Question

1. Discuss the 4 basic layout types. Link the issue of coronavirus and its effect to these 4 basic layout types. Motivate your answer                            (25).

Explain the techniques that can be used to evaluate and improve the preliminary design (18).

Answer 1

Answer 1:

Selection of layout highly depends on type of industry and volume of production. Four basic types of layout are:

· Process (Functional) Layout: It is employed in production of low volume. In this layout, arrangement of machinery is made as per type of operations rather than sequence of operations. This layout is highly recommended for non-repetitive jobs. In this layout same type of operations facilities are kept at one place/ section. The process carried out in that area is based on the availability equipment in that area.

o Effects of coronavirus on process layout: It is believed that COVID-19 will have significant impact on process layout depending on nature of products being produced. It is important for manufacturers to ensure that as they employ process layout in their production facility, they must strictly follow standard operating procedures (SOP’s) and updated guidelines as directed by government. As this layout is based on keeping same type of operations facilities at one place, it is important to be cautious while employing this layout to avoid spread of COVID-19. Enterprises involved in process layout must establish strong disaster management mechanism.

· Product (Line) Layout: In this layout all the machines and equipment are arranged as per the sequence of operations. Specifically one type of product is produced in one area. This type of layout is used for producing highly standardized products in large quantities. Product layout is employed to ensure minimum work in process, storage as well as material handling. However, lack of flexibility is one of the biggest disadvantages in product layout.

o Effects of coronavirus on product layout: As the product layout is based on sequencing, it is extremely important to be cautious and reduce the production line loads to avoid any contamination. Coronavirus is known to spread in rapidly and it is important to implement standard operating procedures (SOP’s) and updated guidelines as directed by government so that its spread can be avoided in product layout.

· Fixed position Layout: In this type of layout main component remains fixed and other components including labour, materials, machinery, tools etc. are brought to location where main component is fixed. This most inflexible kind of layout and usually employed only where main component like boiler is very heavy and permanently fixed.

o Effects of coronavirus on fixed position layout: It is very important for units that follow fixed position layout to be extra cautious during coronavirus pandemic. The main reason is that in case this type of layout gets contaminated with coronavirus, it will take lot of time and resources to fix this problem. Therefore, it should be ensured that government guidelines are followed religiously. This type of layout is at least risk of getting contaminated if procedures are followed strictly because it is easy to control movement of labour in this layout.

· Hybrid (Combination) Layout: In this layout combination of above three layouts is used for production. This helps in reducing cost of production and time. It also makes the layout flexible and appropriate for the production depending on nature of product being produced.

o Effects of coronavirus on Hybrid (Combination) Layout: As this is the combination of different layouts, there is a high risk of contamination. To avoid any contamination in production facility that utilizes combination layout is important to be careful and follow the procedures, maintain social distancing and ensure less contact. It is also important to limit production in facilities that use combination layout.

Answer 2:

Depending on the type of industry, different techniques can be employed in order to evaluate and improve the preliminary design. Some of these techniques are explained in brief as follows:

· Qualify function deployment (QFD): This technique is used to identify that the innovation in design meets the customer requirement. This technique was developed by Toyota. This technique is also referred as house of quality. The technique focuses on capturing needs of customers and how they can be achieved. This technique is quality oriented.

· Value engineering: This evaluation and improvement technique is frequently employed to determine the best possible balance between cost, productivity, performance and reliability. This technique is function oriented. It helps to identify what basic functions should be employed for value improvements. In order to improve value most of the time this technique focuses on cost reduction. Other important components of value equation are customer perceived quality and performance.

· Taguchi method: This method originated in Japan. This is statistical method that lays emphasis on process evaluation and improvement. The major focus of this method is to minimize the value of target variance for certain classes of identified problems. Design parameters are predefined along with several variables and constraints of design. Based on these predefined constraints and variable optimal solutions are determined and implemented to improve preliminary design.