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Operations Management Facility Layout

CHAPTER05- FACILITY LAYOUT

INTRODUCTION

When a new plant is erected, the question of the placement of machinery at

different places, the location of stores, inspection cabins, tool rooms, maintenance

wings, plating shops, heat treatment chambers, toilets, canteens, trolleys, cranes &other handling equipments & the like receive a priority consideration

This is so because the efficiency of the production flow depends largely on how

well the various machines, production facilities & employee amenities are locatedin a plant

In a properly laid out plant, the movement of materials from the raw material

stage to the end product stage is smooth & rapid The movement is generally in the forward direction i.e. the materials do not

crisscross or go backward & forward for further operations

Also in a properly laid out plant, the production bottlenecks & delays are few &

material handling costs are reduced

Such arrangements constitute the subject matter of plant layout For a good layout, use of expertise is necessary because there is no pattern of

layout for all plants It differs from plant to plant, from location to location, from industry to industry

Layout would be different for processing industry, job industry, small sized

factory, giant plant, a plant located on a flat terrain or on an uneven terrain Changes in product design, production methods and size of the plant necessitates

changes in the existing layout

MEANING, DEFINITION & SCOPE

A plant layout refers to the arrangement of machinery, equipment & other

industrial facilities (such as receiving & shipping departments, tool rooms,maintenance rooms & employee amenities) for the purpose of achieving thequickest & smoothest production at the least cost

A plant layout is the floor plan for determining & arranging the desired machinery

& equipment of a plant, whether established or contemplated, in the one bestplace to permit the quickest flow of material at the lowest cost & with the least

amount of handling in processing the product from the receipt of the raw

materials to the shipment of the finished products

OBJECTIVESOFAGOODLAYOUT

Provide enough production capacity

Reduce material handling costs Reduce congestion that impedes the movement of people or material

Reduce hazards to personnel

Utilize labour efficiently Increase employee morale

Reduce accidents

Utilize available space efficiently & effectively Provide for volume & product flexibility

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Provide ease of supervision

Facilitate co-ordination & face-to-face communication where appropriate

Provide for employee safety & health Allow ease of maintenance

Allow high machine/equipment utilization

Improve productivityFACTORSINFLUENCINGFACILITYLAYOUT

Materials Product

Worker

Machinery

Type of industry Location

Managerial policies

PRINCIPLESOFLAYOUT

The principle of minimum travel

Principle of sequence Principle of usage

Principle of compactness

Principle of safety & satisfaction

Principle of flexibility Principle of minimum investment

TYPESOFLAYOUT

1. Process layout/ functional layout/ job shop layout/ batch production

layout

2. Product layout/ line processing layout/ flow-line layout3. Fixed position layout/ static layout

4. Cellular manufacturing (CM) layout/ group technology layout

5. Combination layout/ hybrid layout

1. PROCESSLAYOUT/ FUNCTIONALLAYOUT/ JOBSHOPLAYOUT/ BATCH

PRODUCTIONLAYOUT

It involves grouping together of like machines in one department E.g.: drill machines- drilling department, casting machines- casting departments

The process arrangement is signified by the grouping together of like machines

based upon their operational characteristics In this, a quantity of raw material is issued to a machine which performs first

operation

This machine may be situated anywhere in the factory For next operation, a different machine may be required, which may be situated in

another part of the factory

In this the materials would move along long distances & along crisscross paths

Sometimes materials may even travel separate building & then brought back

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If machines in any department are engaged then semi finished goods awaiting

operations may be taken to the store & later reissued for production

General purpose machines are used so that many jobs can be performed bythem, work is allotted such that no machine is idle

This type of layout is best suited for intermittent type of production

2. PRODUCTLAYOUT/ LINEPROCESSINGLAYOUT/ FLOW-LINELAYOUT

It involves the arrangement of machines in one line, depending upon the sequenceof operations

In this materials are fed into the first machine & finished products come out of the

last machine In between, partly finished goods travel automatically, from machine to machine,

where the output of one machine becomes input of next machine

E.g.: sugar, paper mill, chemical, rubber, refineries, cement industry etc The machines used are special purpose machines for product layout

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3. FIXEDPOSITIONLAYOUT/ STATICLAYOUT

It involves movement of men & machines to the product which remains stationary

In this, material or major component remains in a fixed location & tools,

machinery, men & material are brought to this location

The movement of men & material to the product is advisable because the cost ofmoving them would be less than the cost of moving the product which is very

bulky E.g.: locomotives, ships, boilers, air craft, generators, construction of building,

hospitals, etc

4. CELLULARMANUFACTURING (CM) LAYOUT/ GROUPTECHNOLOGYLAYOUT

In this, machines are grouped into cells & the cells function somewhat like a

product layout within a larger shop or process layout Each cell in the CM layout is formed to produce a single parts family- a few parts

with common characteristics, which usually means that they require the same

machines & have similar machine settings

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5. COMBINATIONLAYOUT/ HYBRIDLAYOUT

The application of the principles of product layout or process layout or fixedlocation layout in their strict meanings is difficult to come across

Hence a combination of different layouts with stress on a particular type of layout

is noticed in most industrial establishments Plants are never laid out in either pure form

In the final analysis, the combination that produces the desired volume of

products at the least total cost is preferred

E.g.: in soap manufacturing plants, the machine manufacturing soap is arrangedon the product-line principle, but ancillary services such as heating,

manufacturing glycerin, power house, water treatment plant etc are arranged on a

functional basis

SUMMARY

Marketing is concerned with maximizing income, industrial engineering is

concerned with minimizing cost, and management is gambling that there is asufficient difference in its favour

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SERVICEFACILITYLAYOUT

The fundamental difference between service facility & manufacturing facilitylayouts is that, many service facilities exist to bring together customers & services

Based on different degree of customer contact there are two types of service

facility layout

- Those that are almost totally designed around the customer receiving & servicingfunction (banks)

- Those that are designed around the technologies, processing of physical materials

& production efficiency (hospital)

SPECIALARRANGEMENTSFORPARTICULARTYPEOFPLANTS

Some plants require special arrangements which when incorporated make the layout lookdistinct from the types discussed before

Manufacturing of detergent powder- in a vertically set up boiler(80ft.) the

material are the stored & poured at different stages on different floors and

finished product comes out at the ground floor

Newspaper plant- time element is so important that that the finishing ofproduction is calculated in seconds. Reliability, certainty, working arrangements,

co-ordination (of departments, machinery, equipment, materials) is taken utmostcare

Five-star hotel- lodging, bar, restaurant, kitchen, stores, pool, laundry, saloons,

shopping arcades, conference hall, parking areas should have appropriate place inthe layout. Cleanliness, elegant appearance, convenience & looks attract

customers

Cinemas- emphasize on comfort & convenience of cinegoers. The projector,screen, sound-box & fire fighting equipment should be properly located

IMPORTANCEOFFACILITYLAYOUT

Economies in handling Effective use of available area

Minimization of production delays

Improved quality control Minimum equipment investment

Avoidance of bottlenecks

Better production control Better supervision

Improved utilization of labour

Improved employee morale

Avoidance of unnecessary & costly changes

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