Production and Operations Management

Plant Layout

Plant layout
MeaningPlant layout is the physical arrangement of industrial facilities. It involves the allocation of space & the arrangement of equipment in such a manner that overall operating costs are minimized.

L L L L L L L L A A M M M M M M D D D D

G G G

G G G

Objectives of plant layout

1.

2.

3.
4.

An efficient layout can be instrumental in the accomplishment of the following objectivesEconomies in materials, facilitate manufacturing process & handling of semi-finished & finished goods. Proper & efficient utilization of available floor space. To avoid congestion & bottlenecks. Provision of better supervision & control of operations.

Objectives of plant layout cont.

5. Careful planning to avoid frequent changes in layout which may result in undue increase in cost of production. 6. To provide adequate safety to the workers from accidents. 7. To meet the quality & capacity requirements in the most economical manner. 8. Provision of medical facilities & cafeteria at suitable & convenient places. 9. To provide efficient material handling system. 10. To suggest the improvements in production process & work methods.

Principles of plant layout

1. 2. 3. 4. 5. 6. 7.

Principle of integration (of 5Ms) Principle of minimum distance Principle of cubic space utilization( both horizontal & vertical space). Principle of flow( must be forward no backtracking) Principle of maximum flexibility Principle of safety, security & satisfaction Principle of minimum handling.

Types of plant layout

Product layout 2. Process layout 3. Fixed Position/ Stationary layout Product layout1.

Layout that uses standardized processing operations to achieve smooth, rapid, highvolume flow Here machines are arranged acc. To the needs of product & in the same sequence as the operations are necessary for manufacture.

Product Layout
Raw materials or customer
Material and/or labor

Station 1 Material and/or labor

Station 2
Material and/or labor

Station 3
Material and/or labor

Station 4

Finished item

Used for Repetitive or Continuous Processing

Advantages of Product Layout

1.
2. 3. 4. 5. 6. 7.

High rate of output Low unit cost Labor specialization Low material handling cost High utilization of labor and equipment Established routing and scheduling Short processing time

Disadvantages of Product Layout

1. 2. 3. 4. 5. 6.

Creates dull, repetitive jobs Poorly skilled workers may not maintain equipment or quality of output Fairly inflexible to changes in volume Highly susceptible to shutdowns Needs preventive maintenance Require large capital investment

A U-Shaped Production Line

In

4 5

Workers

6
Out

10

Process layoutLayout that can handle varied processing requirements Here all machines performing similar type of operations are grouped together at one location in the process layout. Thus here facilities are grouped together acc. To their functions. E.g. all drilling machines are located at one place known as drilling section.

Process Layout
Milling
Assembly & Test Grinding

Drilling

Plating

Process Layout - work travels to dedicated process centers

Process Layout
Process Layout (functional)
Dept. A Dept. B Dept. C Dept. D Dept. E Dept. F

Used for Intermittent processing Job Shop or Batch

Product Layout
Product Layout (sequential)
Work Station 1 Work Station 2 Work Station 3

Used for Repetitive Processing Repetitive or Continuous

Advantages of Process Layouts

1. 2. 3.

4.
5. 6. 7.

Can handle a variety of processing requirements Machines breakdown doesnt result in shutdown. Equipment used is less costly Wide flexibility in production facilities. Each production unit of system works independently. High utilization of facilities Variety makes the job interesting.

Disadvantages of Process Layouts

1. 2. 3.

4.
5.

6.
7.

In-process inventory costs can be high Challenging routing and scheduling Equipment utilization rates are low Material handling is slow and inefficient & is more. More space is required Longer processing time Back tracking may occur.

factors

Comparison of product & process layout

Product layout

Process layout
Better utilization

1. nature 3. product 4. Processing time

Sequence of facilities Similar aregp2gether

2. Machines utilization Not to full capacity

5. Material handling
6. inventory 7. breakdown 8. Production centre 9.flexibilty 10. floor space 11. investment

standardized less less High WIP Cant tolerate simple low Requires less high

diversified more more Low WIP Can tolerate complex high more low

Fixed position layout- Layout in which the product or project remains stationary, and workers, materials, and equipment are moved as needed. E.g. Employed in large project type organisation construction of DAMS. ISRO Helicopter Nuclear engg. Division of BHEL

The product, because of its size and/or weight, remains in one location and processes are brought to it.

1.
2.

3. 4.

5. 6.

Factors affecting plant layout Nature of product- e.g. some products need airconditioned plants. Size of outputFor bulk-product/line layout For small-functional layout Nature of manufacturing systemFor intermittent-functional layout For continuous-product/line layout Localization of plant- e.g. there will be different transportation arrangement if site is located near railway line. Machines or equipment- e.g. heavy machines need stationary layout Climatic conditions, need of light, temperature also affect design of layout.

COMPANY PROFILE

RYDON GROUP,Coimbatore FOUNDED IN THE YEAR 1991 HAS ESTABLISHED BUSINESS IN THE FIELD OF MANUFACTURING AND AS WELL AS AUTOMOBILE DEALERSHIP. THE COMPANY HAS COMPLETE IN-HOUSE FACILITY TO PRODUCE SPROCKETS FOR TWO WHEELER, FOUR WHEELER AND INDUSTRIAL APPLICATIONS.

Types of sprockets

SPROCKETS

OE

RP

FD

OE: Original Equipment (line-2) RP: Retail Product (line-3) FD: Final Drive (line-1)

FINAL DRIVE SPROCKET-line-1

ORIGINAL EQUIPMENT AND RETAIL PRODUCT SPROCKET:

THE OE AND RP SPROCKETS ARE SIMILAR EXCEPT FOR THE HEAT TREATMENT IS DONE ONLY FOR THE OE SPROCKETS.

PROCESS FLOW FOR FD SPROCKETS in line-1 as shown in the model.

Raw material Turning Drilling

Heat treatment

Tooth cutting

Despatch

PROCESS FLOW FOR OE SPROCKETS in line-2 as shown in the model.

Raw material Turning Boring

Heat treatment

Tooth grinding

Despatch

PROCESS FLOW FOR RP SPROCKETS in line-3 as shown in the model.

Raw material Turning Milling

Gear Hobbing

Despatch

Flow chart of methodology for future layout design change

Process Study

Data Collection

Modeling

Simulation

Evaluation

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