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FACILITY LAYOUT
“ESCORTS AGRI LTD.”
PRESENTED BY:
VISHAKHA
VANEET KUMAR
SHAILENDER SINGH
ANUJ CHAUDHARY
THEORETICAL FRAMEWORK
FACILITY LAYOUT:
The Facility Layout of an Operation is Concerned with the Physical
location of its Transforming Resources;
“Deciding where to put the
Facilities, Machines, Equipment and Staff in the
Operation”.
TYPES OF FACILITY LAYOUT’S :
1) Product Layout
2)Process Layout
3)Fixed Position Layout
4) Hybrid Layout
PRODUCT LAYOUT
: The Resources are placed to Follow Exactly the
Visitation Sequence Dictated by a Product .
Example:
If a Portion of a Manufacturing Operation Requires the
Sequence of Cutting, Sanding, and Painting; then the
Appropriate pieces of Equipment would be Arranged in
that same Sequence.
PROCESS LAYOUT
: Here, Similar Processes or Processes with Similar Needs
are Located Together Because:
i. It is Convenient to Group Them Together, or
ii. The Utilization of the Transforming Resource is
Improved
Example:
In a Machine Shop, which has Separate Departments for
Milling, Grinding, Drilling, and So on.
FIXED POSITION LAYOUT
: Here, The Item Being Worked On; Remains Stationary, and
Workers, Materials, and Equipment's are Moved about as
Needed.
Example:
They are Widely used in Farming, Firefighting, Road
Building, Remodeling and Repairs, etc.
In each Case, Compelling Reasons bring
Workers, Materials, and Equipment's to the PRODUCTS
Location instead of the Other way Round.
5
HYBRID LAYOUT
: Here, a Process Layout is Combined with a Product
Layout or in Some case with Fixed Position Layout .
Example:
• Hospitals use the Basic process
Arrangement, although Frequently Patient care
Involves More of a Fixed-Position Approach, in which
Nurses, Doctors, Medicines, and Special Equipment
are Brought to the Patient.
- Visited Escorts Agro Ltd.
(18/4, Mathura Road, Faridabad - 121007 (Haryana)
-The Escorts Group is an Indian
multinational engineering conglomerate that operates in the
sectors of agri-machinery, construction and material handling
equipment, railway equipment and auto components.
Headquartered in Faridabad, Haryana, the company was launched
in 1944 and has operations in more than 40 countries. Escorts
Group’s management team includes Rajan Nanda as the
Chairman and Managing Director and Nikhil Nanda as the
Managing Director.
PRACTICAL LINKAGE
Escorts AMG has Tractor manufacturing capacity of 98,940 trs /
annum which is the highest in Asia at one location. Its
manufacturing operations are divided in three plants as:
• Component Plant
• Tractor Assembly Plant
• Crankshaft & Hydraulic Plant
Component Plant consists of Machine shops in which all major
castings such as Engine blocks, Gear Box housings, Differential
housings are being machined along with Gears & Shafts.
Machine shop consists of State of the Art machines such as CNC
Horizontal Machining Centres, CNC Turning Centres and variety
of other precision machines, including Gear Hobbing and
Shaving machines, etc. It is important to note that all critical
components are machined in house.
• Tractor Assembly Plant is divided into two lines as Farmtrac Line and
the Powertrac Line. Farmtrac Line is a composite line that has
machining as well as assembly activities of Engine, Transmission &
Tractor whereas on Powertrac line only Assembly activities of
Engine, Transnmission & Tractor are being carried out. Tractor
Assembly Plant has State of the Art Paint Shop that has CED paint
shop facilities. Engine Shop has State of the Art testing facilities that
includes AVL make Eddy Current Dynamometers in Engine Test
House.
• Crankshaft & Hydraulic Plant is divided into two parts as Crankshaft
Line and Hydraulics Line. Crankshaft line consists of machine shop
where crankshafts of all Tractor models are being machined. It has
State of the Art machines such as Rotary Miller, Pin Grinder, Journal
Grinder, etc. Hydraulic line consists of Machining as well as
Assembly activities where critical parts of tractor hydraulics such as
Distributor, Hydraulic Cylinder, etc are being machined and
assembled. It has State of the Art Honing and other precision
machines.
