- Practice · 8 marks
Product layout versus process layout
Short answer
Plant layout arranges machines and facilities for smooth flow, minimal handling, and effective space use. Product layout arranges machines in operation sequence for high-volume standard products (low flexibility, low WIP). Process layout groups similar machines for varied, low-volume jobs (high flexibility, high WIP).
What is plant layout? State its objectives. Differentiate between product layout and process layout.
Plant layout is the arrangement of machines, equipment, storage, service areas and workers in a plant so that the production process runs smoothly at minimum cost. It is the physical arrangement of facilities to give the best use of space, labour and machines.
Objectives
- Minimum material handling and transport distance.
- Smooth, continuous flow with no back-tracking.
- Effective use of floor space and equipment.
- Safe, comfortable working conditions.
- Flexibility for changes in product or volume.
- Easy supervision and communication, and lower work-in-process.
Product (line) layout
Machines are arranged in the sequence of operations of one product, as in an assembly line or bottling plant.
Process (functional) layout
Similar machines or functions are grouped together (lathe section, milling section, grinding section) and jobs move between sections, as in a job shop.
| Basis | Product layout | Process layout |
|---|---|---|
| Arrangement | By sequence of operations | By type of machine/function |
| Product volume | High, standard | Low, varied (job or batch) |
| Machines | Special-purpose | General-purpose |
| Material handling | Mechanised, short, fixed path | Varied paths, more handling |
| Work-in-process | Low | High |
| Flexibility | Low | High |
| Machine utilisation | High if balanced | Moderate, often low |
| Labour skill | Low to medium | High |
| Investment | High | Lower |
| Breakdown effect | Stops the whole line | Affects only one job |
| Production control | Simple | Complex |
Examples
- Product layout: car assembly, soft-drink bottling, sugar plant.
- Process layout: machine shop, hospital, repair workshop.
✓ Answer checked by Claude Opus 5.5 (high effort)
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