unit 2 -topic 2 - plant layout

8/2/2019 Unit 2 -Topic 2 - Plant Layout

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Facilities Layout/Plant Layout Plant layout includes the arrangement and

location of work centres and various servicecentres like inspection , storage and shipping

within the factory .

Layout identically involves the allocation ofspace and arrangement of equipment in sucha manner that overall operating costs areminimized.

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Objectives of Plant Layout

Economy in MH : Economy in handling materials ,WIP & finished stock.

Optimum utilisation of resources optimumutilisation of men , materials, equipment and space

available. Better inventory control the material should

move rapidly through the plant.

Good work flow minimising chances of delay &

eliminating bottle necks

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Objectives of Plant Layout

Efficient control

Avoidance of changes avoiding frequentchanges so that production programme is

not upset Safety Ensuring safety

Better services Providing adequateservices

Higher morale Boosting up morale byproviding comforts at work.

Flexibility Ensuring flexibility of layout for

future changes. 4


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Objectives in Plant Layout

1. Minimize investment in equipment2. Minimize overall production time3. Utilize existing space most effectively4. Provide for employee convenience,

safety and comfort5. Maintain flexibility of arrangement6. Minimize material handling cost

7. Minimize variation of types of MHequipment8. Facilitate the manufacturing process9. Facilitate the organizational structure

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Types of Layout

Process Layout

Product Layout

Cellular Layout

Fixed position layout

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PROCESS LAYOUT

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PROCESS LAYOUT

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Process layout of a automotiveservice station

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PROCESS LAYOUT

Functional layouts, group similar activitiestogether in departments or work centers accordingto the process or function they perform.

For example, all drills would be together in a workcenter, and all mills would be together in another

center. Universities often use a process orfunctional layout.

The English department is in one building or area;the chemistry department is in another building,etc.

People who work in process layouts tend to bevery skilled because they use general purposeequipment or tools.

The equipment is not designed to produce aparticular product, rather, the operator must

intervene in the process to make the productspecified by each customer. 10


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Advantages of Process layout

Flexibility Changes in operations as well as in

orders can be made any time withoutdisturbing the existing layout.

Scope for expansion Machines can be expanded by adding

new machines.

Maximum utilisation of equipment Since general purpose machines are

used there is maximum utilisation.

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Lower financial investment Lower investment because the machines are

general purpose.

Better working conditions Layout makes it easy to isolate machines that

produce fumes, excessive noise , vibrations .This boosts employee morale.

Greater job satisfaction for operator.

High output rate Less vulnerable to breakdown Machine breakdown holds up production only

in that particular machine.

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Enhances overall skill of workers Workers are trained in operations such as

setting up work, performing special

operations etc.

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Disadvantages of Processlayout Insufficient MH

Fixed path material handling such as conveyor belts cannotbe put to use.

Since longer flow line usually result, material handling ismore expensive.

Requires more floor space High inventory investment compared to line layout

High cost of supervision

Large in process inventory

Total production time is usually longer.

Accumulation of WIP The material moves slowly fromone department to another.

Because of the diversity of jobs in specializeddepartments higher grades of skill are required.

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PRODUCT LAYOUT

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Types of Layout1. Product /Line Layout

Machines & equipment are arranged in sequence. The material moves from one machine to another

machine sequentially without any backtracking ordeviation i.e the output of one machine becomes inputof the next machine.

The investment on straight line layout is higher than inthe functional layout.

It requires a very little material handling.

This is best suited for continuous mass productionwhere raw materials are fed at one end and thefinished products are taken out at the other end.

The product layout is followed in plants manufacturing

standardized products on a mass scale such aschemical, paper, sugar, rubber, refineries & cement16


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STARTSPRODUCTION

LATHEDRILLPRESS# 2

PACKAGINGM

ACHINE

DRILLPRESS#1

PAINTINGMACINE

FINISHPRODU

CTION

PRODUCT LAYOUT IN MANUFACTURING PRODUCT

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Cement Production

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Cement production

1. Quarry2. Crusher3. Conveyor4. Mixing bed

5. Raw mill6. Filter7. Preheater8. Kiln9. Cooler10. Clinker silo11. Cement mill12. logistics

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Assembly Lines

Are special case of product layout.

The range of products partially orcompletely assembled includes

Toys

Aplliances

Autos

Planes

Clothing

Electroniccomponents

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Assembly Line Balancing

Assembly line balancing is theprocess of distributing the workload inan assembly line across successive

workstations so that no time orresources are wasted.

A balanced assembly line does notsuffer from bottlenecks orunnecessary idle time

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Workstation cycle time(C) Maximum time spent at any one workstation.

Largest workstation time.

How often a product is completed.

Is the amount of time available at each work station tocomplete all assigned work.

