Facilities Layout/Plant Layout

Plant layout includes the arrangement and location of work centres and various service centres like inspection , storage and shipping within the factory .

Layout identically involves the allocation of space and arrangement of equipment in such a manner that overall operating costs are minimized.

Objectives of Plant Layout

Economy in MH : Economy in handling materials , WIP & finished stock. Optimum utilisation of resources optimum utilisation of men , materials, equipment and space available. Better inventory control the material should move rapidly through the plant. Good work flow minimising chances of delay & eliminating bottle necks

Objectives of Plant Layout

Efficient control Avoidance of changes avoiding frequent changes so that production programme is not upset Safety Ensuring safety Better services Providing adequate services Higher morale Boosting up morale by providing comforts at work. Flexibility Ensuring flexibility of layout for future changes.
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Objectives in Plant Layout

Minimize investment in equipment Minimize overall production time Utilize existing space most effectively Provide for employee convenience, safety and comfort 5. Maintain flexibility of arrangement 6. Minimize material handling cost 7. Minimize variation of types of MH equipment 8. Facilitate the manufacturing process 9. Facilitate the organizational structure
1. 2. 3. 4.
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Types of Layout
Process Layout Product Layout Cellular Layout Fixed position layout

PROCESS LAYOUT

PROCESS LAYOUT

Process layout of a automotive service station

PROCESS LAYOUT

Functional layouts, group similar activities together in departments or work centers according to the process or function they perform. For example, all drills would be together in a work center, and all mills would be together in another center. Universities often use a process or functional layout. The English department is in one building or area; the chemistry department is in another building, etc. People who work in process layouts tend to be very skilled because they use general purpose equipment or tools. The equipment is not designed to produce a particular product, rather, the operator must intervene in the process to make the product 10 specified by each customer.

Advantages of Process layout

Flexibility
Changes in operations as well as in orders can be made any time without disturbing the existing layout.

Scope for expansion

Machines can be expanded by adding new machines.

Maximum utilisation of equipment

Since general purpose machines are used there is maximum utilisation.
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Advantages of Process layout

Lower financial investment Better working conditions

Lower investment because the machines are general purpose. Layout makes it easy to isolate machines that produce fumes, excessive noise , vibrations . This boosts employee morale. Greater job satisfaction for operator.

High output rate

Less vulnerable to breakdown Machine breakdown holds up production only in that particular machine.
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Advantages of Process layout

Enhances overall skill of workers

Workers are trained in operations such as setting up work, performing special operations etc.

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Disadvantages of Process layout

Insufficient MH
Fixed path material handling such as conveyor belts cannot be put to use.

Since longer flow line usually result, material handling is more expensive. Requires more floor space High inventory investment compared to line layout High cost of supervision Large in process inventory Total production time is usually longer. Accumulation of WIP The material moves slowly from one department to another. Because of the diversity of jobs in specialized departments higher grades of skill are required.

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PRODUCT LAYOUT

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Types of Layout
1.

Product /Line Layout

Machines & equipment are arranged in sequence. The material moves from one machine to another machine sequentially without any backtracking or deviation i.e the output of one machine becomes input of the next machine. The investment on straight line layout is higher than in the functional layout. It requires a very little material handling. This is best suited for continuous mass production where raw materials are fed at one end and the finished products are taken out at the other end. The product layout is followed in plants manufacturing standardized products on a mass scale such as 16 chemical, paper, sugar, rubber, refineries & cement

STARTS PRODU CTION

LATHE

DRILLP RESS# 2

PACKAGINGM ACHINE DRILLP RESS# 1

PAINTINGMA CINE

FINISHPRODU CTION

PRODUCT LAYOUT IN MANUFACTURING PRODUCT

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Cement Production

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Cement production
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Quarry Crusher Conveyor Mixing bed Raw mill Filter Preheater Kiln Cooler Clinker silo Cement mill logistics
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Assembly Lines
Are special case of product layout. The range of products partially or completely assembled includes
Toys Aplliances Autos Planes Clothing Electronic components

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Assembly Line Balancing

Assembly line balancing is the process of distributing the workload in an assembly line across successive workstations so that no time or resources are wasted. A balanced assembly line does not suffer from bottlenecks or unnecessary idle time
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Workstation cycle time(C)

Maximum time spent at any one workstation.

Largest workstation time. How often a product is completed.

Is the amount of time available at each work station to complete all assigned work.

