plant layout

Plant Layout Plant Layout

Production and Operations Production and Operations ManagementManagement

Plant layoutPlant layoutMeaning-Meaning-Plant layout is the physical Plant layout is the physical

arrangement of industrial facilities. It arrangement of industrial facilities. It involves the allocation of space & the involves the allocation of space & the arrangement of equipment in such a arrangement of equipment in such a manner that overall operating costs manner that overall operating costs are minimized.are minimized. D D

D D

G G

G G

G G

M M

M M

M M

A A

A A

L

L L

L L

L L

L

Objectives of plant layoutObjectives of plant layout An efficient layout can be An efficient layout can be

instrumental in the accomplishment instrumental in the accomplishment of the following objectives-of the following objectives-

1.1. Economies in materials, facilitate Economies in materials, facilitate manufacturing process & handling manufacturing process & handling of semi-finished & finished goods.of semi-finished & finished goods.

2.2. Proper & efficient utilization of Proper & efficient utilization of available floor space.available floor space.

3.3. To avoid congestion & bottlenecks.To avoid congestion & bottlenecks.4.4. Provision of better supervision & Provision of better supervision &

control of operations.control of operations.

Objectives of plant layout cont.Objectives of plant layout cont.5. Careful planning to avoid frequent changes in 5. Careful planning to avoid frequent changes in

layout which may result in undue increase in layout which may result in undue increase in cost of production.cost of production.

6. To provide adequate safety to the workers 6. To provide adequate safety to the workers from accidents.from accidents.

7. To meet the quality & capacity requirements in 7. To meet the quality & capacity requirements in the most economical manner.the most economical manner.

8. Provision of medical facilities & cafeteria at 8. Provision of medical facilities & cafeteria at suitable & convenient places.suitable & convenient places.

9. To provide efficient material handling system.9. To provide efficient material handling system.10. To suggest the improvements in production 10. To suggest the improvements in production

process & work methods.process & work methods.

Principles of plant layoutPrinciples of plant layout1.1. Principle of integration (of 5M’s)Principle of integration (of 5M’s)2.2. Principle of minimum distancePrinciple of minimum distance3.3. Principle of cubic space Principle of cubic space

utilization( both horizontal & vertical utilization( both horizontal & vertical space).space).

4.4. Principle of flow( must be forward no Principle of flow( must be forward no backtracking)backtracking)

5.5. Principle of maximum flexibilityPrinciple of maximum flexibility6.6. Principle of safety, security & Principle of safety, security &

satisfactionsatisfaction7.7. Principle of minimum handling.Principle of minimum handling.

Types of plant layoutTypes of plant layout1.1. Product layout Product layout 2.2. Process layoutProcess layout3.3. Fixed Position/ Stationary layoutFixed Position/ Stationary layoutProduct layoutProduct layout--

Layout that uses standardized Layout that uses standardized processing operations to achieve processing operations to achieve smooth, rapid, high-volume flowsmooth, rapid, high-volume flow

Here machines are arranged acc. To Here machines are arranged acc. To the needs of product & in the same the needs of product & in the same sequence as the operations are sequence as the operations are necessary for manufacture. necessary for manufacture.

Raw materialsor customer

Finished item

Station 2

Station 3

Station 4

Material and/or labor

Station 1




Used for Repetitive or Continuous Processing

Product LayoutProduct Layout

1.1. High rate of outputHigh rate of output2.2. Low unit costLow unit cost3.3. Labor specializationLabor specialization4.4. Low material handling costLow material handling cost5.5. High utilization of labor and High utilization of labor and

equipmentequipment6.6. Established routing and Established routing and

schedulingscheduling7.7. Short processing timeShort processing time

Advantages of Product LayoutAdvantages of Product Layout

1.1. Creates dull, repetitive jobsCreates dull, repetitive jobs2.2. Poorly skilled workers may not maintain Poorly skilled workers may not maintain

equipment or quality of outputequipment or quality of output3.3. Fairly inflexible to changes in volumeFairly inflexible to changes in volume4.4. Highly susceptible to shutdownsHighly susceptible to shutdowns5.5. Needs preventive maintenanceNeeds preventive maintenance6.6. Require large capital investmentRequire large capital investment

