Which type of layout is called as functional layout?

In an effort to make your production line more efficient, look at the different ways to lay out the production line or overall manufacturing plant. Two of the most common layouts are the process layout and the product layout. Each layout provides a systematic approach to production, with each serving a different type of product assembly. Consider your business needs before you choose the best manufacturing layout for your company.

What is Process Layout?

The process layout, also called the functional layout, is designed to keep everything organized in a manner so that everything has its place. Think about an auto mechanic's shop. New tires are stored in one section, whereas wrenches and other tools are stored in another section. The cans of oil are stored together, as are other groupings of supplies or power tools.

Although this is an organized layout in which everyone always knows where all supplies and tools are located, it isn't the most efficient for production lines, where the same job is performed every single time. The process layout is effective when each job is a custom situation. The mechanic's shop illustrates this well. One customer may come in needing only an oil change, but another may come in needing the entire transmission overhauled.

What is Product Layout?

The product layout is the opposite of the process layout. Rather than have a specific section for each group of tools and supplies, the product layout is an assembly line. The required tools and supplies are located at each section of the assembly line, based on where the product is in production. This is common in auto manufacturing where the car being made is moved down the line and stops at stations where different things are assembled. One section might be where doors are attached, whereas another section inserts the engine.

This is an efficient system when the same product is being made without variation. Workers don't need to search or collect tools or supplies to perform their job. Giving workers one job to perform repeatedly reduces potential mistakes in the product assembly.

How Do You Choose a Layout?

The manufacturing layout will depend on business leaders determining the best process. Even though the functional layout requires more professional skill, automation can counter unskilled workers in the product layout. Because the process layout requires one worker or a small team to complete the entire task, the workflow is generally not as fast nor as smooth as it is with the product layout. However, the quality of the final product in a process layout is usually better than with the product layout.

As you can see, there are advantages and disadvantages to both systems. Evaluate your production space, your workforce and your ability to automate, before deciding on which layout will be the best solution for your business.

Fixed position layout involves the movement of manpower and machines to the product which remains stationary. The movement of men and machines is advisable as the cost of moving them would be lesser. This type of layout is preferred where the size of the job is bulky and heavy. Example of such type of layout is locomotives, ships, boilers, generators, wagon building, aircraft manufacturing, etc.

A functional layout is a workplace organization in which processes are organized by the type of work (function), rather than by value stream or in a cellular configuration where sequential process steps are located in close proximity. In a functional layout, for example, the cutting machines would be in one location, the press brakes would be in one group, the welders would all be together, and so on.

The same is true in office environments. Each functional group sits together in a work area and supports multiple product teams.

This type of arrangement is typical of non-Lean organizations. There is a belief that management is easier when leaders have fewer functions to oversee. Functional arrangements also make sense when large machines support multiple product families. Of course, that also means large batches are necessary, and copious amounts of product must be transported between functional groups to keep from running out of materials.

In a Lean organization, the focus is on value streams and flow. Small, right sizes machines are organized into product-oriented work cells that require less inventory. The early focus of kaizen events in a company just beginning its Lean journey is often on creating flow-oriented work cells.

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