this will help student regarding plant layout

1. FACILITY LAYOUT

2. Facility Layout Defined
⚫ Facility layout can be defined as the process by which the
placement of departments, workgroups within departments,
workstations, machines, and stock-holding points within a facility
are determined.
⚫ This process requires the following inputs:
⚫ Specification of objectives of the system in terms of output and
flexibility
⚫ Estimation of product or service demand on the system
⚫ Processing requirements in terms of number of operations and
amount of flow between departments and work centers
⚫ Space requirements for the elements in the layout
⚫ Space availability within the facility itself

5. Facility Layout
⚫ The way in which the parts of something are arranged or
laid out.
⚫ The physical arrangement of resources (including people)
in the production process.
⚫ The basic meaning of facility is the space in which a
business's activities take place. The layout and design of
that space impact greatly how the work is done—the flow
of work, materials, and information through the system.

6. Layout decisions are concerned with the arrangement of
production, support, customer service and other facilities.
Layout can be costly investments, but they effect material (non
production cost) handling, capital equipment utilization,
inventory storage levels, worker productivity, and even group
communications and employee morale. A good layout will be
enable materials, people, and information to flow in a safe and
efficient manner.
.

7. Objectives of Plant Layout
⚫ Streamline the flow of material through the plant Facilitate the
manufacturing process
⚫ Maintain high turnover of in-process inventory
⚫ Minimize materials handling and cost
⚫ Make effective utilization of cubic space
⚫ Flexibility of manufacturing operations and arrangements

8. ⚫ Provide for employee convenience, safety and comfort
⚫ Minimize investment in equipment
⚫ Minimize overall production time
⚫ Facilitate the organizational structure

9. Factors Affecting Plant Layout:
⚫ Factors Affecting Plant Layout The factors affecting plant layout can
be grouped into 8 categories:
1. Materials 2.Machinery
3. Labor 4. Material
Handling
5. Waiting Time 6. Auxiliary
Services
7. Building 8. Future
Changes

10. Materials
⚫ The layout will depend on the characteristics of the
product to be managed at the facility, including: size,
shape, volume, weight, and the physical-chemical
characteristics.
⚫ The sequence and order of the operations will affect plant
layout as well, taking into account the variety and quantity
to produce

11. Machinery
⚫ Information about the processes, machinery, tools and
necessary equipment, as well as their use and requirements is
essential to design a correct layout.
⚫ It’s essential as well to know about space required, shape,
height, weight, quantity of machine & equipment and type of
workers required, risks for the personnel, requirements of
auxiliary services.

12. Labor
⚫ Labor has to be organized in the production process (direct labor,
supervision and auxiliary services).
⚫ Environment considerations: employees’ safety, light conditions,
ventilation, temperature, noise, etc.
⚫ Process considerations: personnel qualifications, flexibility,
number of workers required at a given time as well as the type of
work to be performed by them.

13. Material Handling
⚫ The objective should be to minimize material handling as
well as combining with other operations when possible,
eliminating unnecessary and costly movements.

14. Waiting time
⚫ Ensuring Continuous Material Flow through the facility,
avoiding the cost of waiting time that happen when the
flow stops.
⚫ As stock sometimes provides safety to protect production,
improving customer service, allowing more economic
batches, etc.

15. Auxiliary Services
⚫ Auxiliary Services Support the main production activities
at the plant:
⚫ Related to labor: Accessibility paths, fire protection
installations, supervision, safety, etc.
⚫ Related to material: quality control.
⚫ Related to machinery: maintenance and electrical and
water lines.

16. Future changes
⚫ One of the main objectives of plant layout is flexibility.
It’s important to forecast the future changes to avoid
having an inefficient plant layout in a short term.
⚫ Possible future extensions of the facility must be taken
into account, as well as the feasibility of production during
re-layout.

17. The building
⚫ If it has been already selected, its characteristics will be a
constraint at the moment of designing the layout, which is
different if the building has to be built.

18. ADVANTAGES OF PERFECT
PLANT LAYOUT

19. 1.Economies in Handling
Nearly 30% to 40% of the manufacturing cost is accounted for, by
materials handling. Every effort should, therefore, be made to cut
down on this cost.
Long distance movements should be avoided and specific handling
operations must be eliminated.
A cynic may say that the cheapest way to handle materials is not to
handle them at all. But, in a factory, materials have to be handled; and
therefore, it all depends on the layout.

20. 2.Effective Use of Available Area
⚫ Every inch of the plant area is valuable, especially in urban areas.
⚫ Efforts should therefore be made to make use of the available area by
planning the layout properly.
⚫ Some steps for achieving this end are: location of equipment and services
in order that they may perform multiple functions; development of
up-to-date work areas and operator job assignments for a full utilization of
the labor force.

21. 3.Minimization of Production
Delays
⚫ Repeat orders and new customers will be the result of
prompt execution of orders. Every management should try
to keep to the delivery schedules.

22. 4.Improved Quality Control
⚫ Timely execution of orders will be meaningful when the
quality of the output is not below expectations. To ensure
quality, inspection should be conducted at different stages
of manufacture. An ideal layout provides for inspection to
ensure better quality control.

