Presentation on Plant Layout

8/14/2019 Presentation on Plant Layout

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Definition

Plant layout refers to the arrangement of

machinery, equipment and other industrial

facilities for achieving quickest and smooth production.

It is done to perform various operations in

the most efficient and convenient manner providing output of high quality and

minimum cost.


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Objectives of Good Layout

Improving productivity is the overall objectiveof good layout.Proper and efficient utilisation of available floor

space.Provision of better supervision and control ofoperations.To provide adequate safety to the workers from

accidents.To provide efficient material handling system.Provision of medical facilities and cafeteria atsuitable and convenient places.


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Stages of Plant Layout

Product DemandProduction requirement

Components and parts analysis.Work methods and measurements.Machine requirements.

Handling and movement requirementSpace requiremnt.


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Factors affecting Plant LayoutPlant location and buildingNature of ProductType of Industry

Plant EnvironmentSpatial RequirementsRepairs and MaintenanceBalanceManagement PolicyHuman NeedsTypes of machinery and equipment


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Plant Layout : Types

Line or Product Layout

Functional or ProcessLayoutStationary Layout


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Product Oriented Plant Layout

This type of plant layout is useful when theproduction process is organized in a continuousor repetitive way. Continuous flow : The correct operations flow

is reached through the layout design and theequipment and machinery specifications. Repetitive flow (assembly line): The correct

operations flow will be based in a line

balancing exercise, in order to avoid problemsgenerated by bottle necks. The plant layout will be based in allocating amachine as close as possible to the next one inline, in the correct sequence to manufacture the

product.


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roduct layouts are used to achieve a smooth and rapidflow of large volumes of goods or customers through asystem.

Product Layout

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Advantages Disadvantages

A high rate of outputLow unit cost due to highvolumeLabor specializationLow material-handling cost perunitA high utilization of labor andequipmentThe establishment of routing

and scheduling in the initialdesign of the systemFairly routine accounting,purchasing, and inventorycontrol

Morale problems and torepetitive stress injuries.Lack of maintaining equipmentor quality of output.Inflexible for output or design

Highly susceptible to shutdownsA high utilization of labor andequipmentPreventive maintenance, thecapacity for quick repairs, andspare-parts inventories arenecessary expensesIncentive plans tied to individualoutput are impractical


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Process Layout rocess layouts are designed to process items or provide

services that involve a variety of processing requirements.


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Process oriented plant layout(Functional Layout)

This type of plant layout is useful when the productionprocess is organized in batches.

Personnel and equipment to perform the samefunction are allocated in the same area.

The different items have to move from one area toanother one, according to the sequence of operationspreviously established.

The variety of products to produce will lead to adiversity of flows through the facility.

The variations in the production volumes from oneperiod to the next one (short periods of time) may leadto modifications in the manufactured quantities as wellas the types of products to be produced.


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Handle a variety of processingrequirements

Not vulnerable to equipmentfailures

General-purpose equipment isless costly and is easier andless costly to maintain

Possible to use individualincentive systems

In-process inventory costs canbe highRouting and scheduling posecontinual challengesEquipment utilization rates are

lowMaterial handling is slow andinefficient, and more costly perunitJob complexities reduce the

span of supervision and resulthigher supervisory costsSpecial attention necessary foreach product or customer andlow volumes result in higher

unit costs.


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Stationery Layout

In fixed-position layouts, the item beingworked on remains stationary, and workers,materials, and equipment are moved aboutas needed.

Fixed-position layouts are widely used infarming, firefighting, road building, homebuilding, remodeling and repair, and drillingfor oil. In each case, compelling reasonsbring workers, materials, and equipment tothe products location instead of the other

way around.


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Saves time and cost inmovementFlexible as changes in

job design can be easilyincorporatedMore economical whenseveral orders in differentstages are executed

Adjustments can bemade to meet shortageof materials or absenceof workers.

Production period beingvery long, capitalinvestment is quite heavyVery large space isrequired for storage ofmaterials and equipment

As several operations arecarried simultaneously,

possibility of confusionand conflicts are high


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Essentials of Ideal Layout

Principle of minimum movementPrinciple of flowPrinciple of spacePrinciple of safetyPrinciple of flexibilityPrinciple of interdependencePrinciple of overall integrationPrinciple of minimum investment


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Thank You

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Presentation on Plant Layout