Manufacturing systems & Plant Layout

- By Hitesh Parmar

Determinants of Manufacturing systems

Volume

Variety
Flow

Manufacturing

Systems

SINGLE ITEM / ONE OFF PRODUCTION

SINGLE ITEM PRODUCTION

SAMPLE PRODUCTS PROTOTYPES SPECIALIST MODELS HANDMADE ITEMS SPECIALIST ENGINEERING ONE OFFS

 Characteristics
A highly specialised company.

A small highly skilled workforce, possibly

one or two workers, sometimes more. Constant communication with the client, constant discussion regarding the design. Company specialises in particular areas such as engineering or musical instruments etc... Specialist materials are often required e.g.. specialist woods or modelling materials

 The final product is expensive due to

the level of skill needed to manufacture the product and the cost of specialist materials and equipment. A high standard of quality control Products are manufactured for a specialist market / clientele eg. musicians, medical profession, aerospace

Advantages
Each Piece is made to the customers exact

requirement. Job Satisfaction is high for the worker. Quality of the goods is very high The design is flexible and can be changed.

Disadvantages
The products are very expensive. Work is very time consuming The advantages of economies of scale are

Cont
BATCH PRODUCTION

BATCH PRODUCTION

SAMPLE PRODUCTS

FURNITURE ELECTRICAL GOODS CLOTHING NEWSPAPERS BOOKS SAMPLE PRODUCTS

Characteristics
A production line is set up.

Each worker completes one task and

passes work down the production line to the next worker. The workers are semi skilled or unskilled. The workers must be able to switch from one part of the production line to another

Advantages
Workers may specialized some degree

Labor cost is reduced so the final price is

lower Machinery may be used Production is faster Begins to take advantages of economies of scale

Disadvantages
The work is less interesting, repetitive than in

Job/One off production system. More space is required for working and storage. Larger stock of raw material must be kept Machines may have to be re-set between batches which looses time

Continue.
CONTINUOUS PRODUCTION

CONTINUOUS PRODUCTION

SAMPLE PRODUCTS

CARS PETROL / OIL PRODUCTS BRICKS MANY FOOD PRODUCTS WASHING POWDER CHEMICALS ELECTRONIC COMPONENTS PAPER / PULP PRODUCTS

 Production line runs twenty four hour in a day and

365 days in a year .Only at the time of any breakdown maintenance or planned shutdown ,the production line stops . Production line is semi-auto mated which is relying on both computer as well as human resources . Investment in machinery is very high Less flexible workers as product line changes less At every stage of production ,quality control is done Training requirement would be less Normally associated with large quantity and high

Advantages
Final Product is inexpensive

Large quantities can be manufactured

The quality of the product is standardized Machinery can be used so the labor cost is

reduced Unskilled wages further reduce costs Assembly lines can run continuously Production is fast Take full advantage of Economies of scale

Disadvantages
The work is repetitive and boring

There is an increased risk of accidents

Employee Motivation is Low The Products are all identical Large capital investment is required Large buildings are usually needed Large stock of raw material must be kept Machinery breakdown can halt production There is a loss of traditional skills

Identify the Method of Production

Designer Cloths

Identical Houses

Design of Kitchen

Production of bread

Assembly Lines

Plant Layout

Objectives of Good layout

Minimize material handling costs

Utilize space efficiently

Utilize labor efficiently Facilitate communication and interaction

between workers and their supervisors, or between workers and customers Reduce manufacturing cycle time or customer service time Eliminate waste or redundant movement

Cont
Facilitate the entry, exit, and placement of

material, products, or people Incorporate safety and security measures Encourage proper maintenance activities Provide a visual control of operations or activities Provide flexibility to adapt to changing conditions

Cont
Provide for volume and product flexibility Provide ease of supervision Provide for employee safety and health Allow ease of maintenance Improve productivity

