Important Differences Between Product and Process Layout

Product Layout

A product layout is a type of manufacturing layout where the resources (workstations, machines, tools, etc.) used in the production process are organized sequentially in a straight line of production. In a product layout, the sequence of operations is fixed, and each workstation performs a specific task in the production process. This layout is most suitable for mass production of identical products, where the same production steps are repeated over and over again.

In a product layout, the raw material is supplied to the first workstation, and then the product is passed from one workstation to the next along a production line, with each workstation adding a new feature to the product until it reaches the end of the line as a finished product. The production line is typically operated by a team of workers, and the product moves along the line on a conveyor belt.

A product layout is highly efficient and allows for a high level of automation, resulting in low unit costs and high productivity. This layout is used in industries such as automobile manufacturing, electronics manufacturing, and food processing, where large quantities of identical products are produced.

Examples of Product Layout

Here are some examples of product layout in different industries:

• Automobile manufacturing: In an automobile manufacturing plant, the assembly line is a classic example of a product layout. The car chassis moves along a conveyor belt, and each workstation along the line performs a specific task, such as installing the engine, adding the wheels, attaching the doors and windows, and adding the final touches such as painting and finishing.
• Electronic goods manufacturing: In the production of electronic goods, such as mobile phones or laptops, the product layout involves a sequential arrangement of workstations where the different components of the device are added to the main circuit board. Each workstation may add a specific component, such as the screen, the battery, the camera, or the processor, until the final product is complete.
• Food processing: In the production of packaged food products, such as potato chips or chocolate bars, the product layout involves a series of workstations where the ingredients are mixed, cooked, shaped, and packaged. Each workstation performs a specific task, such as mixing the ingredients, baking or frying the product, and packaging it for distribution.

Forms of Product Layout

There are different forms of product layout that can be used in manufacturing processes, depending on the specific requirements of the product and the production process. Here are some common forms of product layout:

1. Straight-line layout: In a straight-line layout, the workstations are arranged in a straight line along the production line, and the product moves along the line from one workstation to the next in a sequential manner.
2. U-shaped layout: In a U-shaped layout, the workstations are arranged in a U-shape, and the product moves from the starting point to the end point of the U-shape, with each workstation performing a specific task.
3. L-shaped layout: In an L-shaped layout, the workstations are arranged in an L-shape, and the product moves from one end of the L-shape to the other end, with each workstation performing a specific task.
4. Circular layout: In a circular layout, the workstations are arranged in a circular pattern, and the product moves along the circular path, with each workstation performing a specific task.
5. Combined layout: A combined layout is a combination of two or more of the above layouts to optimize the production process for the specific product being manufactured.

Characteristics of Product Layout

Here are some characteristics of a product layout:

• Sequential arrangement of workstations: The workstations in a product layout are arranged in a sequential order, and the product moves along the line from one workstation to the next, with each workstation performing a specific task.
• Specialization: In a product layout, each workstation is designed for a specific task, and the workers at each station are specialized in performing that task.
• High level of automation: A product layout is highly automated, with machinery performing most of the production tasks. This results in high productivity and low unit costs.
• Fixed sequence of operations: The production process in a product layout follows a fixed sequence of operations, with each workstation performing a specific task in that sequence.
• High production rates: A product layout is designed for mass production of identical products, resulting in high production rates and economies of scale.
• Standardization: Products manufactured using a product layout are highly standardized, with little variation in the final product.
• Low production time: A product layout allows for efficient production with low production time, as the product moves along the line at a constant rate, and there are few interruptions or delays.

Process of Product Layout

The process of designing a product layout involves several steps. Here are the basic steps involved in the process:

Step 1. Define the production process: The first step in designing a product layout is to define the production process, including the sequence of operations and the resources required at each workstation. This involves analyzing the product design and identifying the tasks that need to be performed to produce the product.

Step 2. Analyze the flow of materials and products: The next step is to analyze the flow of materials and products through the production process. This involves identifying the entry and exit points of the production line, and designing the layout to ensure that the product flows smoothly through the production process.