Disadvantages of Product Disadvantages of Product LayoutLayout

1 2 3 4

5

6

78910

In

Out

Workers

A U-Shaped Production LineA U-Shaped Production Line

Process layoutProcess layout--

Layout that can handle varied processing Layout that can handle varied processing requirementsrequirements

Here all machines performing similar type of Here all machines performing similar type of operations are grouped together at one operations are grouped together at one location in the process layout. Thus here location in the process layout. Thus here facilities are grouped together acc. To their facilities are grouped together acc. To their functions. E.g. all drilling machines are functions. E.g. all drilling machines are located at one place known as drilling located at one place known as drilling section.section.

Process Layout - work travels to dedicated process centers

Milling

Assembly& Test Grinding

Drilling Plating

Process LayoutProcess Layout

Dept. A

Dept. B Dept. D

Dept. C

Dept. F

Dept. E

Used for Intermittent processingJob Shop or Batch

Process Layout(functional)

Process LayoutProcess Layout

Work Station 1

Work Station 2

Work Station 3

Product Layout(sequential)

Used for Repetitive ProcessingRepetitive or Continuous

Product LayoutProduct Layout

1.1. Can handle a variety of processing Can handle a variety of processing requirementsrequirements

2.2. Machines breakdown doesn’t result in Machines breakdown doesn’t result in shutdown.shutdown.

3.3. Equipment used is less costlyEquipment used is less costly4.4. Wide flexibility in production facilities.Wide flexibility in production facilities.5.5. Each production unit of system works Each production unit of system works

independently.independently.6.6. High utilization of facilitiesHigh utilization of facilities7.7. Variety makes the job interesting.Variety makes the job interesting.

Advantages of Process LayoutsAdvantages of Process Layouts

1.1. In-process inventory costs can be In-process inventory costs can be highhigh

2.2. Challenging routing and schedulingChallenging routing and scheduling3.3. Equipment utilization rates are lowEquipment utilization rates are low4.4. Material handling is slow and Material handling is slow and

inefficient & is more.inefficient & is more.5.5. More space is requiredMore space is required6.6. Longer processing timeLonger processing time7.7. Back tracking may occur.Back tracking may occur.

Disadvantages of Process Disadvantages of Process LayoutsLayouts

Comparison of product & process Comparison of product & process layoutlayoutfactorsfactors Product Product

layoutlayoutProcess Process layoutlayout

1. nature1. nature Sequence of Sequence of facilities facilities

Similar Similar aregp2getheraregp2gether

2. 2. Machines Machines utilizationutilization

Not to full capacityNot to full capacity Better utilizationBetter utilization

3. product3. product standardizedstandardized diversifieddiversified4. Processing 4. Processing timetime

lessless moremore5. Material 5. Material handlinghandling

lessless moremore6. inventory6. inventory High WIPHigh WIP Low WIPLow WIP7. breakdown7. breakdown Can’t tolerateCan’t tolerate Can tolerateCan tolerate8. Production 8. Production centrecentre

simplesimple complexcomplex9.flexibilty9.flexibilty lowlow highhigh10. floor space10. floor space Requires lessRequires less moremore11. investment11. investment highhigh lowlow

Fixed position layout- Fixed position layout- Layout in which the Layout in which the product or project remains stationary, and product or project remains stationary, and workers, materials, and equipment are workers, materials, and equipment are moved as needed. E.g. moved as needed. E.g.

