Q.1.What is advantage And Disadvantage of Process layout ?

Process or Functional Layout:

Merits:

The major merits of this layout are :

1. There exists a wide flexibility regarding allotment of work to equipment and workers.
2. There is a better utilization of the available equipment.
3. Comparatively less numbers of machines are needed in this layout and hence thus reducing capital investment.
4. There is an improved product quality, because the supervisors and workers attend to one type of machines and operations.
5. Varieties of jobs coming as different job orders thus make the work more interesting for the workers.
6. Workers in one section are not affected by the nature of the operations carried out in another section. For example, a lathe operator is not affected by the rays of the welding as the two sections are quite separate.

Demerits:

The major demerits of this layout are :

1. This layout requires more space in comparison to line or product layout for the same amount of production.
2. Production control becomes relatively difficult in this layout.
3. Raw material has to travel more which increases material handling and the associated costs.
4. This layout requires more efficient co-ordination and inspections.
5. Increased material handling cost due to more movement of process raw material to various paths
6. More material in process remains in queue for further operations.
7. Requires large in-process inventory.
8. Completion of same product takes more time.

Application:

1. This layout is used for batch or moderate production.
2. It specify path for group technology.

Q.2.What is advantage And Disadvantage of Fixed or Position Layout ?

Fixed or Position Layout:

Merits:

Its main merits are—

1. Layout is highly flexible for varieties of products having intermittent demand as the type of product and the related processes can be easily altered without any change in the layout.
2. There is a minimum movement of men, material, and tooling during manufacturing process.
3. The material is drastically reduced.
4. Highly skilled operators are required to complete the work at one point and responsibility for quality is fixed on one person or the assembly crew.
5. Every personnel of manufacturing team is responsible for quality work for manufacturing the product.

Demerits:

The major demerits of this layout are

1. The cost of equipment handling is very high.
2. Labors and equipments are difficult to utilize fully.
3. It is limited to large items only.

Applications:
This type of layout is mostly adopted for extremely large items manufactured in very small quantity such as ships, aero planes, aircraft, locomotive, ship assembly shops, shipyards, boilers, reactors etc.

Q.3.What is advantage And Disadvantage of Line or Product Layout ?

Line or Product Layout:

Merits:

Its main merits are—

1. It involves smooth and continuous work flow.
2. It may require less skilled workers.
3. It helps in reducing inventory.
4. Production time is reduced in this layout.
5. Better coordination, simple production planning and control are achieved in this layout.
6. For the same amount of production, less space requirements for this layout.
7. Overall processing time of product is very less.
8. This layout involves automatic material handling, lesser material movements and hence leads to minimum possible cost of manufacturing.

Demerits:

The major demerits of this layout as compared with process layout are—

1. It is very difficult to increase production beyond the capacities of the production lines.
2. When single inspector has to look after many machines, inspection becomes difficult
3. This layout is very less flexible for product change.
4. The rate or pace rate of working depends upon the output rate of the slowest machine and hence leading to excessive idle time for other machines if the production line is not adequately balanced.

Machines being put up along the line, more machines of each type have to be installed for keeping a few as stand by, because if on machine in the line fails, it may lead to shut down of the complete production line. That is why the line or product layout involves heavy capital investments.

Applications:
It is used in assembly work.

Q.4.What is advantage And Disadvantage of Combination Layout ?

Combination Layout :

Merits:

The merits of this type of layout are:

1. Reduction in cost of machine set-up time and material handling of metals.
2. Elimination of excess work-in-process inventory which subsequently allows the reduction in lot size.
3. Simplification of production planning functions, etc.

Demerits:

The major demerits of this layout are :

1. Change of the existing layout is time consuming and costly.
2. Inclusion of new components in the existing component requires thorough analysis.
3. Change of input component mix may likely to change complete layout structure.
4. Change of batch size may change number of machines.

Application:
Manufacturing circular metal saws, hacksaw, wooden saw, files and crank shaft.