PLMH Unit 1 Notes - JNTUH R13 Syllabus

Plant Layout and Material Handling
(A80365) Credits:4
Dr. S. Deva Prasad
Professor
Mechanical Engineering Department
SYLLABUS
UNIT-I: INTRODUCTION - Classification of Layout, Advantages and Limitations of
different layouts, Layout design procedures, Overview of plant layout. PROCESS
LAYOUT & PRODUCT LAYOUT - Selection, Specification, Implementation and Follow up,
Comparison of Product and Process layout.
UNIT-II: Heuristics for plant layout – ALDEP, CORLAP, CRAFT, Group Layout, Fixed
position layout – Quadratic assignment model. Branch and bound method.
UNIT-III: Introduction, Material Handling Systems, Material Handling Principles, Classification
of Material Handling Equipment, Relationship of material handling to plant layout.
UNIT-IV: BASIC MATERIAL HANDLING SYSTEM: Selection, Material Handling
Method - Path, Equipment, Functional Oriented System.
UNIT-V: Methods to minimize cost of material handling – Maintenance of Material Handling
Equipment, Safety in Handling, Ergonomics of Material Handling Equipment. Design, Miscellaneous
Equipment’s.
BOOKS RECOMMENDED
Text Books
1. Operations Management / PB Mahapatra / PHI.
2. Aspects of Material Handling / Dr. KC Arora & Shinde, Lakshmi
Publications.
References
1. Facility Layout & Location an analytical approach / RL Francis, Leon
F. McGinnis, Jr. and John A. White / PHI.
2. Production and Operations Management/ R Panneerselvam / PHI.
3. Introduction to Material Handling / Ray, Siddhartha / New Age.
4. Facilities Planning / James A. Tompkins and John A White / Wiley India
Edition.
COURSE OVERVIEW
• Study of the arrangement of physical facilities and material handling to

optimize the interrelationships among operating personnel, material flow,
and the methods required in achieving enterprise objectives efficiently,
economically, and safely.
• Proper methods for material handling and storage including safety
practices, proper equipment usage, engineering controls, and personal
protective equipment.
• Included are procedures for storage of non-hazardous and hazardous
materials, material handling equipment preventative maintenance, and
motor fleet safety
COURSE OBJECTIVES
• Understand and be able to complete the following charts with regard to a

specific product: assembly chart, route sheet, operations process chart,
from-to chart, and activity relationship chart.
• Identify equipment requirements for a specific process.
• Understand the benefit of an efficient material handling system.
• Understand what effect process layout has on the material handling
system.
• Recommend improvements to existing plant layouts from the standpoint
of material handling and product flow.
• Design flexibility into a plant layout to accommodate changes in product
volume or product line.
• Integrate concepts and techniques learned through this course in order to
design and efficient plant layout in a team environment.
LAYOUT….
LAYOUT….
Building Construction Layout Office Layout

LAYOUT….
University Layout Assembly Layout

LAYOUT….
An industry…
Typically produce a product or a service
Product: The end result of the manufacturing process to be offered to the market
place to satisfy a need or a want.
Types of Product flow patterns
Time spent by a typical Part/component in
a batch production machine shop…
Introduction
• Layout “decides the space requirement for the facilities and
arranging them in a manner to ensure steady flow of operations
with minimum overall cost”.
• In other words, a layout is a floor plan for arranging the facilities
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(e.g., machinery, equipment) in an optimum location so as to permit
the quickest flow of materials and manpower at the lowest cost and
with the least amount of in process handling from receipt of raw
material to shipment of finished products.
UNIT-I: INTRODUCTION - Classification of Layout, Advantages and Limitations of different layouts,