The Jai Kisan Series comes in five new categories –
• ValueMaxx
• LoadMaxx
• AgMaxx
• InfraMaxx
• SuperMaxx.
While the VALUEMAXX is the variant for basic agricultural
purposes, the LOADMAXX and AGMAXX variants specialize in
haulage-based applications and specialized Agri-applications
respectively. The SUPERMAXX series is ideal for all types of
agriculture and non-farming purposes besides offering add-on
applications for dual needs whereas, the INFRAMXX variant would
specialize in infrastructure-based applications. The 'Jai Kisan Series is
currently available in the FARMTRAC line of Escorts tractors.
Block Diagramming
Gearbox Hydraulic
lift
Final
Assembly
Outsourci
ng
Painted
Engine
Excels
(Rear &
Front )
Parts
Painting
Parts
Manufact
uring
Assembly Line Balancing
• The company works an 12 hours per day for 6
days per week. The production line is operated
for only 12 hours per day. Given the
information in the table below, we determine
the possible efficiency if the line is designed
for about of 960 units per week.
Assembly Line Stages
• Engine Dropping
• Running Board Assy
• Rear & Front Axle
• Hydraulic lift Assy
• Clevis Rod Mounting & Brake Adjustment
• Hydraulic Pump Assy
• Fuel Tank
• Gear Box
• Steering Assy
• Filter & Stator Assy
• Driver Seat Assy
• Radiator Shell Assy
• Battery Panel
• Muffler & Grill
• Stickers & Inspection
Elements Performance Time(secs)
A 10
B 12
C 18
D 16
E 15
F 16
G 17
H 16
I 14
J 18
K 17
L 15
M 17
N 16
O 18
• Cycle Time = It’s taken as the maximum value
of the performance time.
*C.T.= 18
• Efficiency = Total performance time/(C.T. *
W.S.)
= 235/(18*15)
=87.03%
LEARNINGS
• We got to know that facility layout is an important
factor for any organization.
• It helps them to improve their efficiency by observing
the different stages.
• There is proper maintainence activities.
• Reduces the material handling and making the labour
work efficiently.
• Provides ease of supervision & control.
• Reduced no. of accidents.

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Facility layout optimization Escorts Agro Ltd

  • 1. FACILITY LAYOUT “ESCORTS AGRI LTD.” PRESENTED BY: VISHAKHA VANEET KUMAR SHAILENDER SINGH ANUJ CHAUDHARY
  • 2. THEORETICAL FRAMEWORK FACILITY LAYOUT: The Facility Layout of an Operation is Concerned with the Physical location of its Transforming Resources; “Deciding where to put the Facilities, Machines, Equipment and Staff in the Operation”. TYPES OF FACILITY LAYOUT’S : 1) Product Layout 2)Process Layout 3)Fixed Position Layout 4) Hybrid Layout
  • 3. PRODUCT LAYOUT : The Resources are placed to Follow Exactly the Visitation Sequence Dictated by a Product . Example: If a Portion of a Manufacturing Operation Requires the Sequence of Cutting, Sanding, and Painting; then the Appropriate pieces of Equipment would be Arranged in that same Sequence.
  • 4. PROCESS LAYOUT : Here, Similar Processes or Processes with Similar Needs are Located Together Because: i. It is Convenient to Group Them Together, or ii. The Utilization of the Transforming Resource is Improved Example: In a Machine Shop, which has Separate Departments for Milling, Grinding, Drilling, and So on.
  • 5. FIXED POSITION LAYOUT : Here, The Item Being Worked On; Remains Stationary, and Workers, Materials, and Equipment's are Moved about as Needed. Example: They are Widely used in Farming, Firefighting, Road Building, Remodeling and Repairs, etc. In each Case, Compelling Reasons bring Workers, Materials, and Equipment's to the PRODUCTS Location instead of the Other way Round. 5
  • 6. HYBRID LAYOUT : Here, a Process Layout is Combined with a Product Layout or in Some case with Fixed Position Layout . Example: • Hospitals use the Basic process Arrangement, although Frequently Patient care Involves More of a Fixed-Position Approach, in which Nurses, Doctors, Medicines, and Special Equipment are Brought to the Patient.
