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Chapter 7 Layout and flow 179
What is layout?
The layout decision is
relatively infrequent but
important
The ‘layout’ of an operation or process means how its transformed resources are positioned
relative to each other and how its various tasks are allocated to these transforming resources.
Together these two decisions will dictate the pattern of flow for transformed resources as
they progress through the operation or process (see Figure 7.2). It is an important decision
because, if the layout proves wrong, it can lead to over-long or confused flow patterns,
customer queues, long process times, inflexible operations, unpredictable flow and high cost.
Also, re-laying out an existing operation can cause disruption, leading to customer dissatisfaction
or lost operating time. So, because the layout decision can be difficult and expensive,
operations managers are reluctant to do it too often. Therefore layout must start with a
full appreciation of the objectives that the layout should be trying to achieve. However, this
is only the starting point of what is a multi-stage process which leads to the final physical
layout of the operation.
What makes a good layout?
To a large extent the objectives of any layout will depend on the strategic objectives of the
operation, but there are some general objectives which are relevant to all operations:
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Inherent safety. All processes which might constitute a danger to either staff or customers
should not be accessible to the unauthorized.
Length of flow. The flow of materials, information or customers should be appropriate
for the operation. This usually means minimizing the distance travelled by transformed
resources. However, this is not always the case (in a supermarket, for example).
Clarity of flow. All flow of materials and customers should be well signposted, clear and
evident to staff and customers alike.
Staff conditions. Staff should be located away from noisy or unpleasant parts of the operation.
Management coordination. Supervision and communication should be assisted by the location
of staff and communication devices.
Accessibility. All machines and facilities should be accessible for proper cleaning and
maintenance.
Use of space. All layouts should use space appropriately. This usually means minimizing
the space used, but sometimes can mean achieving an impression of spacious luxury, as
in the entrance lobby of a high-class hotel.
Long-term flexibility. Layouts need to be changed periodically. A good layout will have
been devised with the possible future needs of the operation in mind.
Figure 7.2 Layout involves the relative positioning of transformed resources within
operations and processes and the allocation of tasks to the resources, which together
dictate the flow of transformed resources through the operation or process