Manufacturing Systems & Plant Layout

- By Hitesh Parmar

Manufacturing systems & Plant Layout

Determinants of Manufacturing systems

VolumeVarietyFlow

Manufacturing Systems

SINGLE ITEM / ONE OFF PRODUCTION

SINGLE ITEMPRODUCTION

SAMPLE PRODUCTS PROTOTYPESSPECIALIST MODELSHANDMADE ITEMSSPECIALIST ENGINEERINGONE OFFS

CharacteristicsA highly specialised company. A small highly skilled workforce, possibly

one or two workers, sometimes more. Constant communication with the client,

constant discussion regarding the design.Company specialises in particular areas

such as engineering or musical instruments etc...

Specialist materials are often required e.g.. specialist woods or modelling materials

The final product is expensive due to the level of skill needed to manufacture the product and the cost of specialist materials and equipment.

A high standard of quality controlProducts are manufactured for a specialist market / clientele eg. musicians, medical profession, aerospace

Advantages Each Piece is made to the customers exact

requirement.Job Satisfaction is high for the worker.Quality of the goods is very highThe design is flexible and can be changed.

DisadvantagesThe products are very expensive.Work is very time consumingThe advantages of economies of scale are

lost

Cont…

BATCH PRODUCTION BATCHPRODUCTION

SAMPLE PRODUCTSFURNITUREELECTRICAL GOODSCLOTHINGNEWSPAPERS BOOKSSAMPLE PRODUCTS

CharacteristicsA production line is set up. Each worker completes one task

and passes work down the production line to the next worker.

The workers are semi skilled or unskilled.

The workers must be able to switch from one part of the production line to another

AdvantagesWorkers may specialized some degreeLabor cost is reduced so the final price

is lowerMachinery may be usedProduction is fasterBegins to take advantages of

economies of scale

DisadvantagesThe work is less interesting, repetitive than

in Job/One off production system.More space is required for working and

storage.Larger stock of raw material must be keptMachines may have to be re-set between

batches which looses time

CONTINUOUS PRODUCTION CONTINUOUSPRODUCTION

SAMPLE PRODUCTS

CARSPETROL / OIL PRODUCTSBRICKSMANY FOOD PRODUCTSWASHING POWDERCHEMICALSELECTRONIC COMPONENTSPAPER / PULP PRODUCTS

Continue….

Production line runs twenty four hour in a day and 365 days in a year .Only at the time of any breakdown maintenance or planned shutdown ,the production line stops .

Production line is semi-auto mated which is relying on both computer as well as human resources .

Investment in machinery is very highLess flexible workers as product line changes lessAt every stage of production ,quality control is done Training requirement would be lessNormally associated with large quantity and high

rate of demandThere is a smooth flow of materialSkilled and unskilled workers required .Generally

less flexible workers.

AdvantagesFinal Product is inexpensiveLarge quantities can be manufacturedThe quality of the product is standardizedMachinery can be used so the labor cost is

reducedUnskilled wages further reduce costsAssembly lines can run continuouslyProduction is fastTake full advantage of Economies of scale

DisadvantagesThe work is repetitive and boringThere is an increased risk of accidentsEmployee Motivation is LowThe Products are all identicalLarge capital investment is requiredLarge buildings are usually neededLarge stock of raw material must be keptMachinery breakdown can halt productionThere is a loss of traditional skills

Identify the Method of Production

Designer Cloths Identical Houses

Design of Kitchen Production of bread

Assembly Lines

Plant Layout

Objectives of Good layout Minimize material handling costs Utilize space efficiently Utilize labor efficiently Facilitate communication and interaction

between workers and their supervisors, or between workers and customers

Reduce manufacturing cycle time or customer service time

Eliminate waste or redundant movement

Cont………… Facilitate the entry, exit, and placement

of material, products, or people Incorporate safety and security

measures Encourage proper maintenance activities Provide a visual control of operations or

activities Provide flexibility to adapt to changing

conditions

Cont…Provide for volume and product

flexibilityProvide ease of supervisionProvide for employee safety and

healthAllow ease of maintenanceImprove productivity

Factors influencing layout Materials Product Machinery Type of industry Managerial Policies

Principles of layout

The Principle of minimum TravelPrinciple of sequencePrinciple of usagePrinciple of safety and satisfactionPrinciple of flexibilityPrinciple of Minimum investment

