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Chapter 7 Layout and flow 183
figure also shows the route taken by one customer on one visit to the library. If the routes for
the customers were superimposed on the plan, the pattern of the traffic between the various
parts of the operation would be revealed. The density of this traffic flow is an important
piece of information in the detailed design of this type of layout. Changing the location of the
various areas in the library will change the pattern of flow for the library as a whole.
Cell layout
A cell layout is one where the transformed resources entering the operation are pre-selected
(or pre-select themselves) to move to one part of the operation (or cell) in which all the
transforming resources, to meet their immediate processing needs, are located. After being
processed in the cell, the transformed resources may go on to another cell. In effect, cell layout
is an attempt to bring some order to the complexity of flow which characterizes functional
layout. Examples of cell layouts include:
Shop-within-a-shop
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Some laptop assembly – within a contract manufacturer’s factory, the assembly of different
laptop brands may be done in a special area dedicated to that one brand that has special
requirements such as particularly high quality levels.
‘Lunch’ products area in a supermarket – some customers use the supermarket just to
purchase sandwiches, savoury snacks, etc. for their lunch. These products may be located
together so that these customers do not have to search around the store.
Maternity unit in a hospital – customers needing maternity attention are a well-defined
group who can be treated together and who are unlikely to need the other facilities of the
hospital at the same time that they need the maternity unit.
Although the idea of cell layout is often associated with manufacturing, the same principle
can be, and is, used in services. In Figure 7.5 the ground floor of a department store is shown,
comprising displays of various types of goods in different parts of the store. In this sense
the predominant layout of the store is a functional layout. However, some ‘themed’ products
may be put together, such as in the sports shop. This area is a shop-within-a-shop which will
stock sports clothes, sports shoes, sports bags, sports books and videos, sports equipment
and energy drinks, which are also located elsewhere in the store. They have been located in
the ‘cell’ not because they are similar goods (shoes, books and drinks would not usually
be located together) but because they are needed to satisfy the needs of a particular type of
customer. Enough customers come to the store to buy ‘sports goods’ in particular to devote
an area specifically for them. Also, customers intending to buy sports shoes might also be
persuaded to buy other sports goods if they are placed in the same area.
Product layout
Line layout
Product layout involves locating the transforming resources entirely for the convenience
of the transformed resources. Each product, piece of information or customer follows a
prearranged route in which the sequence of activities that are required matches the sequence
in which the processes have been located. The transformed resources ‘flow’ as in a ‘line’
through the process. This is why this type of layout is sometimes called flow or line layout.
Flow is predictable and therefore relatively easy to control. Examples of product layout
include:
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Automobile assembly – almost all variants of the same model require the same sequence of
processes.
Loan application processing – all applications require the same sequence of clerical and
decision-making activities.
Self-service cafeteria – generally the sequence of customer requirements (starter, main
course, dessert, drink) is common to all customers, but layout also helps control customer
flow.