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- 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