Types of LayoutProcess layoutProduct layoutFixed position layoutCellular manufacturing layout

Process Layout

Inward goods store

Raw material holding stores

Turning shop (Lathes)

Planers

Milling Machines

Drilling Shop

Automatics

Central inspection

AreaElectro-

plating shop

Paining shop

Grinders

Heat treatment

Assembly

Packing &

Shipping

Finished goods

storage

Inward goods store

Raw material holding stores

Turning shop (Lathes)

Planers

Milling Machines

Drilling Shop

Automatics

Central inspection

AreaElectro-

plating shop

Paining shop

Grinders

Heat treatment

Assembly

Packing &

Shipping

Finished goods

storage

Inward goods store

Raw material holding stores

Turning shop (Lathes)

Planers

Milling Machines

Drilling Shop

Automatics

Central inspection

AreaElectro-

plating shop

Paining shop

Grinders

Heat treatment

Assembly

Packing &

Shipping

Finished goods

storage

Inward goods store

Raw material holding stores

Turning shop (Lathes)

Planers

Milling Machines

Drilling Shop

Automatics

Central inspection

AreaElectro-

plating shop

Paining shop

Grinders

Heat treatment

Assembly

Packing &

Shipping

Finished goods

storage

Inward goods store

Raw material holding stores

Turning shop (Lathes)

Planers

Milling Machines

Drilling Shop

Automatics

Central inspection

AreaElectro-

plating shop

Paining shop

Grinders

Heat treatment

Assembly

Packing &

Shipping

Finished goods

storage

Inward goods store

Raw material holding stores

Turning shop (Lathes)

Planers

Milling Machines

Drilling Shop

Automatics

Central inspection

AreaElectro-

plating shop

Paining shop

Grinders

Heat treatment

Assembly

Packing &

Shipping

Finished goods

storage

Inward goods store

Raw material holding stores

Turning shop (Lathes)

Planers

Milling Machines

Drilling Shop

Automatics

Central inspection

AreaElectro-

plating shop

Paining shop

Grinders

Heat treatment

Assembly

Packing &

Shipping

Finished goods

storage

Inward goods store

Raw material holding stores

Turning shop (Lathes)

Planers

Milling Machines

Drilling Shop

Automatics

Central inspection

AreaElectro-

plating shop

Paining shop

Grinders

Heat treatment

Assembly

Packing &

Shipping

Finished goods

storage

AdvantagesReduced investment on machines as they

are general purpose machinesGreater flexibility in the production Greater scope for expansion as the

capacities of different lines can be easily increased .

Easier to handle breakdown of equipment by transferring work to another machine .

Investment on equipment would be comparatively low

DisadvantagesThere is a difficulty in the movement of

materials. Mechanical devices for handling materials can not be conveniently used .

Layout requires more floor spaceDifficulty in production controlProduction time is more as work in process

has to travel from place to place

Product Layout

L D M G

L D L G

L M L G

ProductA

ProductC

ProductB

Advantages There is a mechanization of Material

handling Layout facilitates better production controlRequires less floor area per unit of

productionGreater Incentive to a group of workers to

raise their performance .

DisadvantagesInflexibleExpensiveExpansion is difficultAny breakdown of equipment along the

production line can disturb the whole line

Fixed Position layout

Air craft Assembly

Raw material

M/c & Equipment

Labour

Finished Product

Advantages Men and Machines can be used for a wide

variety of operations producing different products .

Small InvestmentWorker identifies himself with the product

and takes pride in it when the work is complete.

Group Technology

Machine 1

Machine 2

Machine 3

Machine 4Machine

5

Materials in

Finished goods out

Group Technology

Cell 3

L M G G

Cell 1 Cell 2

Assembly area

A A

L M DL

L MShippingD

Receiving

G

Group Technology

Cell 3

L M G G

Cell 1 Cell 2

Assembly area

A A

L M DL

L MShippingD

Receiving

G

Group Technology

Cell 3

L M G G

Cell 1 Cell 2

Assembly area

A A

L M DL

L MShippingD

Receiving

G

Group Technology

Cell 3

L M G G

Cell 1 Cell 2

Assembly area

A A

L M DL

L MShippingD

Receiving

G