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=

=

N = Number of work stations

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Steps in Assembly linebalancing Specify the sequence of tasks using

precedence diagram Determine Cycle time C Determine theoretical number of workstations

N Select primary rule by which tasks are to be

assigned Assign tasks one at a time Evaluate Efficiency

=

(

If efficiency in unsatisfactory rebalance.25


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Features of Product Layout

Smooth and logical flow lines

Small in process inventories

Total production time/unit short

Reduced material handling

Little operator skill, training simple

Simple production planning andcontrol

Less space for work in transit andtemporary

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Advantages of Product Layout

Smooth flow of production : Bottlenecks& stoppage of work is eliminated due toproper arrangement of machines insequence.

Mechanisation of material handling :Since machines are in sequence flow ofmaterials in a line through mechanical

devices like conveyors.

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Economy in Manufacturing Time :There is no transportation of rawmaterials backwards & forward, so it

shortens the manufacturing time. Saving in Material Handling Cost :

Materials move from one machine to

another automatically and so notransportation cost.

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Easy inspection : Because theproduction process is integrated &continuous, defective practice can beeasily be detected & segregated. Soinspection is easy.

Maximum utilisation of availableSpace

Effective utilisation of availableresources : Effective utilisation ofmen , machines & materials.

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Disadvantages of Productlayout Product layout is known for its

inflexibility.

This type of layout is also expensive.

There is difficulty of supervision.

Expansion is also difficult.

Any breakdown of equipment along

the production line can be disrupt thewhole system.

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FIXED LAYOUT

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Fixed or Static Layout

Materials remain at a fixed place andthe complete job is done at a fixedstation.

Eg Ship building industry Locomotive

Turbines etc

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Advantages of Fixed alyout

Flexible Fully flexible & capable of absorbing any sort

of change in product or process.

Lower labour cost

People move to their own departments assoon as the job is done.

Saving in time Sequence of operations can be changed if

some materials do not arrive

Lesser floor space No need to fix machines & equipment. More suitable for assemling large, heavy

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Disadvantages of Fixed layout

Higher capital investment Investment is heavy in men, material &

labour

Unstability Not suitable for small products

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CELLULAR LAYOUT

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Cellular or group layout

In this components that are similar indesign or manufacturing operationsare grouped into one family called

part-family. It is a combination of both process and

product layout.

Suitable when large variety ofproducts are needed in small volumes(or batches)

Machines must be closely grouped 37


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Advantages of cellular

Lower WIP Reduction in MH cost

Shorter flow times in production

Simplified scheduling of materials andlabour

Quicker set ups, fewer tooling

changes Improved functional and visual control

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Disadvantages of cellular

Reduced manufacturing flexibility As products & process change, there

is a risk of cells becoming out-of-date.

Increased operator responsibility.

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Factors affecting Layout

Nature of the product Nature of the product to be manufactured

will affect the layout.

Heavy products may need stationarylayout

Small & light products line layout

Volume of production

If standardised commodities are to bemanufactured on large scale, line typelayout

Production to order then functional layout 42


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Management policies Size of the plant

Scope for future expansion

Quality of the product Nature of plant location

The size, shape & topography of the site

Eg : site near railway, - arrangement toreceiving and shipping material

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Type of industry Process Continuous industry

Intermittent industry

Types of methods of production Job shop machines and equipments

can be arranged in a manner to suit the

need of all types of customer. Mass production line layout is most

suitable

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Nature of Machines Heavy machines are generally fixed on

the ground Stationary layout

Ample space should be provided to avoidaccidents.

Nature of Materials

Physical , chemical properties of materialsare to be considered.

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Type of Machine & equipment : General purpose or special purpose

machines & equipment.

Machine & equipment should be used tothe fullest.

Human Factor & working conditions

Specific safety aspects such as

obstruction free floor, emergency exitpoints should be provided.

Sufficient space should be provided for

free movement of workers. 46


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Service Centres Every layout must have provision for the

men and equipment to lubricate, repair oreven replace the parts of the machine.

Characteristics of the building

Shape of the building , covered and openareas, number of stores, facilities of

elevators, storing place, parking area etcalso influence the layout plan.

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Principles of Good Layout

Integration Minimum movement of material handling

Smooth & continuous flow of material

Cubic space utilisation

Safe & improved environment Flexibility

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Advantages of Good layout

Less MH

Less motions between operations

Improved labour productivity

More safety

Better working conditions

Advantages toworkers

Reduced maintenance & replacement cost

Improved quality due to reduced waste

Better cost control

Manufacturingcosts

More space for production operations

Better storage facilities

Scope for better supervision

Better utilization of resources

Productioncontrol

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COMPUTERISED LAYOUT


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COMPUTERISED LAYOUTTECHNIQUES CRAFT Computerized Relative

Allocation of Facilities Techniques

SLP Systematic Layout Planning

unit 2 -topic 2 - plant layout

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