Step 3. Design the layout: Based on the analysis of the production process and the flow of materials and products, the layout can be designed. The layout should optimize the use of resources, minimize the distance between workstations, and ensure that the production process flows smoothly.

Step 4. Implement the layout: Once the layout is designed, it needs to be implemented. This involves installing the equipment and machinery at the workstations, and setting up the production line according to the design.

Step 5. Test and optimize the layout: After the layout is implemented, it needs to be tested and optimized to ensure that it meets the desired performance criteria. This involves monitoring the production process, identifying any issues or bottlenecks, and making adjustments to the layout as necessary to improve efficiency and productivity.

Process Layout

Process layout is a type of manufacturing layout where similar processes or functions are grouped together. In this type of layout, the production process is organized based on the nature of the product or service, rather than the sequence of operations. This means that different resources, such as machines, equipment, and workstations, are grouped together based on their function or process, rather than their order in the production line.

In a process layout, the product or service may require different processes or operations, and each process may have different requirements for the equipment and resources needed. For example, a job shop that produces custom-made products may use a process layout where similar processes, such as drilling, milling, and welding, are grouped together in the same area of the factory.

In a process layout, the production process is not fixed, and the routing of the product or service may be different for each order. This means that the production process may require more planning and coordination than a product layout, as the routing of the product or service needs to be determined for each order.

Examples of Process Layout

Here are some examples of process layout:

• Hospital: Hospitals typically use a process layout, with different departments organized based on their function. For example, the emergency room, laboratory, and operating room are separate areas in the hospital, and patients are routed through the hospital based on their medical needs.
• Restaurant: Restaurants often use a process layout, with different stations for food preparation, cooking, and serving. Each station has its own specialized equipment and resources, and the routing of the food through the kitchen is based on the order from the customer.
• Print shop: A print shop may use a process layout, with different machines and equipment organized based on their function. For example, there may be a separate area for design, printing, cutting, and binding.
• Manufacturing facility: A manufacturing facility may use a process layout, with different workstations organized based on the function of the equipment. For example, a facility that produces metal parts may have separate areas for cutting, drilling, and welding.
• Supermarket: A supermarket may use a process layout, with different sections organized based on the type of product. For example, the produce section, meat section, and bakery section are separate areas in the supermarket, and customers can navigate through the store based on their needs.

Forms of Process Layout

There are different forms of process layout, which are:

1. Job Shop Layout: In this layout, similar processes or machines are grouped together based on the nature of the product or service, rather than the sequence of operations. This layout is used in manufacturing facilities where products are customized, and each product requires different processes or operations.
2. Batch Production Layout: In this layout, the production process is organized based on the type of product or service, and products are produced in batches. The layout is designed to handle a specific number of products or services, which are produced in a single batch.
3. Functional Layout: In this layout, the production process is organized based on the functions or departments of the organization. This layout is used in organizations where different departments perform different functions or operations, and each department has its own specialized equipment and resources.
4. Fixed Position Layout: In this layout, the product or service is produced in a fixed position, and the resources, such as machines and equipment, are brought to the product or service. This layout is used in industries where the product or service is too large or complex to move, such as shipbuilding, construction, or aircraft manufacturing.
5. Cellular Layout: In this layout, the production process is organized into small groups of machines or workstations, called cells. Each cell is designed to produce a specific type of product or service, and the layout is designed to minimize the distance between the cells.

Characteristics of Process Layout

The characteristics of process layout include:

• Flexibility: Process layout allows for flexibility in the production process, as machines and equipment can be easily reorganized to accommodate changes in the production process or product design.
• Variety of products: Process layout is suitable for production facilities that produce a variety of products or services, as it allows for different processes or operations to be performed in the same facility.
• Specialization: Process layout allows for specialization of equipment and resources, as different machines or workstations can be designed for specific tasks or functions.
• Increased efficiency: By grouping similar processes or equipment together, process layout can increase the efficiency of the production process, as resources can be easily shared and used more efficiently.
• Longer production times: Process layout may result in longer production times, as products or services may need to be moved between different machines or workstations.
• Higher costs: Process layout may require a larger facility or more resources than other layout types, which can result in higher costs.
• More complex scheduling: Process layout may require more complex scheduling to ensure that the right machines or workstations are available for each product or service, which can increase the complexity of the production process.

