Unit 02 a - Plant Layout

Plant Layout

Unit 2-B

Overview

What is Layout Planning?

Plant layout is a plan of an optimum arrangement of facilities including personnel, operating equipment, storage space, material handling equipment and all other supporting services along with the design of best structure to contain all these facilities

THE NEED FOR LAYOUT DECISIONSLayout Establishes An Organisation's

Competitive Priorities In Regard To Capacity Processes Flexibility Cost Quality of work-life Customer Contact Image (in case of service organisations)

Layout Achieves Strategic Advantages Differentiation Low Cost Fast Response or Flexibility

Importance of Layout

Economies in Handling  Nearly 30% to 40% of the manufacturing costs

are accounted for, by materials handling 

Effective Use of Available Area 

Minimization of Production Delays  

Improved Quality Control  

Minimum Equipment Investment  

Avoidance of Bottlenecks

OBJECTIVES OF GOOD PLANT LAYOUT

• Higher utilisation of space, equipment and employees• Improved flow of materials,

information and employees • Higher flexibility (to change

the layout easily) • Provide ease of supervision

• Reduced congestion & bottlenecks • Reduced health hazards &

accidents

• To provide product & volume flexibility

• Improved employee morale and safe working conditions

OBJECTIVES OF GOOD PLANT LAYOUT

• Improved production capacity

• Reduced material handling costs

• To facilitate better coordination & communication

• To allow ease of maintenance

• To improve productivity

OBJECTIVES OF GOOD PLANT LAYOUT

ADVANTAGES OF PLANT LAYOUT

• To Worker A good layout -• minimises manual material

handling

• reduces number of accidents

• provides better working conditions

• To Management Plant layout reduces – labour costs – enhances productivity – helps gain competitiveness

in manufacturing

ADVANTAGES OF PLANT LAYOUT

• To Manufacturing–minimises the movement

between work centres – reduces manufacturing cycle

• To Production Control

ADVANTAGES OF PLANT LAYOUT

SYMPTOMS OF BAD LAYOUT

• Long material and zigzag flow lines and backtracking

• Poor utilisation of space • Congestion of materials

movement • Excessive handling of materials • Large amount of work-in-process• Long production cycles• More frequent accidents• Difficult to supervise and control

SIGNIFICANCE OF LAYOUT CHOICES

• Facilitates Flow of Materials and Information

• Increases Utilisation of Labour and Equipment

• Increases Customer Convenience & Sales (in service organisations such as retail stores, malls etc.)

• Reduces Hazards to Employees • Improves Employee Morale • Improves Communication

FACTORS INFLUENCING PLANT LAYOUT

Materials• Raw Materials, Supplies & Components • The type of storage areas, racks, handling

equipments such as cranes, trolleys, conveyors or pipelines 

• type of materials used - such as solid, liquid, light, heavy, bulky, big, small

Product• light or heavy

• big or small

• liquid or solid

• Workers• Gender of employees (men or women)

• Position of employees while working (i.e. standing or sitting)

• Employee facilities needed such as locker rooms, rest rooms, toilets, canteens, coffee / tea bays etc 

• Machinery and Equipments• Type of Product,

• The Volume of Production,

• Type of Processes

• Management Policy on Technology

FACTORS INFLUENCING PLANT LAYOUT

• Type of Industry Synthetic Analytical Conditioning Extraction

• Location The size and terrain of the site Single Story or Multi Story Mode of transportation from and into the plant

and within the plant Storage provision for of fuel, raw materials

power generation requirements

FACTORS INFLUENCING PLANT LAYOUT

• Managerial Policies Volume of Production Provision for Future Expansion Extent of Automation Make-or-Buy Decisions Speed of Delivery of Goods Purchasing and Inventory Policies Personnel Policies

• Type of Production Engineering Industry Process Industry

FACTORS INFLUENCING PLANT LAYOUT

Production System• Job Shop• Batch Production • Mass Production• Process Production

Availability of Total Area Arrangement of Material

Handling System Type of building- Single Storey or

Multi-Storey Type of Production Facilities

• Dedicated • General Purpose

FACTORS INFLUENCING PLANT LAYOUT

Classification of Production System

Classification of Production

System

Intermittent Production

Job Shop Production

Batch Production

Continuous Production

Mass Production

Process Production

PRINCIPLES OF PLANT LAYOUT

The Principle of Minimum Travel Principle of Sequence Principle of Usage Principle of Compactness Principle of Safety Principle of Flexibility Principle of Minimum Investment Principle of Integration Principle of Cubic Space Utilisation Principle of Flow Principle of Minimum Handling

