Layout, Material Handling And

Storage facilities

Presented By
1. Aman Rathod (1602152)
2. Puneet Jain (1602140)
3. Jay Majethiya (1602100)
4. Pradnya Munghate (1602112)
5. Monika Chauhan (1602111)
6. Navodyuti Das (1602114)
7. Hemant Kothari (1602081)
8. Nirmal Madhusoodanan
Layout?

Plant layout ideally involves allocation of space and

arrangement of equipment in such a manner that
overall operating costs are minimized.
Objectives of Layout

1. Improve productivity
2. Efficient utilization of available floor space
3. Reduce material handling costs
4. Provide enough production capacity.
5. Reduce accidents
6. Flexibility
7. Allow ease of maintenance
Types of Layout

a. Fixed Position
b. Process or function
c. Product or line layout
d. Group
Fixed Position layout
Eg: Ship building, Dam & flyover construction.
Fixed position layout
Eg: Ship building, Dam & flyover construction.
 Process (functional)layout:
Machines of a similar type are arranged together at
one place.
 Product layout(line Layout):

Mass production
Materials moves form one workstation to another
sequentially
The output of one machine becoming input of the
next.

Eg: Food Processing Unit; Paper mill

 Group layout:
Group layout is the technique of identifying
and bringing together related or similar
parts in a production process.
Group layout:

Group layout:

Group layout:

 Developing a layout
Sales forecast and production planning.
Storage space
Auxiliary facilities
Cross Chart
Cross Chart
Modifying an existing layout
 MATERIAL HANDLING`
About 20-25% of the total manufacturing cost

On average 59 ton of material handled for 1 ton of FG

Accidents 21% permanent injuries and 25% of temporary injuries

Losses due to damage to parts in handling

Need for Automation Manual labour inadequate

CONCERNED INDUSTRIES

Manufacturing
Processing Handling bulk
materials
Construction
Mining
Power
Railway Coach builders
Ship & Aircraft building
 OBJECTIVES OF MATERIAL HANDLING

A) Eliminate or Reduce Handling

B) Improve the efficiency of handling

C) Make correct choice of material

handling equipment
 TEN PRINCIPLES OF MATERIAL HANDLING
Planning Collaborative effort, Detailed, Concurrent
development

Standardisation Sizes of containers, equipment, standard

operating procedures

Unit load Large vs Small load, Single vs Composite load

 TEN PRINCIPLES OF MATERIAL HANDLING
Work Measured as No of units x Distance,
Reduce Handling work and
movement, use of gravity

Ergonomic Eliminate repetition; Safe and

assisting

Space Utilisation Uncluttered and organised

floor, maximise storage density,
overhead space
 TEN PRINCIPLES OF MATERIAL HANDLING
Automation - Efficiency, Consistency, Eliminate repetitive and unsafe
labour. Linking various systems and information management. Interfaces
become critical.

Environment - Environment impact and Energy consumption.

Reusable/biodegradable containers. Appropriate waste disposal.

System - From packaging at supplier to reverse logistics Fully co-

ordinated process. Easy identification and tracking.

Life Cycle Cost - Entire life cycle of all equipment from capital
 MATERIAL HANDLING EQUIPMENT
CONVEYOR
Between fixed workstations
For continuous and mass
production
Roller/Wheels/Belts
Costly installation
Less flexible
HOIST / CRANE
Can move Heavy unit loads
Utilise overhead space
Relatively cheaper
Intermittent & mass
production
Various types and load
capacities
 MATERIAL HANDLING EQUIPMENT
INDUSTRIAL TRUCKS
High flexibility
Petrol/Diesel/Electric/Hand-
powered
Wide range of attachments
available
Suitable to wide range of
materials and production
processes
INDUSTRIAL ROBOTS
Automation Consistency, Accuracy
Can work in hostile environments
Vary in size, function and
manoeuvrability
Significantly faster than other
methods
 MATERIAL HANDLING EQUIPMENT
AS/RS
Automatic Guided Vehicle
High flexibility
Very costly and difficult installation
Petrol/Diesel/Electric/Hand-
24/7 operation without human
powered
intervention
Wide range of attachments
Dynamic programming possible
available
High productivity
Suitable to wide range of
materials and production
processes
 CHOICE OF HANDLING EQUIPMENT

Properties Of The Material Layout Of The Building

Solid, Liquid, Gas Availability of space

Size, Shape, Weight Multi-storeyed-chutes or ramps
Fragile, Corrosive, Toxic High ceiling cranes

Production flow Cost Considerations

End points fixed conveyors or Initial Investment

chutes Opportunity cost
Changing flow Trucks, Hoists Depreciation
Regular, uni-directional - Hoists Overheads
Operator, maintenance,
supervisions costs
 PROCESS PLANNING
Number of parts

Make or buy Financial analysis

Operation sequence Block/operations chart

New equipment Type of technology

By products Effluent gas/heat/waste

treatment

Equipment handling Type/Skill/Operators

Type of information
 Functional Operation

Similar machinery arranged together

Product moves from one machine to other depending on the operation

Machine tool industries and garment making factories

Planning in Functional
Manufacturing
Define the sequence of operation
Time taken for each operation inc. setup time
Calculate number of tools, machine and material

Disadvantages
Setup time high
Material handling and backtracking is difficult
 Functional to Line Manufacturing

Pareto analysis to identify large volume product

Sequencing machine for a particular product

Use of CNC machines to reduce setup time

Arranging CNC machines producing similar

products
 Line Operation

Design block diagram

Fixed process at the stage of plant design

Minimal change in lead time as the line is subjected to only one produc