Analytical tools for textile plant layout.pptx

Chapter 4: Analytical Tools for Textile Plant Lay-out
 Systematic layout planning
 Methodology for Systematic layout planning
4.1. Plant layout Tools and Techniques
4.2. Facility Layout Procedures
Systematic Layout Planning - 1

Facilities Planning
Layout Design: Systematic Layout Planning
Facility
Planning
Structural Design
Facility
Location
Facility
Design
Handling System
Design
Layout
Design
Hierarchy of Facility Planning

4.1. Plant layout Tools and Techniques
The following tools are used in layout planning
1. Operation process chart
2. Flow process chart
3. Flow Diagrams
4. String diagrams
5. Templates
6. Three dimensional models
7. Machine Data cards

1. Operation Process Chart
The operation process chart subdivides manufacturing process in to
separate operations and inspection.
 It indicates the points at which materials are introduced in to
the process and the sequences of all operations and inspections
except those involved in material handling.
 The chart enables overall visualisation of the process and
serves as a basis for studying possibilities for the improvement of
operations by elimination, combination, re-arrangement or
simplification.
2. Flow Process Chart
 This chart is a graphic(detail) representation of all production
activities including transportation, storage and delay.
It is an extension of operation process chart.
 This chart provides complete information for analysis and
improvement of plant operations as a whole.

3. Flow Diagrams
 This diagram is used to supplement the flow process chart. It is
a plan of the work area drawn to scale. It shows the relative
position of productive machinery, storage area, etc and the path
followed by men or materials is marked on the flow diagram.
 All routes followed by different items are shown by joining the
symbols with straight lines.
4. String Diagrams
 The string diagram is a scale plan or model on which a thread
is used to trace and measure the path of workers, material or
equipment during a specified sequence of events.
Machine Data Cards
 These cards contain information such as capacity, space and
other details required for layout.

5. Templates
 The area (or space) required by machine benches, racks,
material handling equipment etc. maybe cut to scale from a sheet
of card board plywood or plastic.
 Different colours could be used to represent different machines.
These templates can be placed on the work area drawn to scale.
 Layout can be optimised by placing the templates and by
analysing the alternatives.
6. Three Dimensional Models
 The work space is represented in three dimensions to visualise
the actual work situations

Facility Layout Procedures
 Muther’s Systematic Layout Planning (1961)

Muther’s
Systematic
Layout
Planning
Procedure

Systematic Layout Planning Procedure
Information Gathering
 PQRST items
 Product: what is to be produced
 Quantity: volume to be produced
 Routing: how it is to be produced
 Support services: with what will we produce
 Timing/Transport: when to produce and how to move parts in & out
 Quantity & Variety often dictate the layout type (product/process, etc.)
 can be used to determine
o which products justify their own lines,
o which families justify their own cells.

 Photographs about the product
 “Exploded” drawings
 Engineering drawings of individual parts
 Parts list
 Bill of materials (structure of product)
 Assembly chart
 Route sheet
 Operations process chart
 Etc.

Schedule design decisions tell us how much to produce and when
to produce.
Market
Forecast
Number of
Machines
Production
Demand
Production
Rate
Product Mix
+
Production Rate
Continuous or
Intermittent
Production

Flow Analysis and Activity Analysis
Flow analysis concentrates on some quantitative measure of movement
between departments or activities
Activity analysis is primarily concerned with the non-quantitative factors
that influence the location of departments or activities
Charts and diagrams useful in flow analysis:
- Flow process chart
- Multi-product process charts
- Flow diagram
- From-to-charts

A
B
C
D
E
A B C D E
A B
C
D
E
F
A B
D
E
F
B
C
A
D
E
A B C
Basic Flow Patterns
Flow Analysis and Activity Analysis

Flow and Activity Analysis
Layout Types

Layout Types

S
S
S
S
S
S
S
S
S
S
W
W
W
W
W
W
W
W
W
W
W
W
F
F
F
F
F
F
P P P
Receiving and
Shipping PACKING
GARMENT Department
Spinning
Department
WEAVING PR
Department LOOM SHEED Department
FINISHING
Department
SEWING LINE
SEWING LINE

Flow and Activity Analysis - A1

Flow and Activity Analysis A-2

Code Reason
1 Frequency of use high
2 Frequency of use medium
3 Frequency of use low
4 Information flow high
5 Information flow medium
6 Information flow low
Rating Definition
A Absolutely Necessary
E Especially Important
I Important
O Ordinary Closeness OK
U Unimportant
X Undesirable
1. Directors conference room
2. President
3. Sales department
4. Personnel
5. Plant manager
6. Plant engineering office
7. Production supervisor
8. Controller office
9. Purchasing department
I
1
O
5
U
6
O
5
A
4
I
4
U
6
I
4
I
1
U
6
I
4
O
5
A
4
O
5
O
5
U
3
O
5
O
5
O
5
O
5
E
4
O
2
U
6
O
5
O
5
O
5
U
3
U
6
E
4
O
4
U
3
I
4
I
4
U
3
O
5
U
6
Activity Relationship Chart

