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PLANT LAYOUT &

MATERIAL HANDLING

Submitted by

K.N.Jakanathan

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Definition Layout is a Fundamental of every organization and enterprise.

Plant layout involves the development of physicalrelationships among building equipment and productionoperations which will enable the manufacturing process to becarried on efficiently

- Morris

Plant Layout - placement of departments,

placement of workgroups within departments,

placement of workstations,

placement of machines,

placement of stock-holding points

Allwithin a facility

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Objectives Proper and efficient utilization of cubic (i.e. length, width and height)

of available floor space. To ensure that work proceeds from one point to another without any

delay.

Provide enough production capacity.

Reduce material handling costs.

Reduce hazards to personnel.

Utilize labor efficiently.

Increase employee morale.

Eliminate conjugation and bottle neck at work.

Provide for volume and product flexibility.

Provide ease of supervision and control.

Provide for employee safety and health. [ Reduce accidents ] Allow ease of maintenance.

Allow high machine or equipment utilization.

Improve productivity.

Reduce Capital Investment.

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Factors Influencing Layout

Nature of product. Production process. [Including Waiting Time]

Type of machinery.

Repairs and maintenance.

Human needs.

Plant environment.

Materials.

Material Handling Equipments.

Auxiliary Services.

Future Changes.

Factory building.

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Product Flow

P&Q Analysis - Input data and Activities

Activity relationships

Chart relationship (flow, functional)

Establish space requirements Space Availability

Space relationships - Diagram

Practical Limitations Material Handling

Project Project ProjectA B C

Evaluate alternative arrangements

Detail selected la

yout

INSTALLATION

Definition

Analysis

Synthesis

Evaluation

Selection

Implementation

Adjustment

Systematic Layout Design

Process Method

- Muther (1973)

Maintenance

Q&CMat. Handling

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Types of Layout

Manufacturing units

Product or line layout

Process or functional layout

Fixed position or location layout

Combined layout

Fixed LayoutCellular (or) Group Technology Layout

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Product oriented Plant Layout

(Line Layout) Machinery and Materials are placed following the

product path.

This type of plant layout is useful when the production

process is organized in a continuous or repetitive way. Continuous flow: The correct operations flow is

reached through the layout design and the

equipment and machinery specifications.

Repetitive flow (assembly line): The correctoperations flow will be based in a line balancing

exercise, in order to avoid problems generated by

bottle necks.

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The plant layout will be based in allocating a

machine as close as possible to the next one

in line, in the correct sequence to

manufacture the product. Allocating line may be of any form, like

straight line L shape

U shaped S shaped

Cont.,

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Factory Product layout

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Product layout Product oriented plant layout

Advantages:

Economy material handling activities.

Mechanization of material handling equipments.

Work In Process almost eliminated.

Minimum manufacturing time.

Simplification of the production planning and control systems.

Tasks simplification. Greater incentive for group.

Disadvantages:

No flexibility in the production process

Low flexibility in the manufacturing times.

High capital investment.

Difficulty of supervising, since the person is expert in only one function.

Every workstation is critical to the process.- The lack of personnel or shut

down of a machine stops the whole process.

Monotonous work.

Difficulty in expansion.

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Process oriented plant layout

(Functional Layout) This type of plant layout is useful when the production process is

organized in batches.

Personnel and equipment to perform the same function are

allocated in the same area. The different items have to move from one area to another one,

according to the sequence of operations previously established.

The variety of products to produce will lead to a diversity of flows

through the facility.

The variations in the production volumes from one period to the nextone (short periods of time) may lead to modifications in the

manufactured quantities as well as the types of products to be

produced.

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Factory Process layout

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Process Layout

Process oriented plant layout

Advantages:

Flexibility in the production process.

Better control of manufacturing cost.

No Duplication.

Easy to handle the problems.

Better Supervising. [Experts will be there in each department]

Higher Individual incentive.

Disadvantages:

Manufacturing time increases.

Controlling will be costly and complex.

Material handling cost will be higher.

More workspace required.

Accumulation of work-in process.

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Fixed Layout

InFixed productlayout,the products generally circulate

within the production facilities (machines, workers, etc.);

in this particular type of layout, the product does not

move, the different resources are moved to perform the

operations on the product.

This type of layout is commonly found in industries thatmanufacture large size products, such as ships or

aircrafts.

The equipment is brought to the object being processed,

and the object does not move. Example:Air craftmanufacturing.

Arranging materials and equipment concentrically

around the production point in their order of use.

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Factory Fixed Layout

Raw

Material

Machine &

Equipment

Labour

Finishedproduct

AIRCRAFT

AIR CRAFT ASSEMBLY

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Fixed Layout

Advantages of stationery Layout:

Layout is fully flexible and is capable of absorbing any sort ofchange in product and process.

