DEPARTMENT OF INDUSTRIAL ENGINEERING AND

MANAGEMENT

IMPROVEMENT OF PLANT LAYOUT FOR

TRADITIONAL INDIAN SNACKS INDUSTRY

Experiential Learning
FACILITIES PLANNING DESIGN AND ERGONOMICS
Submitted by,
DHANYATA N 1RV20IM013
RISHIKA CHOUDHARY 1RV20IM043
MOHANA PRIYA A 1RV20IM027
 1. ABSTRACT

This report presents a comprehensive study on facilities planning, design, and ergonomics with a
focus on improving the plant layout within the Indian snack industry. The objective of this
project is to enhance the efficiency and well-being of employees by strategically rearranging
department layouts to mitigate employee fatigue. Recognizing the socio-economic impact of
employee well-being, this research delves into optimizing the plant layout to reduce travel
distances between departments, ultimately resulting in decreased fatigue and improved overall
productivity.

The Indian snack industry has experienced significant growth, and as demand increases, the need
for streamlined operations becomes paramount. A critical aspect of this enhancement is the
reduction of employee fatigue, which directly contributes to enhanced employee satisfaction,
reduced absenteeism, and improved product quality. To achieve this, the project employs a
robust approach utilizing Facilities Planning and Ergonomics principles. One key methodology
employed is the "From-To Chart," which quantifies the distances between various departments.
By analysing and optimizing these distances, the study aims to devise an efficient plant layout
that minimizes the travel required by employees.

The proposed approach is rooted in understanding the link between physical work environment
and employee well-being, translating to socio-economic benefits for both the workforce and the
organization. The strategic arrangement of departments not only optimizes resource utilization
but also aligns with a broader commitment to fostering a healthier work environment. The
research outcomes have the potential to substantially impact the Indian snack industry by
enhancing productivity, reducing operational costs, and ultimately contributing to a more
sustainable and competitive business landscape. This report thus serves as a valuable resource for
facilities planners, industry stakeholders, and researchers seeking to optimize plant layouts for
improved ergonomics and socio-economic welfare within the Indian snack industry.

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2. INTRODUCTION

2.1 FACILITY PLANNING

Facility planning plays a crucial role in optimizing the operations and efficiency of any
organization. In this report, we focus on enhancing the capabilities of the Department Janitor by
visualizing and improving the current Standard Operating Procedures (SOPs). The Department
Janitor's role is essential for maintaining cleanliness, hygiene, and overall well-being in an
organization. By streamlining and optimizing their workflow, we aim to increase productivity,
reduce operational costs, and create a healthier environment for all occupants. To achieve this,
we will use a physical model to simulate the department's layout and propose necessary
improvements.

2.2 PLANT LAYOUT

Plant layout refers to the arrangement of physical facilities and resources within a manufacturing
or production facility. It involves the strategic placement of machines, equipment, workstations,
storage areas, and other essential elements to optimize the flow of materials, people, and
information throughout the facility. A well-designed plant layout aims to create an efficient, safe,
and productive work environment that supports the production process and maximizes resource
utilization.

The layout of a plant has a significant impact on various aspects of operations, including
workflow, productivity, safety, quality, and cost-effectiveness. It influences how materials are
handled, how workers interact with equipment, and how processes are organized. A thoughtfully
designed plant layout can streamline operations, reduce bottlenecks, minimize material handling,
and enhance communication among different departments and teams.

2.3 OBJECTIVES OF CHANGING PLANT LAYOUT

 Improved Workflow and Efficiency: One of the primary objectives of changing a plant
layout is to optimize the flow of materials, products, and information. By reorganizing
workstations, equipment, and processes, organizations aim to reduce bottlenecks,
minimize unnecessary movement of materials or personnel, and create a smoother and
more efficient workflow.
 Enhanced Productivity: A well-designed plant layout can lead to increased productivity
by reducing production delays, eliminating wasted time, and improving the utilization of
resources. This can result in higher output levels and better utilization of labor and
equipment.

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  Reduced Costs: Changing a plant layout can help in reducing costs associated with
material handling, transportation, and storage. By minimizing the distance travelled by
materials and streamlining processes, organizations can achieve cost savings and better
resource utilization.

 Increased Safety and Ergonomics: Safety and ergonomics are critical considerations in
any plant layout. Changing the layout can lead to improved workplace safety by
minimizing hazards, reducing the risk of accidents, and ensuring that workstations are
designed to be ergonomic and comfortable for employees.

 Flexibility and Adaptability: Organizations may change their plant layout to create a
more flexible and adaptable production environment. This can enable them to quickly
respond to changes in customer demand, introduce new products, or accommodate
changes in technology.

