Facility Capacity & Layout Planning

Prepared By,Mr. Nishant Agrawal

Plant LayoutMETAS Adventist College (NEHU)

Session outline Facility Layout PlanningProduct LayoutProcess LayoutFixed position layoutCellular layoutFactors affecting location plantMerit and Demerits

Plant LayoutAplant layout studyis anengineeringstudy used to analyze different physical configurations for amanufacturing plant.In industry sectors, it is important to manufacture the products which have good quality and meet customers demand. This action could be conducted under existing resources such as employees, machines and other facilities. However, plant layout improvement, could be one of the tools to response to increasing industrial productivity.

Continue..Plant layout design has become a fundamental basis of todays industrial plants which can influence parts of work efficiency. It is needed to appropriately plan and position employees, materials, machines, equipment, and other manufacturing supports and facilities to create the most effective plant layout.

Plant Layout Principles

1.Integration of all factors- The plant should integrate all the essential resources of men, machines and materials in order to give an optimum level of production.2.Minimum Movement- The less the movement of men, machines and materials, the less will be the cost of production. Thus, minimum movement of theses resources will provide cost efficiency.3.Unidirectional flow- All materials should progressively move towards the same direction i.e. towards the stage of completion.

Continue.4. Maximum protection- The layout should ensure the protection of the materials and machines while they are in the working or the storage stage.5. Maximum flexibility- The plant layout should not be rigid and permanent. If the need arises, the plant layout should be able to change itself without being expensive.6. Safety and security - The environment of the plant should be safe for the workers as well as the machines. There should be minimum contact of the labour to chemicals and environment.

Facility Layout Planning

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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 sequenceThe 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 DisadvantagesEasier material handling and less inventory costs.Less supervision and labour training costsHigh output rate and low cost of item per unitHigh Efficiency of labour and equipment No need of scheduling once the line is operational Maintenance cost is high to ensure smooth running of lineInflexible to design changes in products or processes (expensive) Breakdown of a machine lead to halt in productionRepetitive tasks lead to frustration for workers

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U shaped assembly lineIt 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

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Process LayoutIn 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 deserve continuous manufacturing. Process Layout is very commonly found in service set ups such as banks, hospitals, post offices, universities etc.

Process Layout

ContinueAdvantagesDisadvantagesMaintenance 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 situationsThe 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 processingA low output rate and thus high cost per unit.Routing and scheduling is tedious and time consuming for different productsHigh cost of supervision because of special treatment to every product being processed.

Fixed Position LayoutThe 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 TechnologyProduct layout is desirable by most organization , but low volume. Cellular manufacturing a model for workplace design, is an integral part ofjust-in-time manufacturingandlean manufacturing,In this groups of items with similar processing requirements are identified and separate manufacturing cells forms for each group.

Factors affecting Plant Layout(1) Policies of management:It is important to keep in mind various managerial policies and plans before deciding plant layout.(2) Plant location:Location of a plant greatly influences the layout of the plant. Shape, climate conditions, and size of the site selected will influence the general arrangement of the layout and the flow of work in and out of the building.(3) Nature of the product:Nature of the commodity or article to be produced greatly affects the type of layout to be adopted. In case of process industries, where the production is carried in a sequence, product layout is suitable.

Continue....(4) Volume of production:Plant layout is generally determined by taking into consideration the quantum of production to be produced.(5) Availability of floor space:Availability of floor space can be other decisive factor in adopting a particular mode of layout. On the other hand more space may lead to the adoption of process layout.(6) Repairs and maintenance of equipment and machines:The plant layout should be designed in such a manner as to take proper care with regard to repairs & maintenance of different types of machines & equipment being used in the industry. The machines should not be installed so closely that it may create the problems of their maintenance and repairs.

QuestionsQue.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.ORWhat 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.

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