Layout design procedures, Overview of plant layout. PROCESS LAYOUT & PRODUCT LAYOUT -
Selection, Specification, Implementation and Follow up, Comparison of Product and Process layout.
Introduction
• A layout decision
• Requires substantial investments of money and effort.
• Involves long-term commitments for a particular vision and mission of an
organization
• Has significant I
• For a factory which is already in operation, this may mean the
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arrangement that is already present.
• For a new factory this means the plan of how the machines, equipment,
etc., will be arranged in the different sections or shops. These should be
arranged in such a way that material movement cost, cost of storage in
between processes, the investment on machines and equipment etc.,
should be optimal and the cost of producing a product is as cheap as
possible.
Introduction
Need to plan a layout can emerge due to various reasons.
Some of them could be
Need to make minor changes in present layout due to method improvement,
new type of inspection plan, and new type of product,
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Need to rearrange the existing layout due to marketing and technological
change,
 Re-allocating the existing facilities due to new location, or
 Building a new plant.

Introduction
Plant Layout / Facility Layout / Facility Planning defined as
“the most effective physical arrangement of machines, processing equipment, and
service departments to have the best co-ordination and efficiency of man, machine
and material in a plant. It is the spatial arrangement of physical resources used to
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create the product. It also means how the space needed for material movement,
storage, indirect labor, etc., is arranged in a factory.”
According to Keith and Gubellini, “Plant layout deals with the
arrangement of the physical facilities and the manpower which are
required to manufacture a product or perform a service.
Introduction
Plant Layout / Facility Layout / Facility Planning defined as
According to Keith and Gubellini, “Plant layout deals with the
arrangement of the physical facilities and the manpower which are
required to manufacture a product or perform a service.
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Introduction
Plant layout is an important decision as it represents long-term commitment. An ideal
plant layout
• should provide the optimum relationship among output, floor area and manufacturing
process.
• facilitates the production process, minimizes material handling, time and cost.
• allows flexibility of operations, easy production flow, makes economic use of the building
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• promotes effective utilization of manpower,
• provides for employee’s convenience, safety, comfort at work, maximum exposure to
natural light and ventilation.
• It is also important because it affects the flow of material and processes, labor efficiency,
supervision and control, use of space and expansion possibilities etc.

The Need for Layout Decisions
Inefficient operations
For Example: Changes in the design
High Cost of products or services
Bottlenecks
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Accidents
The introduction of new
products or services
Safety hazards
The Need for Layout Design (Cont’d)
Changes in
environmental Changes in volume of
or other legal output or mix of
requirements products
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Morale problems
Changes in methods
and equipment

The objectives of plant layout are:
 Minimize investment in equipment.
 Minimize overall production time.
 Utilize existing space most effectively.
 Provide for employee convenience, safety and comfort.
 Maintain flexibility of arrangement and operation.
 Minimize materials handling cost.
 Facilitate the manufacturing process.
 Facilitate the organizational structure.
Purpose of a plant layout:
 Integrate the production centres into a logical, balanced and effective
production unit.
 Facilitates satisfactory movement of materials and personnel and an efficient
control mechanism for such transportations.
 Provides a logical distribution of functional facilities in the plant.
 Be adaptable to possible changes in the plant’s production programme,
changes in product designs, changes in output requirements, rearrangement of
facilities or expansion of facilities.
 Proper allocation and utilisation of space to the production centers and service
departments.
 Convenience of operations both to operators and supervisors.
Overview of plant layout:
 It is a classical production engineering problem to wards competitive
advantage helping to produce products and service at optimal cost and time.
• Integrates all facilities and services involved directly or indirectly in
developing (R&D) and producing (Regular Production) the desired set of
products / services.
• Plant operations with due considerations on safety, security and environment
protection while arranging facilities (Layout).
Overview
Principles of Plant Layout
Classification of Layout
Plant Layout
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Product/ Line Process/Functional Fixed Position Group / Cellular
Combination Layout
Layout Layout Layout Layout

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Product Layout
(or Line Layout)
• This layout arrange the machines and equipment's in one line
depending upon the sequence of operations required for the
product.
• The material moves to another machine sequentially without
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any backtracking or deviation i.e., the output of one machine
becomes input of the next machine.
• It requires a very little material handling.
• It is used for mass production of standardized products.