23. 5.Minimum Equipment Investment
⚫ Investment on equipment can be minimized by planned
machine balance and location, minimum handling
distances, by the installation of general purpose machines
and by planned machine loading. A good plant layout
provides all these advantages.

24. 6.Avoidance of Bottlenecks
⚫ Bottlenecks refer to any place in a production process where
materials tend to pile up or are produced at a speed, less rapid
than the previous or subsequent operations.
⚫ Bottlenecks are caused by inadequate machine capacity,
inadequate storage space or low speed on part of the operators.
⚫ The results of bottlenecks are delays in productions schedules,
congestion, accidents and wastage of floor area. All these may
be overcome with an efficient layout.

25. 7.Better Production Control
⚫ Production Control is concerned with the production of
the product of the right type, at the right time and at a
reasonable cost.
⚫ A good plant layout is a requisite for good production
control and provides the production control officers with a
systematic basis upon which to build organization and
procedures.

26. 8.Better Supervision
⚫ A good plant layout ensures better supervision in two
ways:
⚫ 1.Determining the number of workers to be handled by a
supervisor and
2.Enabling the supervisor to get a full view of the entire
plant at one glance.
⚫ A good plant layout is, therefore, the first step to good
supervision.

27. 9.Improved Utilization of Labor
⚫ Labor is paid for every hour it spends in the factory. The
efficiency of a management lies in utilizing the time for
productive purpose.
⚫ A good plant layout is one of the factors in effective
utilization of labor.
⚫ It makes possible individual operations, the process and flow
of materials handling in such a way that the time of each
worker is effectively spent on productive operations.

28. 10.Improved Employee Morale
⚫ Employee morale is achieved when workers are cheerful and
confident. This state of mental condition is vital to the success
of any organization.
⚫ Morale depends on:
⚫ (a)Better working condition;
(b)Better employee facilities;
(c)Reduced number of accidents;
(d)Increased earnings.
⚫ Plant layout has a bearing on all these.

29. 11.Avoidance of Unnecessary and
Costly Changes
⚫ A planned layout avoids frequent changes which are
difficult and costly. The incorporation of flexibility
elements in the layout would help in the avoidance of
revisions.

30. TYPES OF LAYOUT:
There are mainly four types of plant layout:
(a) Product or line layout
(b) Process or functional layout
(c) Fixed position or location layout
(d) Combined or group layout

31. PRODUCT OR LINE LAYOUT:
⚫ In this type of layout the machines and equipments are arranged in
one line depending upon the sequence of operations required for the
product.
⚫ It is also called as line layout. The material moves to another
machine sequentially without any backtracking or deviation i.e. the
output of one machine becomes input of the next machine. It
requires a very little material handling. It is used for mass production
of standardized products.

32. PRODUCT OR LINE
LAYOUT

33. Advantages of Product layout:
1.Low cost of material handling, due to straight and short route
and absence of backtracking
2. Smooth and continuous operations Continuous flow of work
3.Lesser inventory and work in progress
4.Optimum use of floor space
5.Simple and effective inspection of work and simplified
production control
6. Lower manufacturing cost per unit
Disadvantages of Product layout:
1.Higher initial capital investment in special purpose machine .
2.High overhead charges
3.Breakdown of one machine will disturb the production process.
4.Lesser flexibility of physical resources.

34. PROCESS LAYOUT
In this type of layout the machines of a similar type are
arranged together at one place. This type of layout is used
for batch production. It is preferred when the product is
not standardized and the quantity produced is very small.

35. Advantages of Process layout:
⚫ Lower initial capital investment is required.
⚫ There is high degree of machine utilization, as a machine is not
blocked for a single product
⚫ The overhead costs are relatively low
⚫ Breakdown of one machine does not disturb the production
process.
⚫ Supervision can be more effective and specialized.
⚫ Greater flexibility of resources.
Disadvantages of Process layout:
⚫ Material handling costs are high due to backtracking
⚫ More skilled labour is required resulting in higher cost.
⚫ Work in progress inventory is high needing greater storage
space
⚫ More frequent inspection is needed which results in costly
supervision

36. COMBINED LAYOUT
A combination of process & product layout is known as
combined layout.
Manufacturing concerns where several products are
produced in repeated numbers with no likelihood of
continuous production, combined layout is followed

37. FIXED POSITION OR LOCATION
LAYOUT:
⚫ Fixed position layout involves the movement of
manpower and machines to the product which remains
stationary.
⚫ The movement of men and machines is advisable as the
cost of moving them would be lesser.
⚫ This type of layout is preferred where the size of the job
is bulky and heavy. Example of such type of layout is
ships, boilers, generators, wagon building, aircraft
manufacturing, etc.

40. ⚫ Advantages of Fixed position layout:
⚫ The investment on layout is very small.
⚫ The layout is flexible as change in job design and operation sequence
can be easily incorporated.
⚫ Adjustments can be made to meet shortage of materials or absence of
workers by changing the sequence of operations.
Disadvantages of Fixed position layout:
⚫ As the production period being very long so the capital investment is
very high.
⚫ Very large space is required for storage of material and equipment
near
the product.
⚫ As several operations are often carried out simultaneously so there is
possibility of confusion and conflicts among different workgroups.