Problems in Facility Layout

Process Layout/Functional Layout Problem

i. Longer processing time.

ii. Requires more floor space.

iii. Inspection is more frequent and costlier.

iv. More material handling due to backtracking of material.

v. More skilled labour is required resulting in high-labour costs.

vi. Technical supervision is required.

vii. Work-in-progress inventory is high requiring greater a storage space.

2. Line or Product Layout Problem

i. Project cost increases because of duplication of machines.

ii. More receptive equipments are required.

iii. Breakdown of one single machine disturbs whole line.

iv. Individual incentive scheme is not possible. Less flexibility of operations.

v. Heavy overload charges due to underutilization of machines.

3. Stationary Layout/Fixed Position Layout

i. Materials handling cost is high.

ii. Special purpose equipments are required.

iii. Layout may change with the change in product.

iv. Lead-time may increase for each and every operation.

v. Process time is very high.

4. Combined Layout Problem

i. Materials handling cost is less.

ii. Flexibility is less.

5. Cellular Manufacturing Layouts Problems

i. Implementing cellular manufacturing could lead to a decrease in manufacturing flexibility.

ii. It is felt that conversion to cells may cause some loss in routing flexibility, which could then impact the viability of cell use.

iii. Obtaining balance among cells is also more difficult than for flow or job shops.

iv. If demand diminishes greatly, it may be necessary to break up that cell and redistribute the equipment or reform the families.