  • 7. - Visited Escorts Agro Ltd. (18/4, Mathura Road, Faridabad - 121007 (Haryana) -The Escorts Group is an Indian multinational engineering conglomerate that operates in the sectors of agri-machinery, construction and material handling equipment, railway equipment and auto components. Headquartered in Faridabad, Haryana, the company was launched in 1944 and has operations in more than 40 countries. Escorts Group’s management team includes Rajan Nanda as the Chairman and Managing Director and Nikhil Nanda as the Managing Director. PRACTICAL LINKAGE
  • 8. Escorts AMG has Tractor manufacturing capacity of 98,940 trs / annum which is the highest in Asia at one location. Its manufacturing operations are divided in three plants as: • Component Plant • Tractor Assembly Plant • Crankshaft & Hydraulic Plant Component Plant consists of Machine shops in which all major castings such as Engine blocks, Gear Box housings, Differential housings are being machined along with Gears & Shafts. Machine shop consists of State of the Art machines such as CNC Horizontal Machining Centres, CNC Turning Centres and variety of other precision machines, including Gear Hobbing and Shaving machines, etc. It is important to note that all critical components are machined in house.
  • 9. • Tractor Assembly Plant is divided into two lines as Farmtrac Line and the Powertrac Line. Farmtrac Line is a composite line that has machining as well as assembly activities of Engine, Transmission & Tractor whereas on Powertrac line only Assembly activities of Engine, Transnmission & Tractor are being carried out. Tractor Assembly Plant has State of the Art Paint Shop that has CED paint shop facilities. Engine Shop has State of the Art testing facilities that includes AVL make Eddy Current Dynamometers in Engine Test House. • Crankshaft & Hydraulic Plant is divided into two parts as Crankshaft Line and Hydraulics Line. Crankshaft line consists of machine shop where crankshafts of all Tractor models are being machined. It has State of the Art machines such as Rotary Miller, Pin Grinder, Journal Grinder, etc. Hydraulic line consists of Machining as well as Assembly activities where critical parts of tractor hydraulics such as Distributor, Hydraulic Cylinder, etc are being machined and assembled. It has State of the Art Honing and other precision machines.
  • 10. The Jai Kisan Series comes in five new categories – • ValueMaxx • LoadMaxx • AgMaxx • InfraMaxx • SuperMaxx. While the VALUEMAXX is the variant for basic agricultural purposes, the LOADMAXX and AGMAXX variants specialize in haulage-based applications and specialized Agri-applications respectively. The SUPERMAXX series is ideal for all types of agriculture and non-farming purposes besides offering add-on applications for dual needs whereas, the INFRAMXX variant would specialize in infrastructure-based applications. The 'Jai Kisan Series is currently available in the FARMTRAC line of Escorts tractors.
  • 12. Assembly Line Balancing • The company works an 12 hours per day for 6 days per week. The production line is operated for only 12 hours per day. Given the information in the table below, we determine the possible efficiency if the line is designed for about of 960 units per week.
  • 13. Assembly Line Stages • Engine Dropping • Running Board Assy • Rear & Front Axle • Hydraulic lift Assy • Clevis Rod Mounting & Brake Adjustment • Hydraulic Pump Assy • Fuel Tank • Gear Box • Steering Assy • Filter & Stator Assy • Driver Seat Assy • Radiator Shell Assy • Battery Panel • Muffler & Grill • Stickers & Inspection
  • 14. Elements Performance Time(secs) A 10 B 12 C 18 D 16 E 15 F 16 G 17 H 16 I 14 J 18 K 17 L 15 M 17 N 16 O 18
  • 15. • Cycle Time = It’s taken as the maximum value of the performance time. *C.T.= 18 • Efficiency = Total performance time/(C.T. * W.S.) = 235/(18*15) =87.03%
  • 16. LEARNINGS • We got to know that facility layout is an important factor for any organization. • It helps them to improve their efficiency by observing the different stages. • There is proper maintainence activities. • Reduces the material handling and making the labour work efficiently. • Provides ease of supervision & control. • Reduced no. of accidents.