plant layouts
DESCRIPTION
Plant Layouts. Prepared by Bhakti Joshi June 27, 2014. Class Activity. Steel Iraq Indian Railways US Economy India’s Trade NHAI Bonds Excise Duty Natural Gas Stock markets Defense Industry Water Transport Agricultural Prices Banking. Coal Mutual Funds Airlines Employment - PowerPoint PPT PresentationTRANSCRIPT
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Plant Layouts
Prepared by Bhakti JoshiJune 27, 2014
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Class Activity
• Steel• Iraq• Indian Railways• US Economy• India’s Trade• NHAI Bonds• Excise Duty• Natural Gas• Stock markets• Defense Industry• Water Transport• Agricultural Prices• Banking
• Coal• Mutual Funds• Airlines• Employment• Consumer appliances• Anti-dumping duties• Cement• Telecommunication• Maharashtra Government• Non-Government Organizations• Mobile Phones• Premium Goods
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Class Activity Review• 9 Teams• Constraints: 1 copy of 5 Newspapers; (Time is given)• 3 Teams hoarded on 1 Newspaper – Not Optimal• Couple of Teams had 1 resource writing maximum articles – Not optimal (No teamwork)• Many teams took photographs of articles, shared and collaborated newspapers with each
other – • Some teams had members not writing but allocating resources• Proof-reading/editing as a critical process was missing in all teams (though many teams
cross-checked for repetition of content)
Team 1
Team 2
Team 3
Team 4
Team 5
Team 6 Team 7
Team 8
Team 9
Max 4 5 4 3 5 7 6 5
Min 2 3 3 2 1 1 3 2
Total 12 16 15 11 16 14 17 1 16
Newspapers #
3 3 3 3 4 1 1 1 4
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Examples
• Chemist shop• Tailor Shop• Kiraana • Restaurant• College• Grocery store in a mall• Movie Theatres
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Organisation’s context…
There are plant layouts
“…floor plan for determining arranging the desired machinery and equipment of a plant to permit the quickest flow of material at the lowest cost and with the least amount of handling in processing the product from the receipt of the raw materials to the shipment of the finished products.”
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Why Layouts?
• Efficiency in use of workers and space• Minimisation of material handling costs• Elimination of unnecessary movements of
workers and materials• Minimisation of production and customer time• Elimination in delays• Safety and improved working conditions• Attainment of product/service quality
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Types of Plant Layouts
PROCESS PRODUCT FIXED POSITION CELLULAR
COMBINATION
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Process Layout: Example 1
Embroidery
StitchingSewing
Output
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Process Layout: Example 2 (Metal)
Source: Google Images, Transtutors.com
*
* Lathe is a machine in which work is rotated about a horizontal axis and shaped by a fixed tool# Milling machine creates corrugated edges like in a coin
#
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Process Layout
• Also known as functional layout
• Evolved from handicraft production
• Grouping the same kinds of machines in one department
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Process Layout – Key Principles
• Minimum distance between departments
• Departments in a sequence of operations
• Convenience for inspection and supervision
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Process Layout: Advantages and Disadvantages
Advantages
Flexibility
Cost
System Protection
Economies of Scale
Incentives for Workers
Disadvantages
Utilisation
Excess material handling
Difficulties in operations control
Is this layout meant for bulk orders or small orders?
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Product Layout: Example
Making a boat …?
How was it made…?
What were it’s input…?
Could be taught…?
Could it be replicated …?
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Product Layout
• Also known as straight- line layout
• Sequence of workstations interconnected in one line
• Work done in small amounts
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Product Layout – Key Principles
• Specific volume to be manufactured/serviced
• Stable product demand
• Product Standardisation
• Continuous material supply
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Product Layout: Advantages and Disadvantages
Advantages
Simplicity
Small Space
Optimum cost of materials
Time efficiency
Limited skill sets
Disadvantages
Dull and repetitive
Product variety is limited
Fault in one can affect all
Is this layout cost-effective? High capital
investments
Inelastic capacities
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Fixed Position Layout: Example
• Paper boat versus the real one?
• Operations in hospitals?
• Manufacturing a plane
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Fixed Position Layout: Example (Contd…)
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Fixed Position Layout
• Job done at a fixed position• The main equipment/s, heavy materials, sub-
assemblies, etc., remain fixed• Completion done by movement of machines,
workers and tools
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Fixed Position Layout: Advantages and Disadvantages
Advantages
Easy for immobile products
Flexibility
Possibly cost-effective
Feasible for large projects
Disadvantages
High capital investments
Large storage spaces
Careful planning
Can such layouts be discouraged completely?
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Cellular Layout: Example 1
Source: http://www.teiminc.com/product_flow.htm
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Cellular Layout: Example 2
Source: http://www.thefullwiki.org/Cellular_manufacturing
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Cellular Layout
• Also known as functional layout• Suitable for large variety of products in small
volumes• Based on Group Technology (GT) principle– Parts with similar product design characteristics– Parts with similar process characteristics
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Cellular Layout: Advantages and Disadvantages
Advantages
Flexibility
Small batches of production
Higher machine utilisation
Workers’ empowerment
Disadvantages
Requirement of skills
Possibility of imbalances
Disadvantages of process and
product layouts
What kind of businesses will require cellular layouts?
Low cost of production
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Combination Layout
• Hybrid Layout
• Mixture of three main layouts
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Projects• Identify your own business’ product/service • Determine the possible inputs • Determine the possible layout for this business intuitively• Find a real-life business providing your product/service• Determine their inputs, layouts, processes involved (in real-life) to provide
their product• Compare your imaginary and real business of the same product/service• Document it into a report• Present in your findings as a presentation• Report and presentation should be submitted in a CD with your team
members names and roll numbers.• NO hard copies will be accepted • Hard copy of the presentation’s agenda/TOC MUST be given
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