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Product layout arranges workstations and equipment around the needs of the final product, with each station completing a small task in sequence. This design increases productivity and proficiency but can cause bottlenecks if one workstation is disabled. Separate lines can be used to divide the workload.
Product layout is one of the three basic layouts for manufacturing and manufacturing facility. In this project, the layout of the equipment and processes in the workstations is distributed around the needs of the final product. Each station is given a small task to complete in a certain sequence. When this activity is completed, the part is moved to the next workstation in the sequence for further assembly.
On a production assembly line, workpieces in this design travel past individual workstations on a conveyor belt. As individual workstations pass, the operator at the station completes a small task, such as adding an adhesive or tightening a bolt. As these jobs are completed in turn, the completed product begins to form.
The design used in product layout differs from process layout and fixed position layout in that the assembly line is arranged in a logical order of assembly. In some cases, this simple production layout is implemented as a single production line with several workstations. Product layout design can be further broken down into lines of smaller modules that use different processes to complete a group task. For example, an automobile manufacturer may have an assembly line module where the car body is cleaned, primed, and painted in one area of the plant, rather than being moved to three different workstations.
Product layout arrangements often offer some distinct advantages over other plant layout designs. Using this design, manufacturers have noticed an increase in productivity and a reduction in labor. Also, because each section of the layout specializes in its own function, workers often become more proficient at their tasks, resulting in a better overall product.
The disadvantage of product layout designs is that the manufacturing process is focused on the final product. In a single line project, the production process can become a bottleneck if one workstation is disabled. While preventative measures can be taken to avoid this problem, unplanned maintenance or training of new operators for a station can result in the need to shut down the entire assembly line. Workstations upstream of the line can continue to operate, but downstream modules are affected by production issues upstream in product layout projects. To get around this, some production layouts use separate lines to further divide the workload, ensuring that one line remains operational under most circumstances.
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