Value
A
E
I
O
U
X
Closeness
Line
code
Numerical
weights
Absolutely necessary
Especially important
Important
Ordinary closeness OK
Unimportant
Undesirable
16
8
4
2
0
-80
Relationship Diagram

1
2
4
3
5
U U
E
A
I
The number of lines
here represent paths
required to be taken in
transactions between
the departments. The
more lines, the more
the interaction
between departments.
Note here again, Depts. (1) and
(2) are linked together, and
Depts. (2) and (5) are linked
together by multiple lines or
required transactions.
Relationship Diagram (or Activity Relationship Diagram)

Code Reason
1 Flow of material
2 Ease of supervision
3 Common personnel
4 Contact Necessary
5 Conveniences
Rating Definition
A Absolutely Necessary
E Especially Important
I Important
O Ordinary Closeness OK
U Unimportant
X Undesirable
1. Offices
2. Foreman
3. Conference Room
4. Parcel Post
5. Parts Shipment
6. Repair and Service Parts
7. Service Areas
8. Receiving
9. Testing
10. General Storage
O
4
I
5
U
U
U
E
3
U
U
E
3
E
5
O
4
U
O
4
U
U
E
3
A
1
O
3
I
2
U
U
U
I
4
U
U
I
2
U
U
U
U
U
I
2
U
U
A
1
U
O
2
U
I
1
U
I
2
U
U
I
2
U
Activity Relationship Chart

10
5 8 7
9 6
4 2 3
1
The Relationship Diagram
positions activities spatially.
Proximities are typically used
to reflect the relationship
between pairs of activities

Muther’s
Systematic
Layout Planning
Procedure
Based on the input data and an understanding of the roles and
relationship between activities, a material flow analysis (from-to-chart)
and an activity relationship analysis (activity relationship chart) are
performed.
From the analysis performed, a relationship diagram is developed.

Step 4 and 5: Space requirement and available
determined space needs , space availability; space requirements
This can be done through estimates or calculations adjustment of
areas. This is a critical stage, but for almost all organizations, in-
process storage and machine areas can be predicted accurately,
so that space requirements can be determined. requirements are
known, it is necessary to consider the space available

• Raw material storage
• In-process inventory
storage
• Finished-goods storage
• Aisles, cross isles, and
main aisles
• Receiving and shipping
• Material handling
equipment storage
• Tool rooms and tool cribs
• Maintenance
• Packaging
Space Determination
• Quality control and
inspection
• Supervision
• Health and medical
facilities
• Food service
• washrooms, etc.
• Offices
• Employee and visitor
parking
• Receiving and shipping
parking
• Other storage

Muther’s
Systematic
Layout
Planning
Procedure

10
5 8 7
9 6
4 2 3
1

2
(125)
3
(125)
1
(1000)
4
(350)
3
(125)
6
(75)
9
(500)
10
(1750)
5
(500)
8
(200)
7
(575)
step 6: Space Relationship Diagram

Relationship diagram:
all departments are of equal size.
Space Relationship diagram:
templates proportional in size to departmental space requirement

Relationship diagram
Activity Relations and Relationship Diagram – Another example

Space relationship diagram

Step 7 and 8: Modifying considerations and limitations
Site-specific and Operation-specific conditions
possible adjustment to the layout
Example:
 Location of external transportation system (e.g., rail, road, river access)
→ may restrict the location of shipping and receiving
 limitations on access to utilities ( lighting, etc) in certain areas
 aisles should be straight and close to the point where move requests are
generated without obstructing manufacturing activities

Alternative block layout
Step 9: develop layout alternative

Muther’s
Systematic
Layout
Planning
Procedure

Step 10: Evaluation
Factor-analysis method (evaluating the layout alternatives)
 List all of the factors to be considered important
 Weight the relative importance of each of these factors to each other
 Rate the alternative plans against one factor at a time
 Calculate the weighted rating values and sum up those values to obtain
the total value for each of the alternatives
 Select the alternative with the highest total value
Factors
Cost, flexibility, maintainability, expandability (modularity), safety, operation
ease

Evaluation - Location Rating Factor
 Identify important factors
 Weight factors (usually 0.00 - 1.00 or 0.00 - 100)
 Subjectively score each factor
 Sum weighted scores

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