Lower labor cost [People are drawn from functional departments]

Saving in time

Less floor space because machines and equipment are inmoving position.

Most suitable way of assembling large and heavy products.

Disadvantages Of Stationery Layout:

Higher capital investment Unsuitability for manufacturing or assembling small products in

large quantities. It is suitable only in case where the product isbig or the assembling process is complex.

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Combined Layout or Mixed Layout

Manufacturing concerns where several products

are produced in repeated numbers with no

likelihood of continuous production , combined

layout is followed. Generally, a combination of the product and

process layout or other combination are found,

in practice, e.g. for industries involving the

fabrication of parts and assembly, fabricationtends to employ the process layout, while the

assembly areas often employ the product layout.

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Factory Combined Layout

1

1

1

2

2

2 4

4

4C

o

mb

i

n

e

d

Milling Grinding

3

Painting Packing

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P-Q Analysis

Product

Layouts

Fixed

Position

Layouts Mixed Layouts Process Layouts

Q

u

a

nt

i

t

y

Number of different products

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CELLULAR OR GROUP

TECHNOLOGY LAYOUT Work cells

Definition:

Group of equipment and workers that perform a sequence of

operations over multiple units of an item or family of items.

Looks for the advantages of product and process

layouts:

Product oriented layout: Efficiency

Process oriented layout: Flexibility

Group Technology

Grouping outputs with the same characteristics to families, and

assigning groups of machines and workers for the production of

each family.

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CELLULAR OR GROUP

TECHNOLOGY LAYOUT In a cellularlayout the design is not according to

the functional characteristics of equipment, but

rather by self-contained groups of equipment

(called cells), needed for producing a particularset of goods or services.

Group technology, or cellular manufacturing,

classifies parts into families so that efficientmass-production-type layouts can be designed

for the families of goods or services.

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Cellular Layout

Process (Functional) Layout Group (Cellular) Layout

Similar resources placed

togetherResources to produce similar

products placed together

T T T

M

M M T

M

SG CG CG

SG

D D D

D

T T T CG CG

T T T SG SG

M M D D D

M M D D D

A cluster

or cell

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CL or GT: BENEFITS

Advantages Lower work-in-process Inventories

Reduced material handling costs.

Shorter flow times in production.

Simplified production planning. (MEN, MATERIAL ETC.) Overall performance increased by lowering production

costs & improving on time delivery.

Improved Quality.

Disadvantages Reduced manufacturing flexibility & potentially increased

machine downtime.

Duplicate pieces of machinery may be needed so as toavoid movement of parts between cells.

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Break Even Analysis

costs

VolumeUse fixedposition Useprocess Use cellor GT Use product

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EXAMPLE OF SYSTEMATIC LAYOUT PLANNING:

REASONS FOR CLOSENESS

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Code

1

2

3

4

5

6

Reason

Type of customer

Ease of supervision

Common personnel

Contact necessary

Share same price

Psychology

Justification Code

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EXAMPLE OF SYSTEMATIC LAYOUT

PLANNING: IMPORTANCE OF CLOSENESS

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Value

AE

I

O

U

X

ClosenessLine

code

Numerical

weights

Absolutely necessaryEspecially important

Important

Ordinary closeness OK

Unimportant

Undesirable

168

4

2

0

80

Priority code

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EXAMPLE OF SYSTEMATIC LAYOUT PLANNING:

RELATING REASONS AND IMPORTANCE

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From

1. Credit department

2. Saree department

3. Wine department

4. Camera department

5. jewelry department

6

A

--

U

4

I

6

A

--

U

1

I

1,6

A

--

U

1

X

1

X

To2 3 4 5

Area

(sq. ft.)

100

400

300

100

100

Closeness rating

Reason for rating

Note here

that the (1)

Credit Dept.

and (2) SareeDept. are

given a high

rating .Letter

Number

Note here that

the (2) SareeDept. and the (5)

Jwellry Dept. are

given a high

rating of A.

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EXAMPLE OF SYSTEMATIC LAYOUT PLANNING:INITIAL RELATIONSHIP DIAGRAM

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1

2

4

3

5

U U

E

A

I

The number of lines

here represent paths

required to be takenin transactions

between the

departments. The

more lines, the morethe interaction

between

departments.

Note here again, Depts. (1) and(4) are linked together, and

Depts. (2) and (5) are linked

together by multiple lines or

required transactions.

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EXAMPLE OF SYSTEMATIC LAYOUT PLANNING:INITIAL AND FINAL LAYOUTS

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1

2 4

3

5

Initial Layout

Ignoring space and

building constraints

2

5 1 4

3

50 ft

20 ft

Final Layout

Adjusted by square

footage and building

size

Note in the

Final Layout

that Depts.