Best Layout -Model

Best Layout- Model

Best Layout

Types of Layouts

Lathe Machine

Ultra-modern Lathe Machine

Grinding Machine

Ultra-modern Grinding Machine

Ultra-modern Grinding Machine

Ultra-modern Milling Machine

Conventional Drilling Machine

Ultra-modern Drilling Machine

TYPES OF LAYOUT

Process or Functional Layout

Product Layout Fixed-position Layout Cellular Manufacturing

(CM) or Group Technology (GT) Layout

Combination / Hybrid Layout

Process Layout

PROCESS LAYOUT

Process Layout involves a

grouping together similar

machines in one department

Process / Functional Layout

Process Layout

Process Layout

Advantages & Disadvantages of Process LayoutAdvantages

Lower Investment Greater Flexibility Better & More Efficient Supervision Scope for Expansion Better Utilisation of Men & Machines Easy Handling of Breakdown of Equipment

Disadvantages Difficult Materials Movements Restricted Automation in Materials Movements  Requires more Floor Space Difficult Production Control More Production Time Accumulation of Work-In-Progress (WIP)

When to Use Process Layout

Process Layout is used when  General Purpose Machines Variety of Products “Make to order“ Production  Wide Variation in Manufacturing

Time  Small or Intermittent Demand for

Products

Product Layout

PRODUCT LAYOUT

Product Layout involves the

arrangement of machines

according to the sequence of

operations

Product Layout

Product Layout

Product Layout

Advantages Mechanisation of Materials Handling Reduction in Materials Handling Cost Avoids Production Bottlenecks Economy in Manufacturing Time Facilitates Better Production Control Requires Less Floor Area Per Unit of Production Reduced work-in-progress (WIP) Better and Ease of Supervision

 Disadvantages Not Flexible Very High Initial Investment Expansion – Difficult Breakdown – Disrupt Production System

PRODUCT LAYOUT

When to Use Product Layout

Product Layout is used when “Make to stock" or Mass Production

System Limited Variety Standardised Product Low Volume Steady Demand Balanced Operations Continuity of Material Flow

Fixed Position Layout

Fixed Position Layout or Static Layout

• Material or major component remains in a fixed location, and tools, machinery and men as well as other pieces of material are brought to this location

• Usually suitable for bulky and heavy products, such as locomotives, ships, boilers, aircrafts, generators

Fixed-position Layout : Ship Building Layout Map

Fixed-position Layout : Ship Building

Fixed-position Layout

Fixed-position Layout

• Advantages  Men and machines can be used

for a wide variety of operations producing different products

Low Investment

The high cost of, and difficulty in transporting a bulky product are avoided

Fixed Position Layout or Static Layout

Fixed-position Layout is used when  The operation requires only hand tools

or single machine Producing only one or few pieces of

product The cost of moving product is very

high

WHEN TO USE FIXED POSITION LAYOUT

Cellular Manufacturing (CM) Layout / Group Technology (GT) Layout

Cellular Manufacturing (CM) Layout / Group Technology (GT) Layout

Machines are grouped into cells, and the cells function somewhat like a Product Layout within a larger Process Layout.

Each cell in the CM layout is formed to produce a single family of parts - a few parts, all with common characteristics, which usually means that they require the same machines and have similar machine settings

Group Technology – Family of Products

Group Technology - Family of Product

GT Plant Layout

Various Different Layouts

Materials Flow Pattern

Material Flow Patterns

Horizontal Flow System Usually devised for a single story

building when the flat floor area is

available

 Vertical Flow System This system is used in case of multi-

storey buildings and limited area is

available

Basic Flow Patterns – Horizontal

Combination Flow Patterns - Horizontal

Basic Flow Patterns –Vertical

U-Shape Layout

Tools & Techniques of Plant Layout

Process Charts Travel Chart Diagrams - Flow Diagrams &

String Diagrams RELChart - Relationship Chart Templates Scaled Models – 3D Models Computer-aided Layout Tools

• CRAFT (Computerized Relative Allocation of Facilities Technique)

• CORELAP (Computerized Relationship Layout Planning)

• ALDEP ( Automated Layout Design Planning)

• RMA (Richard Muther Associates)

Re-designing of Existing Layout

Need for Redesign of Layout

Inefficient Operations high cost, bottleneck operations

Accidents, Health Hazards & Low Safety Changes in Product / Service Design Introduction of New Products / Services Changes in Volume of Output or

Product-mix Changes Changes in Processes, Methods or

Equipments Changes in Environmental or Legal

Requirements Low Employee Morale

Reasons for Revision

Expansion Increased Output of Existing

Product Introduction of a New Product in

the same line Diversification

Reasons for Revision

Technological Advancements

Replacement of labour by Machines

Developments in Process

Developments in Materials

Improvements in Product Design

Advancement in IT

Reasons for Revision

Improvement In The Layout  The evils of a poor layout are a hidden

cost not revealed even by the best accounting method 

Even if the limitations are revealed, the management may not be willing to initiate remedial steps

Best Layout

Building Layout

End of Unit 1

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