PLANT LOCATION Module 2

Introduction
Plant layout planning includes decisions regarding the physical allocation of the economic activity centers in a facility.

Facility Layout Definition

A facility layout is an arrangement of everything needed for production of goods or delivery of services. A facility is an entity that facilitates the performance of any job. It may be a machine tool, a work centre, a manufacturing cell, a machine shop, a department, a warehouse, etc. (Heragu, 1997).

Objectives of Plant Layout The main objective consists of organizing equipment and
working areas in the most efficient way, and at the same time satisfactory and safe for the personnel doing the work.

Sense of Unity Minimum Movement of people, material and resources. Safety Flexibility

Objectives of Plant Layout

These main objectives are reached through the attainment of the following facts:

Congestion reduction. Better adjustment to changing conditions. Better utilization of the workforce, equipment and services. Reduction of material handling activities and stock in process. Reduction on health risks and increase on workers safety. Reduction on delays and manufacturing time, as well as increase in production capacity.

Factors affecting Plant Layout

The factors affecting plant layout can be grouped into 8 categories:
Materials Machinery Labor Material Handling Waiting Time Auxiliary Services The building Future Changes

Factors affecting Plant Layout

Materials
Main factors to be considered: size, shape, volume, weight, and the physical-chemical characteristics, since they influence the manufacturing methods and storage and material handling processes.

Machinery
Regarding machinery, we have to consider the type, total available for each type, as well as type and quantity of tools and equipment. Its essential as well to know about space required, shape, height, weight, quantity and type of workers required, risks for the personnel, requirements of auxiliary services, etc.

Factors affecting Plant Layout Labor

Environment considerations: employees safety, light conditions, ventilation, temperature, noise, etc. Process considerations: personnel qualifications, flexibility, number of workers required at a given time as well as the type of work to be performed by them.

Material Handling
Material handling does not add value to the product; its just waste!

Objective: Minimize material handling as well as combining with other operations when possible, eliminating unnecessary and costly movements.

 The factors affecting plant layout can be grouped into 8 categories:

Waiting time - Stock
Objective: Continuous Material Flow through the facility, avoiding the cost of waiting time. Resting time to cool down or heating up.

Factors affecting Plant Layout

Auxiliary Services
Support the main production activities at the plant:
Related to labor: Accessibility paths, fire protection installations, supervision, safety, etc. Related to material: quality control. Related to machinery: maintenance and electrical and water lines.

The auxiliary services represent around 30% of the space at a facility.

Factors affecting Plant Layout The factors affecting plant layout can be grouped into 8
categories:
The building
If it has been already selected, its characteristics will be a constraint at the moment of designing the layout, which is different if the building has to be built.

Future changes
One of the main objectives of plant layout is flexibility. Its important to forecast the future changes to avoid having an inefficient plant layout in a short term.

Plant Location
Possible Factory Location
Criterion PROXIMITY TO: Skilled labour A pool of unskilled labour A motorway An airport The sea / a river Housing Amenities Potential for expansion Availability of grants/incentives Safety Planning constraints Environmental impact Weighting 7 8 7 4 0 5 5 7 8 2 5 4 TOTAL 2 5 3 1 2 4 3 2 1 3 2 3 A 14 40 21 4 0 20 15 14 8 6 10 12 164 3 2 2 3 5 3 2 1 2 2 3 2 B 21 16 14 12 0 15 10 7 16 4 15 8 138 0 0 1 4 5 0 0 5 5 5 5 4 C 0 0 7 16 0 0 0 35 40 10 25 16 149 1 4 3 2 2 3 2 3 1 2 4 1 D 7 32 21 8 0 15 10 21 8 4 20 4 150 4 2 4 2 1 4 3 2 3 2 2 2 E 28 16 28 8 0 20 15 14 24 4 10 8 175

Process Layouts
General purpose & flexible resources Lower capital intensity & automation Higher labor intensity Resources have greater flexibility Processing rates are slower Material handling costs are higher Scheduling resources & work flow is more complex Space requirements are higher

Process layout
Receiving Mills Raw matl. Grinders

storage

Assembly

Large number of low volume products

Drills
Planers Finished Inspec- goods tion storage

Lathes

Automatics

Part A Part B
Facility Layout

Product Layouts
Specialized equipment High capital intensity & wide use of automation Processing rates are faster Material handling costs are lower Less space required for inventories Less volume or design flexibility

Product layout
Receiving Raw matl. storage Fabrication line-part B Fabrication Planer line-part A Lathe Drill Mill Mill Drill Grinder Mill Assembly line Automatic

Finished goods storage

Small number of high volume products

Facility Layout

 Advantages:
Reduced material handling activities. Work In Process almost eliminated. Minimum manufacturing time. Simplification of the production planning and control systems. Tasks simplification.

Disadvantages:
No flexibility in the production process. Low flexibility in the manufacturing times. High capital investment. Every workstation is critical to the process.- The lack of personnel or shut down of a machine stops the whole process. Monotonous work.

Cellular Plant Layout

Group Technology Each cell manufactures products belonging to a single family. Cells are autonomous manufacturing units which can produce finished parts. Commonly applied to machined parts. Often single operators supervising machines in a cell, with robots for materials handling. Productivity and quality maximised. Throughput times and work in progress kept to a minimum. Flexible. Suited to products in batches and where design changes often occur. M D M G
ASSEMBLY CELL 2

L
D

M
G

ASSEMBLY
CELL 1

L
L

L
G

ASSEMBLY CELL 3

Other Plant Layouts

Fixed Position Layout (right) Single large, high cost components or products. Product is static. Labour, tools and equipment come to the work rather than vice versa. PRODUCT COMPONENTS MATERIAL LABOUR

LABOUR COMPONENTS

MATERIAL

CIA 1
The groups shall name themselves based on any production management concept (No two groups shall have the same name) Each member of the group shall give a write up of about 200 words on the concept (Members shall not repeat or copy any of their team mates content) Date of Submission: 10/12/2012 In case two or more groups have the same names, by mistake or coincidence the group that submits first shall be final and the others have to repeat !!

CIA COMPONENT 2
The groups shall identify an industry and product (No two groups shall work on the same product or industry) The groups to report on the following Plant location (Factors affecting location-To be justified) Plant layout (Factors affecting layout-To be justified, with suggested layout diagram)

The report must clearly indicate the individuals contribution.

Date of Submission: 10/12/2012 In case two or more groups have worked on the same product or industry, by mistake or coincidence the group that submits first shall be final and the others have to repeat !!

Niranjan.lr@christuniversity.in