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= =

N = Number of work stations

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Steps in Assembly line balancing

Specify the sequence of tasks using precedence diagram Determine Cycle time C Determine theoretical number of workstations N Select primary rule by which tasks are to be assigned Assign tasks one at a time Evaluate Efficiency =
(

If efficiency in unsatisfactory rebalance.

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Features of Product Layout

Smooth and logical flow lines Small in process inventories Total production time/unit short Reduced material handling Little operator skill, training simple Simple production planning and control Less space for work in transit and temporary

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Advantages of Product Layout

Smooth flow of production : Bottlenecks & stoppage of work is eliminated due to proper arrangement of machines in sequence. Mechanisation of material handling : Since machines are in sequence flow of materials in a line through mechanical devices like conveyors.

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Advantages of Product Layout

Economy in Manufacturing Time : There is no transportation of raw materials backwards & forward, so it shortens the manufacturing time. Saving in Material Handling Cost : Materials move from one machine to another automatically and so no transportation cost.

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Advantages of Product Layout

Easy inspection : Because the production process is integrated & continuous, defective practice can be easily be detected & segregated. So inspection is easy. Maximum utilisation of available Space Effective utilisation of available resources : Effective utilisation of men , machines & materials.

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Disadvantages of Product layout

Product layout is known for its inflexibility. This type of layout is also expensive. There is difficulty of supervision. Expansion is also difficult. Any breakdown of equipment along the production line can be disrupt the whole system.

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FIXED LAYOUT

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Fixed or Static Layout

Materials remain at a fixed place and the complete job is done at a fixed station. Eg Ship building industry Locomotive Turbines etc

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Advantages of Fixed alyout

Flexible

Fully flexible & capable of absorbing any sort of change in product or process. People move to their own departments as soon as the job is done. Sequence of operations can be changed if some materials do not arrive No need to fix machines & equipment. More suitable for assemling large, heavy products.
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Lower labour cost Saving in time

Lesser floor space

Disadvantages of Fixed layout

Higher capital investment

Investment is heavy in men, material & labour

Unstability
Not suitable for small products

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CELLULAR LAYOUT

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Cellular or group layout

In this components that are similar in design or manufacturing operations are grouped into one family called part-family. It is a combination of both process and product layout. Suitable when large variety of products are needed in small volumes (or batches) Machines must be closely grouped

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Advantages of cellular
Lower WIP Reduction in MH cost Shorter flow times in production Simplified scheduling of materials and labour Quicker set ups, fewer tooling changes Improved functional and visual control

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Disadvantages of cellular
Reduced manufacturing flexibility As products & process change, there is a risk of cells becoming out-of-date. Increased operator responsibility.

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Factors affecting Layout

Nature of the product Nature of the product to be manufactured will affect the layout. Heavy products may need stationary layout Small & light products line layout Volume of production If standardised commodities are to be manufactured on large scale, line type layout Production to order then functional layout 42

Factors affecting Layout

Management policies
Size of the plant Scope for future expansion Quality of the product

Nature of plant location

The size, shape & topography of the site Eg : site near railway, - arrangement to receiving and shipping material

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Factors affecting Layout

Type of industry Process

Continuous industry Intermittent industry

Types of methods of production

Job shop machines and equipments can be arranged in a manner to suit the need of all types of customer. Mass production line layout is most suitable
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Factors affecting Layout

Nature of Machines
Heavy machines are generally fixed on the ground Stationary layout Ample space should be provided to avoid accidents.

Nature of Materials
Physical , chemical properties of materials are to be considered.

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Factors affecting Layout

Type of Machine & equipment : General purpose or special purpose machines & equipment. Machine & equipment should be used to the fullest. Human Factor & working conditions Specific safety aspects such as obstruction free floor, emergency exit points should be provided. Sufficient space should be provided for free movement of workers.

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Factors affecting Layout

Service Centres Every layout must have provision for the men and equipment to lubricate, repair or even replace the parts of the machine.

Characteristics of the building

Shape of the building , covered and open areas, number of stores, facilities of elevators, storing place, parking area etc also influence the layout plan.

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Principles of Good Layout

Integration Minimum movement of material handling Smooth & continuous flow of material Cubic space utilisation Safe & improved environment Flexibility

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Advantages of Good layout

Advantages to workers
Less MH Less motions between operations Improved labour productivity More safety Better working conditions

Manufacturing costs

Reduced maintenance & replacement cost Improved quality due to reduced waste Better cost control

Production control

More space for production operations Better storage facilities Scope for better supervision Better utilization of resources

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COMPUTERISED LAYOUT TECHNIQUES

CRAFT Computerized Relative Allocation of Facilities Techniques SLP Systematic Layout Planning

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