PLANT LAYOUT

A layout is a physical configuration of departments, work stations and equipments in the conversion process. It is the spatial arrangement of physical resources used to create a product.

OBJECTIVES OF PLANT LAYOUT STUDY

1. 2. 3.

4.

5.

6.

Minimize investment in equipment Minimize over all production time. Utilize existing space most effectively Provide for employee convenience, Safety and comfort Maintain flexibility of arrangement and operation. Minimize material handling cost

OBJECTIVES OF PLANT LAYOUT STUDY

7. Minimize variation in types of material handling equipment. 8. Facilitate the manufacturing process.

PLANT LAYOUT STUDY

It is interrelated .
Product design

Layout design Schedule Design Process Design

SOME MOST COMMONLY INVOLVED FACTORS / CONSIDERATIONS

1. 2. 3. 4. 5. 6.

Ease of future expansion Flexibility of layout Material handling effectiveness Space utilization Safety & Housekeeping Working Conditions

SOME MOST COMMONLY INVOLVED FACTORS / CONSIDERATIONS

7. 8. 9.

10. 11.

12.

Ease of Supervision & Control Appearance, Promotional value Fit with Company Organization Structure Equipment utilization Ability to meet capacity or Requirements Investment or capital required.

REEDS SYSTEMATIC PLAN OF ATTACK PLANT LAYOUT PROCEDURE Steps to be taken

Analyse the production or processes to be produced Determine the process required to manufacture the product Prepare layout planning charts Determine work stations Analyse storage area requirements

REEDS SYSTEMATIC PLAN OF ATTACK PLANT LAYOUT PROCEDURE Steps to be taken

Establish minimum aisle widths Establish office requirements Consider personnel facilities and services Survey plant services Provide for future expansion

THE MOST POPULAR APPROACH DEVELOPED BY MUTHER - SLP

The procedure applied to: 1. Production 2. Transportation 3. Storage 4. Support services 5. Office activities etc

INPUT DATA AND ACTIVITIES

1. Flow of Material 2. Activity Relationships

3.Relationship Diagram
4. Space Requirements 6. Space Relationship Diagram 7. Modifying Considerations 9. Develop Layout Alternatives 8. Practical Limitations 5. Space Available

Analysis Search Selection

10. Evaluation

TYPES OF FLOW PATTERNS

Classifications of flow patterns

Horizontal or vertical

a)

b)

c)

d)

TYPES OF FLOW PATTERNS

Classifications of flow patterns

Horizontal or vertical

e)

f)

TYPES OF FLOW PATTERNS

Vertical flow pattern a)

b)

c)

TYPES OF FLOW PATTERNS

Vertical flow pattern d)

e)

f)

TYPES OF LAYOUT

Four General layout categories are:1. 2. 3. 4.

Fixed or Static product Layout Product layout Process Layout Product Layout

Fixed position layout

It is not feasible to move the product Product stays in one location; tools,men,material etc. are brought to it.

FIXED PRODUCT LAYOUT

Drill

Mill

Lathe

Grind

Stores

WORK PIECE

Warehouse

Saw

Assembly

Weld

Paint

PRODUCT LAYOUT

Saw

Lathe

Mill

Drill Warehouse Assembly

Saw

Mill

Drill

Paint

Stores

Grind

Mill

Drill

Paint

Weld

Grind

Lathe

Drill

Product layout or line production

Appropriate for producing one standard product in large quantities Each unit of output require the same sequence of operations from beginning to end Work centers and equipments are arranged in a line

Process layout or layout by function

Work centres and departments are grouped together according to their function or type Useful where volume of manufacture is low and variety is high Provides tremendous flexibility- no solid sequencing

GROUP LAYOUT

Lathe Saw Stores Saw Grind

Mill Group A

Drill

Warehouse

Paint

Assembly

Lathe

Group B Paint

Mill

Drill

ADVANTAGES & LIMITATIONS OF LAYOUTS

Fixed Product Layout Advantages Limitations
1. 2.

3.

4.

5.

Material movement is 1. reduced Promotes Job enlargement 2. by allowing individuals or teams to perform the whole 3. job Continuity of Operations 4. and responsibility results from team 5. Highly flexible; can accommodate changes in product design, product mix6. and production volume Independence of production centers allows scheduling to achieve min. total prodn

Increased movement of personal and equipment. Equipment duplication may occur Higher skill requirements for personnel General supervision required Cumbersome and costly positioning of material and machinery Low equipment utilization

ADVANTAGES & LIMITATIONS OF LAYOUTS

Product Layout Advantages Limitations
Since the layout 1. corresponds to the sequence of operations, smooth and logical flow line result. Since the work from one 2. process is fed directly into the next, small in process inventories result. Total production time per unit is short. 3. Since the m/cs are located so as to minimize distances b/w consecutive operations, 4. materials handling is reduced. 5. A breakdown of one machine may lead to a complete stoppage of the line that follows that machine. Since the layout is determined by the product, a change in product design may require major alterations in the layout. The pace of production is determined by the slowest machine. Supervision is general, rather than specialized. Comparatively high

1.

2.

3.

4.

ADVANTAGES & LIMITATIONS OF LAYOUTS

Group Layout Advantages Limitations
Increased machine 1. utilization. Team attitude and job 2. enlargement tend to occur. Compromise between product layout and process 3. layout, with associated advantages Supports the use of general purpose equipment. 4. Shorter travel distances and smoother flow lines than for process layout.
5.

1.

2.

3.

4.

5.

General supervision required. Higher skill levels required of employees than for product layout. Compromize between product layout and process layout with associated limitations. Depends on balanced material flow through the cell; otherwise buffers and work-in-process storage are required. Lower machine utilization than for process layout.

ADVANTAGES & LIMITATIONS OF LAYOUTS

Process Layout Advantages Limitations
Better utilization of 1. machines can result; consequently fewer machines are required. 2. A high degree of flexibility exists relative to equipment or manpower allocations for 3. specific tasks. Comparatively low 4. investment in machines is required. The diversity of tasks offers 5. a more interesting and satisfying occupations for 6. the operator. Specialized supervision is Since longer flow line usually results, materials handling is more expensive. Production planing and control system are more involved. Total production time is usually longer Comparatively large amount of in-process inventory result. Space and capital are tied up by work in process. Because of the diversity of jobs in specialized departments, higher grades

1.

2.

3.

4.

5.

Raw Matl for Cu-T Moulding Cu-T Moulding

Quarantine

Component Store

Receiving Bay Copper Tee Production (Assembly) Operations 1. Cu-Wire Rewinding / Cleaning 2. Winding 3. Tying 4. Pouching 5. Assembling 6. Sealing 7. QA

Finished Product Store

Space for Future Expansion

Space for Future Expansion

Final Packing Area For Cu-T QA