Product Layout (or Line Layout) - Flowshop
Set up production equipment along a
product-flow line, and the work in process
moves along this line past workstations.
Mass Production – Assembly Line structure -
Flowshop
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Product Layout (or Line Layout) – Typical
Examples..
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Product Layout – Merits / Demerits..
Advantages:
1. The flow of product will be smooth and logical in flow lines.
2. In-process inventory is less and throughput time is less.
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3. Material handling cost is minimum.
4. Operators need not be skilled.
5. Simple production planning and control systems are possible.
6. Less space is occupied by work in transit and for temporary storage.
Product Layout – Merits / Demerits..
Limitations:
1. A breakdown of one machine in a product line may cause stoppages of
machines in the downstream of the line.
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2. Duplication of machines (To avoid backtracking - Tracing of path)
3. A change in product design may require major alterations in the layout.
4. The line output is decided by the bottleneck machine.
5. Comparatively high investment in equipment's is required.
Process / Functional Layout - Jobshop
 Process layout groups
machinery and equipment
according to their
functions.
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 Facilitates production of a
variety of nonstandard
items in relatively small
batches.

Process Layout
Process/Functional Layout (Jobshop)

• Similar Machines grouped together
• Suitable for Low Production volumes
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• Rapid changes in the product mix
• High interdepartmental flow (Material
Handling cost is high)

Process Layout
Process/Functional Layout (Jobshop)

• Similar Machines grouped together
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• Suitable for Low Production volumes
• Rapid changes in the product mix
• High interdepartmental flow (Material
Handling cost is high)

Process Layout another example
Process/Functional Layout
(Jobshop)
• Similar Machines grouped
• Suitable for Low Production
volumes
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• Rapid changes in the product
mix
• High interdepartmental flow
(Material Handling cost is
high)

Process Layout Merits/Demerits
Advantages:
1. Machines are better utilized; fewer machines are required.
2. A high degree of flexibility in terms of task allocation to machines exists.
3. Comparatively low investment in machines is required.
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4. The diversity of tasks offers a more interesting and satisfying occupation
for the operator

Process Layout Merits/Demerits
Disadvantages:
1. Material handling cost will be high.
2. Processing planning and control systems are more involved.
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3. Throughout time is longer.
4. Large amounts of in-process inventory will result.
5. Space and capital are tied up by work in process.
6. Higher grades of skill are required.
Process Layout, Process Layout - Limitations
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Process Layout Vs Product Layout
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Process Layout Vs Product Layout
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Fixed Position Layout
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• The product (a large item such as ship, aircraft or process equipment)
occupies the central stage of the layout and the facilities are locate
around the product.
• Helps in job enlargement and upgrade skills of the operators
• Layout capital investment is lower
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• Greater flexibility with this type of layout
• The workers identify themselves with a product in which they take
interest and pride in doing the job

The fixed position layout is followed in following conditions
1. Manufacture of bulky and heavy products such as locomotives,
ships, boilers, generator, wagon building, aircraft, etc.
2. Construction of building, flyovers, dams
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3. Hospital, the medicines, doctors and nurses are taken to the
patient.

• Advantages:
 Reduces movement of m/c & equipment;
 Minimizes damage/cost of movement;
 continuity of assigned work force
• Disadvantages:
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• Skilled & versatile workers needed due to multiple operations;
• skill combination may be difficult to obtain; higher pay;
• movement of people/material may be expensive;
• equipment utilisation low as they are left at location for subsequent usage
instead of being moved as & where needed
Group / Cellular/ combined Layout
• Often referred as Hybrid

Manufacturing system.
• Cells are formed based
on dominant activity
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(Product family)
• Often finds
Combination of Process
and Product Layout

Group / Cellular Layout
• Basic philosophy is to identify families of components requiring
similar processing on the set of machines available in the same cell
• ‘m’ number of machines and ‘n’ number of components are divided
into distinct number of machine-component cells or groups in such a
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way that all the components assigned to a cell or group are mostly
processed in the same cell.
• The aim is to prevent the moment of work in progress from one cell
to the other.

