facility capacity & layout planning
TRANSCRIPT
Prepared By,Mr. Nishant Agrawal
Facility Capacity &
Layout Planning
Session outline Need for Capacity Planning
Type of Capacity
Roles of forecasting in Capacity Planning
Facility Layout Planning
Product Layout
Process Layout
Fixed position layout
Cellular layout
Capacity and Capacity Planning
Capacity of facility is defined as Maximum load that can be
handled by it during given period.
The load can expressed in terms of amount of inputs or output.
Ex. Capacity of Sugar mill can expressed in terms of the tones of
sugar cane (inputs) crushed per day or in terms of tones of sugar
(output) produced per day
Need for Facility Capacity Planning
Low capacity of facility may result in costs of under capacity,
especially during periods of high demand of the product. Loss of
potential profit.
Over Capacity of plant means less number of units of product
are produced due to lower demand as compared to capacity
available.
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1. To keep initial investment in the facility as low as possible to
achieve break even volume
2. Investments in facility capacity are long term and can not be
reversed easily.
3. To satisfy the future demand of products without any shortage.
4. Optimal Capacity(Minimum) = Under Capacity + Over Capacity
Types of Capacity
Capacity
Design Capacity
Effective Capacity
Actual Capacity
Design Capacity
This is capacity design for the facility. It depends upon the number
and capacity of machines and equipments.
Effective Capacity
If facility used to make different products, a set up time will be
required between batches of different products to be produced.
Always lower than design capacity.
Actual Capacity
Maximum rate of output rate which is actually achieved under the
constraints of machine breakdown.
Actual capacity can be equal to or less than effective capacity.
Way of increasing effective capacity
Proper process quality control so that there are lesser defective
items requiring rework.
Good Training, High Motivation, Less Absenteeism
Good coordination with suppliers for timely and defective
suppliers and proper scheduling of products on machines.
Properly following the environmental and pollution norms,
which result in inspected by government agencies and less
disruption of production activities.
Proper Facility Location, layout and internal working condition.
Roles of Forecasting in Capacity Planning
Four types of General trends are possible.
1. Growth
2. Decline
3. Cyclical
4. Stable
Facility Layout Planning
Layout
Product
ProcessFixed
Cellular
Product Layout / An assembly lineIt is suitable when product having standard features is to be
produced in large volumes.
The production process involves repetitive tasks to be performed
on items arrange in sequence
The specialized machines and equipment are arranged once after
other. This production line is often called assembly line.
The assembly line has mechanized moving platform , which moves
at regular interval of time.
The basic structure of the products to be manufactured in the raw
form are placed on conveyor at equal distance from each other.
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Across conveyor, there are workstation which have required
machines, equipments, components , tools to perform assembling of
tasks on the basic product.
The total performance time of tasks assigned to each workstation
should be almost equal.
This is necessary because conveyor moves after definite period of
time.
Advantages Disadvantages
Easier material handling and less
inventory costs.
Less supervision and labour
training costs
High output rate and low cost of
item per unit
High Efficiency of labour and
equipment
No need of scheduling once the
line is operational
Maintenance cost is fairly high
to ensure smooth running of
line
Inflexible to design changes in
products or processes
(expensive)
Breakdown of a machine lead
to halt in production
Repetitive tasks lead to
frustration for workers
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U shaped assembly line
It is useful particularly when there is a single worker in the line
taking care of all workstation.
It reduce the walking distance of worker almost by half.
The closeness of workstations allows workers to helps a fellow
worker catch up. Increase team work among workers.
Reduce material handling as entry and exit point of material on
line are nearby.
At the same time , many workstation close to each other may
result in conversation, noise etc. resulting distraction from work.
U shaped assembly line
Assembly line balancing
The assembly line can be efficient only when tasks are assigned to
different workstations in such a way that as far as possible, total
processing times at these workstation are equal.
This is so because conveyor moves at regular intervals of time and
therefore time available for each workstation to complete list of set of
assigned tasks is the same. This is achieve by assembly line balancing
Process Layout
In this machines are arranged in no particular sequence as processing
requirements and sequence are different for various type of products
to be manufactured.
It is suitable when different produces are produced in lots or
batches. This is called intermittent manufacturing.
The demand of items is not high enough to warrant continuous
manufacturing.
Process Layout is very commonly found in service set ups such as
banks, hospitals, post offices, universities etc.
Process Layout
Continue…Advantages Disadvantages
Maintenance cost is low because of low
cost general purpose machines.
The system is more flexible to design
changes in products as compare to
product layout.
Breakdown of machine does not lead to
halt in production as substitute machines
are kept ready for such situations
The system promote creativity of
workers due to the variety of tasks
performed by them.
Material handling is time consuming as
there is no fixed route.
Work in process inventory is usually
high in batch processing
A low output rate and thus high cost
per unit.
Routing and scheduling is tedious and
time consuming for different products
High cost of supervision because of
special treatment to every product
being processed.
Fixed Position Layout
The product is very bulky , heavy , large or has fixed
position. Ex. Construction of building, dam or plant
Equipment , raw materials, and workers team are brought
to side according to a time schedule for better utilization of
the space available.
Cellular layout and Group Technology
Product layout is desirable by most organization , but low volume.
Intermittent layout called cellular layout. Cellular manufacturing, a model for
workplace design, is an integral part of just-in-time manufacturing and lean manufacturing,
In this groups of items with similar processing requirements are identified and separate manufacturing cells forms for each group.
AssignmentsQue.1 ) Explain Product layout and Process layout in detail
ORDiscuss types of Plant Layout with suitable examples.
ORDefine the various types of plant layout in brief with suitable
examples of each.OR
What is Plant layout? List the various types of Plant layout. Carry out a comparative analysis product and process layout with an example.
ORHow many types of Basic Layouts are there for a facility? Briefly
explain each of them.
Thank You…!!!!
“Everything does happen
for Good”