(1) and (5)are both not

placed

directly next

to Dept. (2).

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Re-layout

A good plant layout involves not only the

designing and installing of the layout for the

first time but also revision of existing layout.

The best layout becomes obsolete over a

period of time.

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Reasons for Re-Layout

Product Design Change. New Product Production.

Changes in volume of demand.

Facilities become obsolete.

Rearranging the department within the factory. Consideration of safety.

Change in location of market.

Poor worker environment.

Cost reduction.

Technology Advancement.

Improvement in layout technology.

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Plant locations influence Plant layout

Location may affect make/buy decisions.

Location near the source.

Location near the transport facilities.

Easy Power supply.

Cheap labour.

Climate.

Waste disposal facility.

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Material handling systems

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Asthe science is getting developed new

modern equipments are getting introduced

in material handling area.

It is accelerating the activity of loading andunloading. These equipments are used for

the movement of material over a short

distance. The bulk handling of the material takes

place in shipyards, ports, airports etc.

Role of material handling in logistics

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Unloading the incoming material from transport

vehicle.

Moving the unloaded material to assigned

storage places in warehouses.

Lifting the material from the storage place

during order picking.

Moving the material for inspection & packing.

Loading the boxes on transport vehicle.

Material handling Operation steps

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Designing the system for continuous flowof material.

No idle time.

Going in for the standard equipments itreduces the cost.

If possible use gravitational force.

continuous material movement is mosteconomical

Material Handling Efficiency

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Volume of operations. Speed of handling.

Productivity.

Nature of product. Size, shape, weight of the product.

Nature of equipment.

Selecting Material handling Equipment

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Commonly used equipments in industry

Lift

Fixed Path

Conveyors

Wheeled trolley

Variable Path Forklift truck.

Overhead cranes

Auxiliary Rigging, Clamps

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Wheeled trolley two wheeled and four

wheeled trolleys are used for transferring boxesfrom one place to another place within the

organization. Trolleys have wide range of sizes

and shapes. Organizations decide as per their

requirement. Overhead cranes - these are used for

movement of heavy items but for a shorter

distances. The movement is controlled by a

person having controls in his hand. Many times itis a computerized activity. These cranes are

installed on the fixed girders near the ceiling.

Variable path

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Wheeled TrolleyOverhead Crane inside the factory

Overhead cranes outside the factory

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Forklift truckthis is highly usefulin materialhandling activity. It got invented after II world war.The main advantages are,

Movement of larger loads over a longer distance.

Moving the load vertically also.

Movement of loads vertically and horizontally,exactly positioning for loading and unloadingoperations.

It can transfer the load in any direction.

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Fixed Path

Conveyors these are used where

continuous flow of material is essential. It is

used in mass production activity on

production shop floor also. conveyors arewidely used in automated warehouses in big

retail shops.

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Wheel conveyors the small wheels made

out of steel or plastic bearing. The load iskept on the bearings and either pushed or

gravitational force is utilized for the forward

movement of the material.

Roller conveyor these are mainly used indocks for faster unloading of the goods.

They are like wheel conveyors but powered

rollers are used.

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Belt conveyor these are commonly

used for material movement. It is used in

mass production activity.

Chain conveyor this is mainly used for

movement of heavy material. It is used in

mass production activity also. Pallets arekept on the chain and stoppers are

provided for carrying out the production

related work.

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Wheel Conveyor Belt Conveyor

Chain Conveyor Roller Conveyor

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LIFT

These are used to lift the heavy materials vertically. It is

useful to lift to upper floor.

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Clamps

These are used for mainly clamping and

picking the material in large volumes. It can

have more number of trailers.

eg. Clip, metal mesh, Hooks, rings, oblonglinks.

Riggings

These are used for picking and placingthe materials. It is lengthy depends on use.

eg. Chains, ropes, wires.

Auxiliary

Riggings,Clamps,Chains,oblong links

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F i fl i i l

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Factors influencing material

handling equipments

Required path of travel (fixed or variable)

Nature of the material.

Physical characteristics of the building.

Space requirement of handling equipment.

Required handling capacity.

Cost consideration.

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Relation between plant layout and Material Handling

Close relation between plant layout and Material Handling. Material Handling methods influence the layout and factory

building.

Material Handling is to be considered as an integral part of plantlayout to design low cost handling system.

Good Material Handling is resulted based on the arrangement ofproduction equipment, location of departments, logical sequenceof operations, location of stores, tools.

Material Handling system/equipment can be selected only after theappropriate floor plan.

Plant layout considers the points for material receiving and

shipping of products Careful arrangement of work centers and storage areas

Consider horizontal or vertical material transportation

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Thank you