Process of Process Layout

The process of creating a process layout includes the following steps:

Step 1. Analyze the requirements: The first step in creating a process layout is to analyze the requirements of the production process. This includes understanding the nature of the product or service, the volume of production, and the types of processes or operations required.

Step 2. Identify the processes: Once the requirements have been analyzed, the next step is to identify the processes or operations required to produce the product or service. This involves breaking down the production process into smaller, more manageable components.

Step 3. Group the processes: After identifying the processes, the next step is to group similar processes together based on their characteristics or requirements. This involves considering factors such as the type of equipment required, the skill level of the workers, and the volume of production.

Step 4. Design the layout: With the processes grouped together, the next step is to design the layout of the production facility. This involves determining the location of each group of processes or operations, and the arrangement of the equipment and resources required for each process.

Step 5. Optimize the layout: Once the layout has been designed, the next step is to optimize it to ensure maximum efficiency and productivity. This may involve adjusting the location of certain processes or operations, or reorganizing the equipment and resources to reduce waste and improve workflow.

Step 6. Implement the layout: Once the layout has been optimized, the final step is to implement it in the production facility. This involves physically arranging the equipment and resources according to the layout design, and training workers on the new production process.

Important Difference Between Product and Process Layout

Here is a table comparing the features of product and process layouts:

Key Difference Between Product and Process Layout

Here are some key differences between product and process layouts:

1. Volume of Production: Product layout is best suited for high-volume production of standardized products, while process layout is better suited for low-volume production of customized or varied products.
2. Flow of Materials: In product layout, the flow of materials is continuous and predictable, moving from one workstation to another in a linear fashion. In process layout, the flow of materials is intermittent and unpredictable, as products move between workstations based on the specific needs of the production process.
3. Workforce: Product layout requires a large and specialized workforce to operate the specialized equipment and manage the dedicated resources. In contrast, process layout requires a smaller and more flexible workforce that can adapt to changing production processes and share resources as needed.
4. Space Requirements: Product layout requires a large amount of floor space to accommodate the specialized equipment and dedicated resources, while process layout requires less space due to the use of general purpose equipment and shared resources.
5. Production Planning: Product layout requires a high degree of planning and coordination to ensure the continuous flow of materials and efficient use of resources. Process layout requires more flexibility in production planning, as the flow of materials and use of resources may change based on the specific needs of the production process.
6. Level of Standardization: Product layout requires a high level of standardization in the production process to ensure the efficient use of specialized equipment and dedicated resources. Process layout allows for more customization and variation in the production process, as resources are shared and adapted to the specific needs of each production cycle.

Similarities Between Product and Process Layout

Although product and process layouts have significant differences, there are a few similarities between the two:

1. Both layouts are used to optimize the use of resources and increase production efficiency.
2. Both layouts require careful planning and management to ensure the smooth flow of materials and the efficient use of resources.
3. Both layouts involve the use of different workstations or departments to complete the production process.
4. Both layouts require skilled workers who are trained to operate the equipment and machinery used in the production process.
5. Both layouts aim to reduce waste and increase the quality of the final product or service.
6. Both layouts can be modified or adapted over time to better meet the changing needs of the production process or the market demand.

Conclusion Between Product and Process Layout

In conclusion, product and process layouts are two different approaches to organizing a production process. Product layout is ideal for high-volume production of standardized products, where each workstation is dedicated to a specific task, and the flow of materials is continuous and predictable. Process layout, on the other hand, is better suited for low-volume production of customized or varied products, where each workstation is multi-functional and the flow of materials is intermittent and unpredictable.

Each layout has its own set of advantages and disadvantages, and the choice between the two depends on the specific needs and characteristics of the production process. However, both layouts share a common goal of optimizing the use of resources, increasing production efficiency, and delivering high-quality products or services to the customers. Ultimately, the success of a production process depends on the ability to adapt and evolve over time to meet the changing demands of the market and the customers.