KIOT

Plant Layout and Facility Design

Course code: Greg 4181
Target group: 4th year GED
Chapter five
Plant layout techniques and models
By: Endashaw Yohannes
Kombolcha/Ethiopia
January, 2020

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Outline
Flow planning and analysis

Plant arrangement

Process arrangement

Space planning and area allocation

Factors for consideration in space planning

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 1. Flow planning and analysis
Factors to be considered flow planning process
Analysis of material movement
Planning flow patterns
Determination of departmental locations
Dependency of one area to another
Volumes of movement between area
Some techniques used for flow planning process
Assembly chart
Operation process chart
Flow process chart
Activity relationship chart etc
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 2. Plant & Process arrangement
Plant arrangement is a system composed of interacting individual
departments.

Process arrangement is to design arrangements of facilities with in the

department .

To systematically arrive at the arrangement

1. First consider the combination of production departments in to necessary
for manufacturing areas .

2. Second add the complementary or supplementary departments and their

required offices areas ,these include :-

o Production control,

o Inventory and materials control,

o Quality control and storerooms,

o Engineering and plant maintenance.

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 2. Plant & Process arrangement cont..
3. Third to manufacturing related department add their general
business department like such as

o Accounting and finance

o Sales and purchasing personnel

o Human resource office and

o Administrative office

4. Finally at last add welfare and Colony to complete the layout.

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3. SPACE PLANNING AND AREA ALLOCATION
1. SPACE PLANNING
For a proper layout it is necessary to analyze space available,
required, or to be allocated to each activity or function of the
enterprise.
For this, first task is to identify the production, service and auxiliary
activities necessary for the enterprise.
Activity Centers
Main activity centers for various types of facilities are :
1. Production
Work stations, Receiving, storage, Warehousing, shipping, Scrap and
waste disposal
Production control: Industrial/Garment engineering and Quality
control.
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 Activity Centers cont…
2. Administrative 4. Colony
General manager. Residences.
Sales, Purchasing and marketing. Parks, landscaping etc.
Finance, Accounting and HR Rest rooms.
Reception, data processing community halls.
Library, Time keeping and etc. Shopping complex.
3. Welfare (Happiness and Safety) Power generation.
Medical, Education facilities.

Guest house, toilet.

Recreation, and Canteen/cafeteria.

Parking, Fire fighting and

Communication.
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4.1.Factors for determining the space requirement for the enterprise:
Business trends, long term planning,
and Sales forecast.
Possible changes in product or line.
Expansion plans and Flexibility
desired.
Competition and Time frame.
Expected technological advances in
product or production processes.
Production capacity and Inventory
policy.
Organisational set-up and Number of
shifts.
Pollution and Safety aspect.
Equipment sizes and numbers
Type of product and Number of product.
Raw material and Finished product.
Product size.
Material flow pattern and Manufacturing
methods.
Materials handling system an equipment.
Storage methods and Services activities.
Location.
Transportation and Aisles space.
Stairs, elevator, lifts and ramp
Type of construction and Number of floors.
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From practical point of view our solution to the plant layout is constrained by
the amount and configuration of available space.

Constraint can be in the form of

o An existing building,

o A limitation on the size of the building site, or

o The availability of capital for new construction.

Total space requirement depends on following major factors:

1. Production rate
2. Equipment requirements
3. Employee requirements

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1. OFFICES
Offices for the purpose of plant layout means administrative and
personnel services, and includes work-space and space required for
other services and amenities.
Requirements for office layout planning are
o Electrical needs,
o Direction of natural light,

o Spacing between rows of desks and chairs,

o Size of the rooms of senior executives in relation to their status,
o Widths of aisles should be considered.

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 The office space includes:

• Work-place. • Canteen.

• Reception area. • Security.

• Conference area. • Communication.

• Passages, stairs, lifts etc.
• Time keeping.
• Parking and transport
• Lavatories/toilet.
facilities.
• Record room.
• Air conditioning, electric
• Internal services.
room etc.
• Storage.
• Lawn and other landscaping.

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 (a) Receiving.
 Receiving is concerned with the receipt of materials

factors affecting the receiving space requirements are:

• Amount and type of goods, etc.
• Unloading methods, equipment needed and time required.
• Characteristics of goods received, size of packages, unit loads etc.
• Frequency of receipts.
(b) Storage
Factors considered for storage planning are:
• Value of items.
• Type of stores : raw material, spares,
parts, supplies, scrap, wastes, salvage • Expansion programme.
items. • Handling methods and equipments.
• Characteristics of stores: shape, size,
weight age, etc • Storage method, Rack or raw spacing.
• Quantity to be stored (expected • Record keeping, information, and
maximum).
• Frequency and schedule of receipts. communication system.
• Inventory policies and Replacement • Capacity, flexibility and working space
practices.
requirements, isles. 12
(c) In-Processes Storage
 The item after one operation IS 'hold' before proceeding to the next
operation, until a machine and operator are' ready to perform next operation.
 This holding of item is known as in-process store.
 The items which are required to be hold for smaller period are usually kept
between the work-places or machines, or adjacent to a workplace.
 Whereas, the items which are to be kept for a longer period of time are stored
at a separate place, till they are needed for next operation.

