that manufacture a single or few items in large quantities, such as a sports utility vehicle assembly plant. Benefits of the product layout include reduced material handling time, reduced processing time, and easier planning and control. Its main disadvantage is the lack of flexibility. Once a particular product layout is adopted, the cost to make changes is significant, so a product layout is not suitable for a company that makes frequent product changes. The reader is encouraged to identify other disadvantages in Exercise 3 at the end of the chapter. Figure 7.6 is an example of a product layout.
Focused Factories and Group Technology
Published in John Nicholas, Lean Production for Competitive Advantage, 2018
A traditional product layout is an automated transfer line or an assembly line of workers at stations connected by a conveyor system. In either case, the layout can be difficult to modify to meet changes in product mix and product volume. A flexible alternative is a series of work benches. Schonberger suggests using benches of roughly 5 feet by 30 feet, and putting them end to end to form a product line.10 The benches can be easily moved around, added, or deleted to suit current production requirements. Further, each bench can be considered a mini-focused factory, that is, the first bench focused on making parts and components, the next bench on making subassemblies, the next on final assembly, and the last on testing and packaging.
The Location and Layout Plan
Published in David C. Kimball, Robert N. Lussier, Entrepreneurship Skills for New Ventures, 2020
David C. Kimball, Robert N. Lussier
Use of product layout enables a business to produce large volumes of one or a few standardized products at low unit costs. Because machines are highly specialized, expensive, and single purpose in design, a product layout has heavy fixed costs and is thus a relatively costly method to use. However, the more units of a product that are manufactured, using product-type layout, the broader the base upon which to spread these fixed costs. The relationship of fixed costs to volume is shown in Exhibit 7–4.
Facility layout improvement in sewing department with Systematic Layout planning and ergonomics approach
Published in Cogent Engineering, 2019
Bambang Suhardi, Eldiana Juwita, Rahmaniyah Dwi Astuti
The sewing department is the center of production activities for PT. PMJ. Direct observations were carried out and showed that the arrangement of machines and facilities in the sewing department applied the product layout type. Product layout is the preparation of machines according to the process sequence of a product (Purnomo, 2004). The flow pattern of the material used in the sewing department has a straight line material type. This flow pattern makes the production activities go straight in accordance with the order of the machine. However, the order of production machines has not been arranged which causes a long distance of material transfer. In addition, the condition of the flow pattern of this material causes the worker to rotate their body when taking material. Rotating posture of the body includes an unnatural work attitude if maintained for more than 10 seconds and performed as much as more than 2 times per minute (Humantech, 1995). Based on the interviews and the results of the assessment of the condition of the workers in the layout of the initial facility at the sewing department using the Quick Exposure Check (QEC) method, the highest total exposure score is on the back. This shows that the flow pattern of materials found in the sewing department has a high risk of musculoskeletal injury, especially in the back part of the body. This condition causes workers to experience work fatigue and will decrease worker productivity.