Group / Cellular/ combined Layout
Cellular Layout
Component Shape &
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Size Product (components)
Models
flow / Production flow
(Simple / Composite)
Mathematical
Codification (Linear / combined /
simulation)
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Suitability
Process layout is adopted when
1. Products are not standardized
2. Quantity produced is small
3. There are frequent changes in design and style of product
4. Job shop type of work is done
5. Machines are very expensive
The process layout is suitable for job order production involving non-
repetitive processes and customer specifications and non-standardized
products, e.g. tailoring, light and heavy engineering products, made to
order furniture industries, jewelry etc.
Suitability
Product layout is useful under following conditions:
1) Mass production of standardized products
2) Simple and repetitive manufacturing process
3) Operation time for different process is more or less equal
4) Reasonably stable demand for the product
5) Continuous supply of materials
Therefore, the manufacturing units involving continuous manufacturing

process, producing few standardized products continuously on the firm’s own
specifications and in anticipation of sales would prefer product layout e.g.
chemicals, sugar, paper, rubber, refineries, cement, automobiles, food
processing and electronics etc.
Suitability
The fixed position layout is followed in following conditions
1. Manufacture of bulky and heavy products such as

locomotives, ships, boilers, generators, wagon building, aircraft
manufacturing, etc.
2. Construction of building, flyovers, dams.
3. Hospital, the medicines, doctors and nurses are taken to the
patient (product).
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Traders
When two outlets carry almost same merchandise, customers
usually buy in the one that is more appealing to them.
Thus, customers are attracted and kept by good layout i.e. good
lighting, attractive colors, good ventilation, air conditioning,
modern design and arrangement and even music.
All of these things mean customer convenience, customer
appeal and greater business volume.
The customer is always impressed by service, efficiency and

quality. Hence, the layout is essential for handling merchandise,
which is arranged as per the space available and the type and
magnitude of goods to be sold keeping in mind the convenience of
customers.
There are three kinds of layouts in retail operations.
1. Self service or modified self service layout
2. Full service layout
3. Special layouts
The self-service layouts, cuts down on sales clerk’s time and allow customers to
select merchandise for themselves.
Customers should be led through the store in a way that will expose them to as
much display area as possible, e.g. Grocery Stores or department stores.
In those stores, necessities or convenience goods should be placed at the rear of
the store. The use of color and lighting is very important to direct attention to
interior displays and to make the most of the stores layout.
All operations are not self-service. Certain specialty enterprises sell to fewer
numbers of customers or higher priced product, e.g. Apparel, office machines,
sporting goods, fashion items, hardware, good quality shoes, jewelry, luggage
and accessories, furniture and appliances are all examples of products that
require time and personal attention to be sold.
These full service layouts provide area and equipment necessary in such cases.
Some layouts depend strictly on the type of special store to be set up, e.g. TV
repair shop, soft ice cream store, and drive-in soft drink stores are all examples
of business requiring special design.
Thus, good retail layout should be the one, which saves rent, time and labor.
Services centers and establishment
Services establishments such as motels, hotels, restaurants, must give

due attention to client convenience, quality of service, efficiency in
delivering services and pleasing office ambience.
In today’s environment, the clients look for ease in approaching

different departments of a service organization and hence the layout
should be designed in a fashion, which allows clients quick and
convenient access to the facilities offered by a service establishment.
Factors influencing Layout
•Factory building
•Nature of product
•Production process
•Type of machinery
•Repairs and maintenance
•Human needs
•Plant environment
Layout design
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Layout design
• A single objective mostly.

