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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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