Employed in large project type organisationEmployed in large project type organisationconstruction of DAMS.construction of DAMS. ISROISROHelicopterHelicopterNuclear engg. Division of BHELNuclear engg. Division of BHEL

The product, because of its size and/or The product, because of its size and/or weight, remains in one location and weight, remains in one location and processes are brought to it.processes are brought to it.

Factors affecting plant layoutFactors affecting plant layout1.1. Nature of product-Nature of product- e.g. some products need e.g. some products need

air-conditioned plants.air-conditioned plants.2.2. Size of output-Size of output- For bulk-product/line layout For bulk-product/line layout For small-functional layout For small-functional layout 3.3. Nature of manufacturing system-Nature of manufacturing system- For intermittent-functional layout For intermittent-functional layout For continuous-product/line layout For continuous-product/line layout 4.4. Localization of plant-Localization of plant- e.g. there will be e.g. there will be

different transportation arrangement if site is different transportation arrangement if site is located near railway line.located near railway line.

5.5. Machines or equipment-Machines or equipment- e.g. heavy e.g. heavy machines need stationary layoutmachines need stationary layout

6.6. Climatic conditions, need of light, temperature Climatic conditions, need of light, temperature also affect design of layout.also affect design of layout.

COMPANY PROFILECOMPANY PROFILE RYDON GROUP,CoimbatoreRYDON GROUP,Coimbatore FOUNDED FOUNDED

IN THE YEAR 1991 HAS ESTABLISHED IN THE YEAR 1991 HAS ESTABLISHED BUSINESS IN THE FIELD OF MANUFACTURING BUSINESS IN THE FIELD OF MANUFACTURING AND AS WELL AS AUTOMOBILE DEALERSHIP. AND AS WELL AS AUTOMOBILE DEALERSHIP. THE COMPANY HAS COMPLETE IN-HOUSE THE COMPANY HAS COMPLETE IN-HOUSE FACILITY TO PRODUCE SPROCKETS FOR TWO FACILITY TO PRODUCE SPROCKETS FOR TWO WHEELER, FOUR WHEELER AND INDUSTRIAL WHEELER, FOUR WHEELER AND INDUSTRIAL APPLICATIONS.APPLICATIONS.

Types of sprocketsTypes of sprockets

SPROCKETS

OE RP FD

OE: Original Equipment (line-2)OE: Original Equipment (line-2)RP: Retail Product (line-3)RP: Retail Product (line-3)FD: Final Drive (line-1)FD: Final Drive (line-1)

FINAL DRIVE SPROCKET-line-1FINAL DRIVE SPROCKET-line-1

ORIGINAL EQUIPMENT AND RETAIL ORIGINAL EQUIPMENT AND RETAIL PRODUCT SPROCKET:PRODUCT SPROCKET:

THE OE AND RP SPROCKETS ARE SIMILAR EXCEPT FOR THE HEAT THE OE AND RP SPROCKETS ARE SIMILAR EXCEPT FOR THE HEAT TREATMENT IS DONE ONLY FOR THE OE SPROCKETS. TREATMENT IS DONE ONLY FOR THE OE SPROCKETS.

PROCESS FLOW FOR FD SPROCKETS in PROCESS FLOW FOR FD SPROCKETS in line-1 as shown in the model.line-1 as shown in the model.

Raw material

Turning

Drilling

Heat treatment

Tooth cutting

Despatch

PROCESS FLOW FOR OE SPROCKETS in PROCESS FLOW FOR OE SPROCKETS in line-2 as shown in the model.line-2 as shown in the model.

Raw material

Turning

Boring

Heat treatment

Tooth grinding

Despatch

PROCESS FLOW FOR RP SPROCKETS in PROCESS FLOW FOR RP SPROCKETS in line-3 as shown in the model.line-3 as shown in the model.

Raw material

Turning

Milling

Gear Hobbing

Despatch

Flow chart of methodology for Flow chart of methodology for future layout design changefuture layout design change

Process Study

Data Collection

Modeling

Simulation

Evaluation

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plant layout