Operations Management Layout And Flow Notes

Layout and Flow

WHAT IS LAYOUT

• The layout of an operation or process means how its transformed resources are positioned relative to each other and how its various tasks are allocated to these transforming resources.

• Together these two decisions will dictate the patter of flow for transformed resources as they progress through the operation or process.

• It is an important decision because if the layout proves wrong it can lead to over long or confused flow patterns, customer queues, long process times, inflexible operations, unpredictable flow and high cost.

• Re-laying out an existing operation can cause disruption leading to customer dissatisfaction or lost operating time.

• Layout must start with a full appreciation of the objectives that the layout should be trying to achieve.

• To a large extent the objectives of any layout will depend on the strategic objectives of the operation, but there are some general objectives that are relevant to all operations:

  • Inherent safety – all processes which might constitute a danger to either staff or customers should not be accessible to the unauthorised.

  • Length of flow – the flow of materials, information or customers should be appropriate for the operation. This usually means minimising the distance travelled by transformed resources.

  • Clarity of flow – all flow of materials and customers should be well signposted, clear and evident to customers and staff alike.

  • Staff conditions – staff should be located away from noisy or unpleasant parts of the operation.

  • Management coordination – Supervision and communication should be assisted by the location of staff and communication devices.

  • Accessibility – all machines and facilities should be accessible for proper cleaning and maintenance.

  • Use of space – all layouts should use space appropriately; this usually means minimising the space used.

  • Long term flexibility – layouts need to be changed periodically. A good layout will have been devised with the possible future needs of the operation in mind.

THE BASIC LAYOUT TYPES

• Layout is related to process types. It is the physical manifestation of a process type.

• Most practical layouts are derived from only four basic layout types:

  • Fixed position layout

    • Instead of materials, information or customers flowing through an operation, the recipient of the processing is stationary and the equipment, machinery, plant and people who do the processing move as necessary.

    • This could be because the product or the recipient of the service is too large to be moved conveniently. It may be too delicate to move, or it may object to being moved.

  • Functional layout

    • Conforms to the needs and convenience of the functions performed by the transforming resources within the process.

    • Similar resources or processes are located together. This may be because it is convenient to group them together, or that the utilisation of transforming resources is improved.

    • It means that when materials, information or customers flow through the operation their route is determined according to their needs.

    • Different products or customers will have different needs and therefore take different routes.

  • Cell layout

    • Transformed resources entering the operation are pre-selected to move to one part of the operation in which all the transforming resource, to meet their immediate processing needs are located.

    • After being processed in the cell the transformed resources may go into another cell. In effect cell layout is an attempt to bring some order to the complexity of flow which characterises functional layout.

    • Although the idea of cell layout is often associated with manufacturing, it can also be used for services,

  • Product layout

    • Involves locating the transforming resources entirely for the convenience of the transformed resources.

    • Each product, piece of information or customer follows a prearranged route in which the sequence of events that are required matches the sequence in which the processes have been located.

    • The transformed resources flow as in a line through the process. Flow is predictable and therefore relatively easy to control.

  • Mixed layouts

    • Many operations either design themselves hybrid layouts which combine elements of some or all of the basic layout types or use pure basic layout types in different parts...

Buy the full version of these notes or essay plans and more in our Operations Management Notes.