• Process Layout – minimize cost of equipment
• Product Layout - Maximise utilization of machines or minimize
cost of material handling.
• Group Layout – Minimise cost of transportation and cost of
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equipment
• Fixed Layout – Limited scope, dynamic project based study

Travel Chart
A Travel Chart is a simple table that is useful where there are multiple
(and possibly irregular) movement between places. It is a variation on
the Check Sheet, indicating movements from and to any combination of
a given set of locations.
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Travel Chart
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Systematic Layout Design Procedure (Simply referred as
“SLP”):
• Organized approach to layout planning developed by Muther, 1961.
• Widely accepted application in solving a large variety of layout problems
• Once the appropriate information is gathered, a flow analysis can be combined
with an activity analysis to develop the relationship diagram.
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• The space relationship diagram is constructed by combining space
considerations with the relationship diagram.
• Based on the space-relationship diagram, modifying considerations and
practical limitations, a number of alternative layouts are designed and
evaluated.
• In comparison with the design process, SLP begins after the problem is
formulated.
Computerised Method:
Some of widely used are given below to help the plant layout engineer in
planning the best possible plant layout :
• Computerized Relationship Layout Planning (CORELAP)
• constructs layouts by locating rectangular shaped departments.
• most related departments are placed close to one another, other
facilities are added progressively.
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• Attempts to maximise a nearness rating within the facility dimension
constraint.
• Relationship charts provide the basis for the order in which different
departments are placed.
• Analyses multi-level structures,
• Based on actual footage travelled by materials-handling component.

Automated Layout Design Program (ALDEP)
• A construction algorithm, to develop an optimum layout for organizational units (functions)
within the restraints of space availability.
• Layout planner eliminates the repetitious task of constructing and evaluating numerous
block layouts.
• The program considers thousands of possibilities, scores them, selects the better results for
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further study by the planner, and produce an output.
• Attempts to maximize a nearness rating within the facility dimension constraints.
• Used to study in a multi-story building.
• Generates many alternative layouts and compared.
• In this technique, the first activity/facility is randomly selected and located. Then, the
subsequent activities/facilities, in desired size, are selected and located as per relative
closeness desired, or at random (if no particular inter-relationships are desired).

• Plant Layout and Evaluation Technique (PLANET)
• In this analysis, it is to estimate penalty cost associated with separating departments (on
the basis of inter-departmental flow). The objective function for the computer
programme is to minimize this cost.
• Three heuristics algorithms are used for generating alternative layout plans for final
adjustments manually.
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• Plant Re-Layout and Evaluation Package (PREP),
• Analyses multilevel structures, and is based on actual footage travelled by materials-
handling equipment.
• Evaluates up to 99 departments/work centers at one time.
• The actual travel of the materials is computed and capable of multi-story plant layouts.

• Computerised Relative Allocation of Facilities Technique (CRAFT), for situations where
materials-handling costs a major consideration.
• Most widely known algorithm and best known of the heuristic approaches
• Require an initial layout developed by hand.
• Attempts to minimize materials-handling cost, pair-wise interchanging departments, and
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calculating costs until a good solution is obtained.
• original CRAFT was used only for single-story building layout, while an extension of
CRAFT, called SPACECRAFT, can handle multi-story building layout.
• The input data is: inter-departmental flow per unit time, unit load, material handling cost
per unit distance, initial block programs.
• When the total materials handling cost has been minimized and no further improvement is
possible, the computer provides block type layout of the location of each department and
facility.
Possible Questions
• Define plant layout? Classify it?
• What are the types of layouts? Explain with examples.
• Explain systematic layout planning (SLP) procedure.
• Discuss features of various construction algorithms used in plant layout design.
• Give merits and demerits of
• Process Layout
• Product Layout
• Fixed Position Layout
• Combined Layout
• Cellular Layout
• What is a process layout/Product Layout? Discuss limitations.
• Compare Process and Product Layout.
Computerised Facilities Design (COFAD) combines CRAFT-based layouts with materials

