6.4.3: Product (Line) Layout
- Page ID
- 117790
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\(\newcommand{\avec}{\mathbf a}\) \(\newcommand{\bvec}{\mathbf b}\) \(\newcommand{\cvec}{\mathbf c}\) \(\newcommand{\dvec}{\mathbf d}\) \(\newcommand{\dtil}{\widetilde{\mathbf d}}\) \(\newcommand{\evec}{\mathbf e}\) \(\newcommand{\fvec}{\mathbf f}\) \(\newcommand{\nvec}{\mathbf n}\) \(\newcommand{\pvec}{\mathbf p}\) \(\newcommand{\qvec}{\mathbf q}\) \(\newcommand{\svec}{\mathbf s}\) \(\newcommand{\tvec}{\mathbf t}\) \(\newcommand{\uvec}{\mathbf u}\) \(\newcommand{\vvec}{\mathbf v}\) \(\newcommand{\wvec}{\mathbf w}\) \(\newcommand{\xvec}{\mathbf x}\) \(\newcommand{\yvec}{\mathbf y}\) \(\newcommand{\zvec}{\mathbf z}\) \(\newcommand{\rvec}{\mathbf r}\) \(\newcommand{\mvec}{\mathbf m}\) \(\newcommand{\zerovec}{\mathbf 0}\) \(\newcommand{\onevec}{\mathbf 1}\) \(\newcommand{\real}{\mathbb R}\) \(\newcommand{\twovec}[2]{\left[\begin{array}{r}#1 \\ #2 \end{array}\right]}\) \(\newcommand{\ctwovec}[2]{\left[\begin{array}{c}#1 \\ #2 \end{array}\right]}\) \(\newcommand{\threevec}[3]{\left[\begin{array}{r}#1 \\ #2 \\ #3 \end{array}\right]}\) \(\newcommand{\cthreevec}[3]{\left[\begin{array}{c}#1 \\ #2 \\ #3 \end{array}\right]}\) \(\newcommand{\fourvec}[4]{\left[\begin{array}{r}#1 \\ #2 \\ #3 \\ #4 \end{array}\right]}\) \(\newcommand{\cfourvec}[4]{\left[\begin{array}{c}#1 \\ #2 \\ #3 \\ #4 \end{array}\right]}\) \(\newcommand{\fivevec}[5]{\left[\begin{array}{r}#1 \\ #2 \\ #3 \\ #4 \\ #5 \\ \end{array}\right]}\) \(\newcommand{\cfivevec}[5]{\left[\begin{array}{c}#1 \\ #2 \\ #3 \\ #4 \\ #5 \\ \end{array}\right]}\) \(\newcommand{\mattwo}[4]{\left[\begin{array}{rr}#1 \amp #2 \\ #3 \amp #4 \\ \end{array}\right]}\) \(\newcommand{\laspan}[1]{\text{Span}\{#1\}}\) \(\newcommand{\bcal}{\cal B}\) \(\newcommand{\ccal}{\cal C}\) \(\newcommand{\scal}{\cal S}\) \(\newcommand{\wcal}{\cal W}\) \(\newcommand{\ecal}{\cal E}\) \(\newcommand{\coords}[2]{\left\{#1\right\}_{#2}}\) \(\newcommand{\gray}[1]{\color{gray}{#1}}\) \(\newcommand{\lgray}[1]{\color{lightgray}{#1}}\) \(\newcommand{\rank}{\operatorname{rank}}\) \(\newcommand{\row}{\text{Row}}\) \(\newcommand{\col}{\text{Col}}\) \(\renewcommand{\row}{\text{Row}}\) \(\newcommand{\nul}{\text{Nul}}\) \(\newcommand{\var}{\text{Var}}\) \(\newcommand{\corr}{\text{corr}}\) \(\newcommand{\len}[1]{\left|#1\right|}\) \(\newcommand{\bbar}{\overline{\bvec}}\) \(\newcommand{\bhat}{\widehat{\bvec}}\) \(\newcommand{\bperp}{\bvec^\perp}\) \(\newcommand{\xhat}{\widehat{\xvec}}\) \(\newcommand{\vhat}{\widehat{\vvec}}\) \(\newcommand{\uhat}{\widehat{\uvec}}\) \(\newcommand{\what}{\widehat{\wvec}}\) \(\newcommand{\Sighat}{\widehat{\Sigma}}\) \(\newcommand{\lt}{<}\) \(\newcommand{\gt}{>}\) \(\newcommand{\amp}{&}\) \(\definecolor{fillinmathshade}{gray}{0.9}\)These are used in businesses that use assembly lines or production lines. If the product has high volume an assembly line might be the best option. The equipment in these types of layouts are often very capital intensive and are laid out according to the progressive steps of the process. Each work station is located along the line and may consist of a worker with equipment, or robots. Often each work station is adding components (assembly line) or modifying a product (production line). It is important to note that it is not necessarily a straight line, often assembly lines zig zag or are in a shape to use the maximum amount of space available. Some services may use a line layout, such as preparing hospital meals, or a cafeteria line. Due to considerable cost involved with setting up an assembly line, a large volume of product needs to be produced. Demand that is steady and consistent is ideal.
The goods produced in a line layout are generally very standardized, and the work processes are also highly standardized. Each product follows the same set of steps so that a fixed path material handling system is used such as a conveyor belt. This conveyor belt may be manual or automatic. It may operate at a pre determined speed, or it may be worker paced. It may run continuously or pulsed. The speed of the conveyor will determine the amount of product that will be produced per shift.
In contrast to a process layout a product layout is very efficient. There are a number of reasons for this.
- Because of the division of labour and the repetition, there is less variability in the work performed
- There is no build up of inventory, and no waiting. When completed at one work station, the job automatically moves to the next workstation. Only the inventory that is in process is in the system. Goods tend to be shipped when they are completed.
- Due to the material handling system, goods move quickly and not very far.
- Changeovers are not necessary so very little time is lost in changing between products.
It is important that assembly lines are balanced. The amount of time required at a preceding work station should be relatively similar to the amount of time required at the following work station.
Challenges in a product (line) layout include:
- The fact that the line may be susceptible to shut downs if there are equipment malfunctions so preventative maintenance is critical. Preventative maintenance involves the inspection and replacement of any parts that have a high probability of failures, as well as holding ample spare parts in stock and having a detailed maintenance schedule for each piece of equipment.
- Training and job rotation are critical activities to make sure employees are capable of completing the work tasks and that there are multiple people that can work at each individual job
- With repetitive standardized jobs, it is critical that good ergonomic job design is performed. Organizations that ensure the health, safety and comfort of their employees reap rewards in terms of the quality of work they receive from employees.
Here is a fun video; see Rick Mercer on the Assembly line in GM Oshawa: