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Introduction
Facility layout refers to the physical arrangement of production facilities. The facility layout plan institutionalizes the fundamental organizational structure. It is the configuration of department, work centers & equipment in the conversion process.
Definition
According to Moore: Plant layout is a plan of an optimum arrangements of facilities including personnel, operating equipment, storage space, material handling equipments and all other supporting services along with the design of best structure to contain all these facilities.
Plant layout
A floor plan for determining and arranging the desired machinery and equipment of a plant It permits The quickest flow of materials in processing the product From the receipt of the raw materials to the shipment of the finished product At the lowest cost, and With the least amount of handling
Objectives
The primary goal of the plant layout is to maximize the profit by arrangement of all the plant facilities to the best advantage of total manufacturing of the product.
Objectives
Provide enough production capacity Reduce material handling cost Reduce congestion impeding movement of men and material Reduce hazards to working personnel Utilize labour efficiently Increase employee morale Utilize available floor space efficiently and effectively
Objectives
The objectives of plant layout are:
Streamline the flow of materials to the plant. Facilitate the manufacturing process. Maintain high turnover of process inventory. Minimize material handling Effective utilization of men, equipment and space. Flexibility of manufacturing, operations & arrangements Provide for employee convenience, safety and comfort
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Vvolume-variety characteristics Low VOLUME Fixed position layout Process layout Cell layout Product layout High
Low
VARIETY
High
Product layout
Machines arranged in a line depending upon sequence of operations Material moves in a line from the first machine to the finished product on the last machine. Investment higher as compared to process layout
Product Layout
Plant & machinery layout is designed to cater to continuous flow of Materials. The position and order in the sequence for a machine performing particular operation is fixed. Once a machine is in line, it cannot perform any operation , which is not designated in the sequence of operations. There is a continuous flow of material during the production process from start to finish.
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RAW MATERIALS
PRODUCTION SUBSYSTEM
RECEIVING OPERATION B STORAGE OPERATION A CONTROL SYSTEMS
MATERIAL FLOW
Important Considerations
All machines placed at points demanded by sequence of operation No crossing over of one line with the other Materials may be fed where they are required for assembly but not necessarily all at one point All operations including assembly, testing and packing included in the line
Washing Machine
Dryer
Steam press
Delivery Counter
Each unit produced undergoes same sequence of operations and uses same flow of work. The work centers and equipments are arranged in a line for continuous operation.
Advantages
To workers:
Reduce effort Minimizes manual material handling Reduces accidents Provide better working conditions
To the management:
Reduce labor cost Enhance productivity Reduce cost per unit Gain competitiveness in manufacturing
Contd
In manufacturing:
Minimizes the movement between work centers Reduced manufacturing cycle
In production control:
Uniform and uninterrupted flow of materials Helps carrying out production activities within the predetermined time period Effectiveness in production
Contd
Reduced material handling cost due to mechanized handling flow and straight flow. Perfect line balancing which eliminates bottlenecks and idle capacity. Manufacturing cycle is short due to uninterrupted flow of materials. Simplified production, planning and control. Small amount of work in process inventory. Unskilled workers can learn and manage the production.
Disadvantages:
Inflexible & expensive layout Difficulty in supervision Expansion is difficult Any breakdown along the line can disrupt total production Requires heavy capital investment.
Process layout
It is also known as functional layout. It is recommended for batch production. All machines performing similar operations is grouped at one location. type of
Car servicing Hospital-Patient requiring various tests Garment factory producing half sleeve shirts, full sleeve shirts, pants and suits. Office buildings, schools, universities, hospitals, aerodrome, library, book store or amusement centers are planned on this basis.
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Important considerations
Distance between departments as small as possible Departments to be located as per sequence of operation Convenience for inspection as well as supervision
Process layout
Work Shop Office Product A Fitting Table 1 Lathe 1 Fitting Table 2 Product B Lathe 2 Lathe 3 Milling Machine
Flow of work is not standardized Plant produces a variety of products Some of the processes / operations might be common.
Air Compressor
Side Entry
Fitting Table 3
Advantages
Each production unit of the system works independently and is not affected by the happenings in another section of the plant. Scope for more skilled labour leads to better quality in production. Wide flexibility in production facilities. Machine breakdown doesnt disrupt production. Lower capital investment. (Less duplication of machines). Better utilization of resources Full utilization of machinery
Disadvantages
More material handling. Longer processing time:- as more time s required for material handling, transportation n inspection. Requires substantial production planning and control. Requires more floor space. Inspection s more frequent n costlier. Requires highly skilled labour creating difficulty in labour procurement. Production time increased because of extra travel Accumulation of work-in-process at different machines
Best suited for bulky & heavy products ex.Ships, aeroplanes etc.
The material remains in a fixed position , but the machinery, tool workmen etc are brought to the material
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AIRCRAFT ASSEMBLY
LABOUR
Employed in large project type organisation Example ISRO Helicopter Nuclear engg. Division of BHEL
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Advantages
Men/machinery can be moved for a wide variety of operations producing different products Worker identifies himself with the product & takes pride when the work is completed Investment on layout is small High cost & difficulty in transporting a bulky job avoided
Mixed layouts
Mixed layouts pure basic layouts can be used in different departments in one organisation. Example: A hospital would be arranged on process-layout principles. Within individual departments different layouts are used e.g. x-ray department probably process, surgical theatres fixed-position and the blood-processing lab a product layout.
Combined layout
Combination of product & process layout with an emphasis on either Generally adopted in industry In fabrication plants including assembly, fabrication tends to employ process layout while assembly areas employ product layout
Soap manufacturing industry employs product line for manufacturing of soap, but ancillaries such as heating, manufacturing of gleycerine, power house etc. Are arranged on functional basis.
PRODUCT LAYOUT
RAW MATERIAL
F.P.
G.C.
H.T.
G.G.
FINISHED PRODUCTS (GEARS)
RAW MATERIAL
PROCESS LAYOUT
F.P.
G.C.
H.T.
G.G.
G.C.
Combination layout
In an industrial plant, it is difficult to confine to one type of layout only i.e. process or product layout. It becomes necessary to use process layout for some of the activities and to use product layout for certain other activities in the same plant. Cement manufacturing may need process layout for rawmaterial preparation, which require crushing, grinding and mixing of the various raw-materials such as limestone, clay, bauxite and iron-ore.
Combination layout
Once the raw materials are prepared and converted into raw-meal by mixing different raw materials in predetermined proportion, production processes such as pre-heating, pre-calcining, calcinations for conversion of raw-meal into clinker and cooling of clinker would use product layout. Within the plant, workshop activities are arranged by using process layout, whereas the packing and dispatch operations of the cement through trucks need product layout.
Combination layout
If different modes of dispatches are adopted such as dispatch by rail (both by bags and bulk containers), sea (bags and bulk loading) or by road in trucks (bags) or in bulk containers, the dispatch operations would need process layout. In cases of repairs of kiln in a cement plant, which cannot be moved, a fixed layout is to be used. It is clear from the example of cement plant that a big plant needs application of all the three types of layouts for different applications or a combination of all the layouts for meeting the requirements of its total operations.
Rotary kiln
Inlet chamber Clinker cooler Of kiln ESP Cement Mill Product layout for a portion of Cement plant
Group Technology
This is philosophy that seeks to exploit the commonality in manufacturing and uses this as a basis for grouping components and resources. This is also known as cellular manufacturing. Pioneered by Russians Mid volume & mid variety scenario 70% of mfg. industry may fall under this category)
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Products move from station to station and operators move between stations
2 1 3 2 3
PART D
PART X
4
PART Y
1
PART A
2 3
1 4
CELL # 4
PART B
CELL # 3
PRODUCTION OPERATION
3333
Lathe Mill
4444
Mill
- 4444
Assembly
2222
Mill
Drill
CM LAYOUT
ADVANTAGES
PPC becomes simpler Material handling becomes easier Traceability improves Employees are able to relate better. Helps in implementing SGA, Kaizen an JIT
CM layout limitations
Reduced manufacturing flexibility & potentially increased machine downtime Duplicate pieces of machinery may be needed so as to avoid movement of parts between cells
Hotels, cinema halls etc have different areas to cater to the comfort & convenience of customers
EXIT
ENTRANCE
HOSPITAL WARDS
CAFETERIA
ADMIN. OFFICE PARKING AREA CASUALTY DEPT / INPATIENT DEPT PARKING AREA
ENTRANCE
EXIT
PARKING AREA
NURSES LOUNGE
PARKING AREA
PARKING AREA
PARKING AREA
Flow line approach followed in fast food service Process line layout occurs in many services like medical clinics, offices etc.
WAITING LINE
WAITING LINE
SERVICE FACILITY
WAITING LINE
SERVICE FACILITY
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