handling selection based on various criteria.
Computer Analysis of Network of Queues (CAN-Q), used to analyse the work flow in a
production system. It is quite easy to use, very efficient and versatile.
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Design of Product Layout
• Product layout makes sense when the batch size of a product is large
and at the same time limited number of different products are
produced (i.e. Low Variety and High-Volume Production - Flowshop)
• Assembly Lines, are special case of product layout, refers to a
progressive assembly linked by some material-handling device.
• Line Balancing used to analyze balancing assembly line, where
workstation size or the number used (workstation cycle time is
studied) investigated.
• Evaluate the efficiency of the line based on a decision rule under the
line is designed.
Design of Product Layout
Model Requirement
Total: 195 sec
Workstation Time
A 45
D 50
WORKSTATION
B,E,H,I 50 WORKSTATION WORKSTATION 3 WORKSATION 4
WORKSATION 5
1 2 B,E,H,I C,F,G
C,F,G 33 A (45) D (50)
J,K (8+9=17)
(11+15+12+12 (9+12+12=33)
J,K 17 = 50)
Specify the sequential relationships among tasks using precedence diagram.
Determine the required workstation cycle time [C], using formula
C=
( )
Determine the theoretical minimum number of workstation (Ntheo) required to satisfy the workstation cycle
time constraint using the formula
( )
Ntheo = ( )
Select a primary rule by which tasks are to be assigned to workstations, and a secondary rule to brake any ties.
Assign task, one at a time, to the first workstation until the sum of the task times is equal to the workstation
cycle time (calculated) until no other task to be assigned (because of time or sequence restrictions as per the
order of processing). Repeat the process for workstations 2, workstations 3, and so on until all tasks are
considered for assignment to a workstation. Find actual number of workstations (Na)
Evaluated the efficiency of the line balance derived using the formula
( )
Line Efficiency =
× ( )
If found efficiency is unsatisfactory, rebalance using a different decision rule

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Plant Layout and Material Handling

• Study of the arrangement of physical facilities and material handling to

• Understand and be able to complete the following charts with regard to a

Building Construction Layout Office Layout

University Layout Assembly Layout

UNIT-I: INTRODUCTION - Classification of Layout, Advantages and Limitations of different layouts,

UNIT-I: INTRODUCTION - Classification of Layout, Advantages and Limitations of different layouts,

UNIT-I: INTRODUCTION - Classification of Layout, Advantages and Limitations of different layouts,

UNIT-I: INTRODUCTION - Classification of Layout, Advantages and Limitations of different layouts,

UNIT-I: INTRODUCTION - Classification of Layout, Advantages and Limitations of different layouts,

UNIT-I: INTRODUCTION - Classification of Layout, Advantages and Limitations of different layouts,

UNIT-I: INTRODUCTION - Classification of Layout, Advantages and Limitations of different layouts,

Process/Functional Layout (Jobshop)

UNIT-I: INTRODUCTION - Classification of Layout, Advantages and Limitations of different layouts,

Process/Functional Layout (Jobshop)

UNIT-I: INTRODUCTION - Classification of Layout, Advantages and Limitations of different layouts,

UNIT-I: INTRODUCTION - Classification of Layout, Advantages and Limitations of different layouts,

UNIT-I: INTRODUCTION - Classification of Layout, Advantages and Limitations of different layouts,

UNIT-I: INTRODUCTION - Classification of Layout, Advantages and Limitations of different layouts,

UNIT-I: INTRODUCTION - Classification of Layout, Advantages and Limitations of different layouts,

• Often referred as Hybrid

UNIT-I: INTRODUCTION - Classification of Layout, Advantages and Limitations of different layouts,

UNIT-I: INTRODUCTION - Classification of Layout, Advantages and Limitations of different layouts,

Component Shape &

Therefore, the manufacturing units involving continuous manufacturing

The fixed position layout is followed in following conditions

1. Manufacture of bulky and heavy products such as

The customer is always impressed by service, efficiency and

Services establishments such as motels, hotels, restaurants, must give

In today’s environment, the clients look for ease in approaching

• A single objective mostly.

UNIT-I: INTRODUCTION - Classification of Layout, Advantages and Limitations of different layouts,

UNIT-I: INTRODUCTION - Classification of Layout, Advantages and Limitations of different layouts,

UNIT-I: INTRODUCTION - Classification of Layout, Advantages and Limitations of different layouts,

UNIT-I: INTRODUCTION - Classification of Layout, Advantages and Limitations of different layouts,

Computerised Facilities Design (COFAD) combines CRAFT-based layouts with materials

If found efficiency is unsatisfactory, rebalance using a different decision rule

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