Factors influencing layout

Materials Product Machinery Type of industry Managerial Policies

Principles of layout
The Principle of minimum Travel Principle of sequence Principle of usage Principle of safety and satisfaction Principle of flexibility Principle of Minimum investment

Types of Layout
Process layout Product layout Fixed position layout Cellular manufacturing layout

Process Layout
Packing & Shipping

Inward goods store Raw material holding stores

Planers Milling Machines

Automatics Central inspection Area Electroplating shop

Grinders Heat treatment

Drilling Shop

Assembly

Turning shop (Lathes) Paining shop

Finished goods storage

Inward goods store Raw material holding stores

Planers Milling Machines

Automatics Central inspection Area Electroplating shop

Grinders Heat treatment

Packing & Shipping

Drilling Shop

Assembly

Turning shop (Lathes) Paining shop

Finished goods storage

Inward goods store Raw material holding stores

Planers Milling Machines

Automatics Central inspection Area Electroplating shop

Grinders Heat treatment

Packing & Shipping

Drilling Shop

Assembly

Turning shop (Lathes) Paining shop

Finished goods storage

Inward goods store Raw material holding stores

Planers Milling Machines

Automatics Central inspection Area Electroplating shop

Grinders Heat treatment

Packing & Shipping

Drilling Shop

Assembly

Turning shop (Lathes) Paining shop

Finished goods storage

Inward goods store Raw material holding stores

Planers Milling Machines

Automatics Central inspection Area Electroplating shop

Grinders Heat treatment

Packing & Shipping

Drilling Shop

Assembly

Turning shop (Lathes) Paining shop

Finished goods storage

Inward goods store Raw material holding stores

Planers Milling Machines

Automatics Central inspection Area Electroplating shop

Grinders Heat treatment

Packing & Shipping

Drilling Shop

Assembly

Turning shop (Lathes) Paining shop

Finished goods storage

Inward goods store Raw material holding stores

Planers Milling Machines

Automatics Central inspection Area Electroplating shop

Grinders Heat treatment

Packing & Shipping

Drilling Shop

Assembly

Turning shop (Lathes) Paining shop

Finished goods storage

Inward goods store Raw material holding stores

Planers Milling Machines

Automatics Central inspection Area Electroplating shop

Grinders Heat treatment

Packing & Shipping

Drilling Shop

Assembly

Turning shop (Lathes) Paining shop

Finished goods storage

Advantages
Reduced investment on machines as they are

general purpose machines Greater flexibility in the production Greater scope for expansion as the capacities of different lines can be easily increased . Easier to handle breakdown of equipment by transferring work to another machine . Investment on equipment would be comparatively low

Disadvantages
There is a difficulty in the movement of materials.

Mechanical devices for handling materials can not be conveniently used . Layout requires more floor space Difficulty in production control Production time is more as work in process has to travel from place to place

Product Layout

Product A

Product B

Product C

Advantages
There is a mechanization of Material handling

Layout facilitates better production control

Requires less floor area per unit of production Greater Incentive to a group of workers to raise

their performance .

Disadvantages
Inflexible

Expensive
Expansion is difficult Any breakdown of equipment along the

production line can disturb the whole line

Fixed Position layout

Raw material Finished Product M/c & Equipment

Air craft Assembly

Labour

Advantages
Men and Machines can be used for a wide variety

of operations producing different products . Small Investment Worker identifies himself with the product and takes pride in it when the work is complete.

Group Technology
Machine 2 Machine 1 Machine 3

Materials in

Finished goods out Machine 4

Machine 5

Group Technology

L Cell 1

G A

Assembly area A

Cell 2 M
G

Receiving

L
Cell 3

Shipping

Group Technology

L Cell 1

G A

Assembly area A

Cell 2 M
G

Receiving

L
Cell 3

Shipping

Group Technology

L Cell 1

G A

Assembly area A

Cell 2 M
G

Receiving

L
Cell 3

Shipping

Group Technology

L Cell 1

G A

Assembly area A

Cell 2 M
G

Receiving

L
Cell 3

Shipping