Factors should be considered for deciding area requirement for in-

process storage :
o Production rate. Line balancing.
o Storage method and equipment and Flow direction.
o Height, Load of the item, Material Characteristics.
o Handling method and equipment.
o Process reliability, Storage time.

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(3) PRODUCTION
 Space requirement for production mainly
depends on the sum of the areas of individual
work-places. An allowance is added to this,to
provide aisles and other non-productive areas.
 Total production space is determined after
determining the areas for all work-places,
machines and operators engaged for each
operation or activity.

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While designing work-place, designer should
follow the principles of motion-economy and
work-place design.
It should consider the following factors:
• Direction of flow of material or activity.
• Items to be kept in the workplace e.g., machine,
bench, stock containers, and conveyors.
• A sketch be prepared indicating the equipment,
direction of material flow
• Waste and scrap disposal route.
• Path of material handling equipment indicating the
area needed.
• Distances between items in the workplace be
indicated on the sketch drawn as mentioned above.

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(4) TOOL ROOM (workshops)

 Tool room is a place where tools, equipments,

fixtures, etc. are made and maintained.
 these tool rooms are considered for
centralised or decentralised locations.

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Following factors should be considered while
planning for tool rooms:

• Use drawers, racks, bins etc.

• These should be easily accessible.
• Allow enough passage between racks.
• Openings should be provided at convenient
places, both for crib attendants as well as shop
floor personnel.

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(5) PARKING
 With the improvements in living standards, it is
becoming an increasingly difficult problem to
provide an adequate parking space.
 These should be regulated both from the
ecological and appearance point of view.

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 Since rate of manufacturing and demand of
goods is not the same, warehousing has become
necessary for serving as cushion for holding
goods until they are demanded .

 warehousing is that activity which is concerned

with the orderly storage and issuing of finished
goods (or product).

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Factors considered for planning the space requirement
for a warehouse
• Type ,and quantity of goods.
• Turnover of goods.
• Weight ,Volume, shape and stackability of goods.
• Method of storing (bulk, racks, bins, etc.),
• Inventory policy.
• Material handling methods, and handling equipments.
• Areas required for services and facilities.
• Flexibility and expansion requirements, and long range
plans.
• Order picking area.
• Packing area requirement.
• Area requirement for loading and shipping.
• Investment required, return on investment and cost
of land .. 20
(7) SHIPPING
 Shipping is concerned with the,
(i ) disposition of stock selected
to fill the orders,
(ii) packing of items for
shipment, and
(iii) loading them, onto a vehicle
for delivery.

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 Due to close interrelationship between
receiving, warehousing, and shipping, these
must be considered together in the layout
planning. The shipping activity is the reverse
of the receiving activity.

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For determining shipping requirement, following
factors are considered:
1. Physical characteristics of the items to be
handled.
2. Determination of amount of workload;
(a) Number of shipments per unit oftime ;
(b) Pieces per shipment.
(c) Volume of truck or rail.
3. Design of docks and related equipment.
4. Handling methods and equipment.
5. Location of shipping area.

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 Service activities of an appropriate size to the
amount of work/utility should also be planned.
These service activities are:
• Preventive maintenance.
 Repair work.
• Medical services .
• Lavatory, drinking water space, canteen etc.
• Recreation facilities. Etc.

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 Total number of product units Qf = PQ
 Total number of parts produced npf = PQnp
 Total number of operations nof = PQnpno

where
P = Product variety
Q = Product quantity
np = Number of parts in product
no = Number of operations in product

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2.2: The ABC Company is planning a new product line and will build a
new plant to manufacture the parts for a new product line. The
product line will include 50 different models. Annual production
of each model is expected to be 1000 units. Each product will
be assembled of 400 components. All processing of parts will
be accomplished in one factory. There are an average of 6
processing steps required to produce each component, and each
processing step takes 1.0 minute (includes an allowance for
setup time and part handling). All processing operations are
performed at workstations, each of which includes a production
machine and a human worker. If each workstation requires a
floor space of 250 m2, and the factory operates one shift
(2000 hr/yr), determine (a) how many production operations,
and (b) how many workers ,and how much floors pace will be
required in the plant,.

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(a) nof = PQnpno = 50(1000)(400)(6) =
120,000,000 operations in the factory per
year.
(b) Total operation time = (120 x 106
ops)(1min./(60 min./hr)) = 2,000,000 hr/yr.
At 2000 hours/yr per worker, w = = 1000
workers.
(c) Number of workstations n = w = 1000.

Total floorspace = (1000 stations)(250

m2/station) = 250,000 m2

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 Considering the data given in the table below,
develop the most appropriate layout.

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