In facilities planning, a “process layout” (also called a functional layout) groups similar machines together. Which drawbacks typically arise in such a layout? Choose the most complete statement.

Difficulty: Easy

Correct Answer: All of the above

Explanation:


Introduction / Context:
Process layout (functional layout) is common in job shops where varied products follow different routes. While flexible, it introduces challenges in material movement and control. This question checks understanding of the typical disadvantages.



Given Data / Assumptions:

  • Machines are grouped by function (e.g., all lathes together, all drills together).
  • Product mix is diverse; routings differ across jobs.
  • Objective is to identify drawbacks inherent to this layout type.


Concept / Approach:
Because similar resources are clustered, jobs crisscross the shop floor to complete different process steps. This increases travel distance, back-tracking, queueing variability, and makes coordination harder versus line layouts.



Step-by-Step Solution:

Link “functional grouping” to long, non-linear flow paths.Recognise the consequences: higher handling cost and back-tracking.Acknowledge PPC complexity: routing and scheduling grow harder in a high-variability environment.Production control cost rises due to more expediting and work-in-process monitoring.


Verification / Alternative check:
Classic operations texts compare process vs. product layouts: process layout scores high on flexibility, low on material handling simplicity and control ease.



Why Other Options Are Wrong:
(a), (b), (c) each highlight one drawback; the most complete choice is the combination.



Common Pitfalls:
Confusing process layout with cellular or product layout, which shorten flows and simplify control.



Final Answer:

All of the above

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