2.4 TECHNIQUES FOR CHANGING PLANT LAYOUT

 Systematic Layout Planning (SLP): SLP is a structured approach that involves
analyzing existing layouts, identifying problems, and systematically rearranging
workstations and processes to achieve a more efficient layout. It considers factors such as
material flow, distances between workstations, and relationships between different
departments.

 Computer-Aided Design (CAD): CAD software allows organizations to create and

visualize different layout scenarios before implementing them. CAD tools provide a
digital platform to experiment with layout changes, helping to assess their impact and
feasibility.

 Cellular Manufacturing: This technique involves grouping machines and workstations

into cells based on product families or processes. Cellular manufacturing promotes
smoother material flow, reduced transportation, and improved communication within
each cell.

 Just-In-Time (JIT) Production: JIT principles aim to minimize inventory and eliminate
waste. By implementing JIT, organizations can design layouts that support a continuous
flow of materials, reduce storage requirements, and ensure products move through the
production process with minimal delays.
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  Cross-Functional Teams: Involve employees from different departments in the layout
improvement process. Cross-functional teams can provide valuable insights from various
perspectives and help identify opportunities for better integration and collaboration.

3. EXISTING LAYOUT AND PROBLEM STATEMENT

3.1 EXISTING LAYOUT

 This is the current layout of the snacks industry, starting from the loading area, raw
materials such as flour and spices will be stored to the right place.
 The spices will be stored in the spice containers and the flour to the flour storm.
 The flour and the spices will then be taken to the mixing area to the dough processing
before entering to the assembly area to produce various types of Indian snacks.
 Then the dough will be taken to cooking area and then after cooking they will be directed
to cooling area.
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  Once the snacks enters the cooling area, they are brought to normal temperature and then
packed to produce finished products.
 Then they will be stored in the storage area before being distributed to the distributor.

3.2 PROBLEM STATEMENT

 The layout that exists in the factory is based on the owner’s experience in the snack’s
production process as it follows the traditional method.
 Layout is not aligned with the flow process leading to delay consuming in material
handling especially at the store where the snacks are being process.
 Due to the unsystematic arrangement of departments and equipment, the employees have
to travel more unnecessarily in the layout leading to employee fatigue.
 The new model is planned to modify the layout of the factory in order to decrease the
distance between departments and reducing employee fatigue.

FROM TOCURRENT
DISTANCE(METERS)
STORE(SPICES) MIXING AREA 31.2
STORE(FLOUR) MIXING AREA 2.1
MIXING AREA ASEEMBLY AREA 3.2
ASEEMBLY AREA COOKING AREA 7.0
COOKING AREA COOLING AREA 5.3
TOTAL TRAVELLING DISTANCE 48.8

Table 1: Current Travelling distance to complete snacks production

3.3 OBJECTIVES OF THE PROJECT

 To propose new layout improvement using systematic layout planning.

3.4 FOCUS OF PROJECT

 Improving facilities design of the production floor from receiving raw material to
storage of finished goods.
 The distance between departments should be less and the layout of production is
process oriented layout.
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4. METHODOLOGY AND PROPOSED LAYOUT

4.1 METHODOLOGY

NO. DATA COLLECTION TOOLS USED DETAILED

APPROACH
1 Determine plant capacity PQRST Use monthly
production data for 1
month
2 Analysis of operations Work and method study tools Identify waste using
flow process chart
3 Materials flow From-to-chart By multiple factory
tours
4 Relationship between Mileage chart with grade Include the needs for
departments criteria communication and
flow between
departments
5 Layout alternatives Comparison between
current and
alternative layout.

4.2 PROPOSED LAYOUT

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4.3 RESULTS
FROM/TO CURRENT LAYOUT PROPOSED LAYOUT
TRANSPORT DISTANCE (m)
From Store(spices) to mixing 31.2 6
area
From Store(flour) to mixing 2.1 6
area
From mixing area to 3.2 2.5
assembly area
From assembly area to 7 2.5
cooking area
From cooking area to cooling 5.3 5.3
area
Total travelling distance 48.8 22.3

4.4 CONCLUSION
In conclusion, our project on facilities planning, design, and ergonomics has successfully
addressed a significant socio-economic factor in the Indian snack industry by prioritizing
employee well-being and reducing fatigue. Through the strategic redesign of the plant layout,
with a focus on minimizing travel distances between departments, we have implemented an
effective solution to alleviate employee fatigue. By utilizing the "from-to" chart to calculate and
optimize distances, we have not only enhanced the operational efficiency of the plant but also
positively impacted the quality of work life for the employees. This endeavor exemplifies the
importance of integrating ergonomic considerations into facility design, leading to a harmonious
synergy between productivity enhancement and socio-economic advancement within the
industry.