Plant Design: Layout procedure, study of some approaches (Immer, Nadler, Muther, Apple James, and Reed’s approach), systematic layout planning, the activity relationship chart, Constructing the activity relationship chart, Activity relationship diagram.

1. Module : 2
Plant
Design
Rashmi S
Dept of IE&M
JSS Academy of Technical Education,
Bengaluru

2. Contents
Plant Design:
 Layout procedure
 study of some approaches (Immer, Nadler,
Muther, Apple James and Reed’s approach)
 systematic layout planning
 the activity relationship chart
 Constructing the activity relationship chart
 Activity relationship diagram
October 5, 2020
Rashmi S, Dept. of IEM, JSSATE-B
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3. Design Procedure
Typically, design problems do not have well-defined, unique,
optimum solutions. We are interested in obtaining a satisfactory
solution.
General Procedure for Solving Engineering Design Problems
1. Formulate the problem.
2. Analyze the problem.
3. Search for alternative solutions.
4. Evaluate the design alternatives.
5. Select the preferred design.
6. Implement the design.
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Rashmi S, Dept. of IEM, JSSATE-B

4. Application of the Engineering Design Process to Facility Planning
1. Define (or redefine) the objective of the facility: Specify quantitatively the
products to be produced or service to be provided.
2. Specify the primary and support activities to be performed in accomplishing
the objective: Requirements for primary activities include operations,
equipment, personnel, and material flows.
3. Determine the interrelationships among all activities: Both qualitative and
quantitative relationships should be defined.
4. Determine the space requirements for all activities: These are determined
considering the equipment, materials, and personnel requirements.
5. Generate alternative facility plans: Including alternative facility locations and
alternative designs for the facility.
6. Evaluate alternative facility plans: Determine the important factors
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Rashmi S, Dept. of IEM, JSSATE-B

5. Contd…
7. Select a facility plan: Cost may not be the only major consideration. Use
the information in step 6 to determine a plan (pairwise comparison is a good
ranking procedure).
8. Implement the facility plan: Considerable amount of planning must
precede the construction of a facility or the layout of an area.
9. Maintain and adapt the facility plan: The facility plan must be modified as
new requirements are placed, e.g., new energy saving measures, changes in
product design may require different flow pattern or handling equipment,
etc.
10. Redefine the objective of the facility: Similar to step 1. Changes in product
design and/or quantities may require changes into the layout plan.
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Rashmi S, Dept. of IEM, JSSATE-B

6. Facility Layout
A Layout problem may be to
• Determine the location for a new machine
• Develop a new layout for an existing production plant
• Develop a layout for a new production plant
A Layout problem may arises due to changes in the design of a product,
• Addition or deletion of a product
• Change in the demand of a product
• Changes in the design of the process
• Addition or deletion of a process
• Replacement of equipment
October 5, 2020
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Rashmi S, Dept. of IEM, JSSATE-B

7. Facility Layout
A Layout problem may be to
 Determine the location for a new machine,
 Develop a new layout for an existing production plant,
 Develop a layout for a new production plant,
A Layout problem may arises due to
 Changes in the design of a product,
 Addition or deletion of a product,
 Change in the demand of a product,
 Changes in the design of the process,
 Addition or deletion of a process,
 Replacement of equipment,
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Rashmi S, Dept. of IEM, JSSATE-B

8. Objectives of Facility Layout
• Minimize investment in equipment.
• Minimize production time.
• Minimize material handling cost.
• Maximize utilization of space.
• Maintain flexibility of arrangement and operation.
• Provide safety and comfort to employees.
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Rashmi S, Dept. of IEM, JSSATE-B

9. Product
Design
Production
Planning
Process
Design
Facility
Layout
Material
Handling
System
Design
Sequential Approach vs Integrated Approach
Sequential Approach :
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Rashmi S, Dept. of IEM, JSSATE-B

10. Sequential Approach vs Integrated Approach
Integrated
Approach :
Impressive results in
cost, quality,
productivity, sales,
customer satisfaction,
delivery time, inventory
levels, space +
handling requirements,
building size, etc.
Product
Design
Process
Design
Schedule
Design
Layout Design
+
Material
Handling System
Design
Concurrent Engineering
Terms of product,
process, scheduling
and facility design
planners work with
marketing, purchasing,
etc. Personnel address
the design process in
an integrated way.
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Rashmi S, Dept. of IEM, JSSATE-B

11. Traditional Facility Layout Procedures
• Naddler’s Ideal System Approach (1961)
• Immer’s Basic Steps (1950)
• Apple’s Plant Layout Procedure (1977)
• Reed’s Plant Layout Procedure (1961)
• Muther’s Systematic Layout Planning (1961)
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Rashmi S, Dept. of IEM, JSSATE-B

12. Naddler’s Ideal System Approach
The ideal system approach is based on the
following hierarchical approach toward
design:
1. Aim for the “theoretical ideal
system.”
2. Conceptualize the “ultimate ideal
system.”
3. Design the “technologically
workable ideal system.”
4. Install the “recommended system.”
Theoretical ideal system
Ultimate ideal system
Technologically workable
system
Recommended
system
Present system
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Rashmi S, Dept. of IEM, JSSATE-B

13. Immer’s Basic Steps
Immer described the analysis of a layout problem to be composed of three
simple steps, which can be applied to any type of layout problem.
The steps are:
1. Put the problem on the paper.
2. Show lines of flow.
3. Convert flow lines to machine lines.
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Rashmi S, Dept. of IEM, JSSATE-B

14. Apple’s Plant Layout Procedure
Apple recommended that the following detailed sequence of steps be used in
designing a plant layout.
1. Procure the basic data. 11. Determine storage requirements
2. Analyze the basic data. 12. Plan service and auxiliary activities.
3. Design the productive process. 13. Determine space requirements.
4. Plan the material flow pattern. 14. Allocate activities to total space.
5. Consider the general material handling plan. 15. Consider building type
6. Calculate equipment requirements. 16. Consider master layouts.
7. Plan individual work stations. 17. Evaluate, adjust and check the layout.
8. Select specific material handling equipment. 18. Obtain approval.
9. Coordinate groups of related operations. 19. Install the layout.
10. Design activity relationships. 20. Follow up on implementation of layout.
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Rashmi S, Dept. of IEM, JSSATE-B

15. Reed’s Plant Layout Procedure
In “planning for and preparing the layout,” Reed recommended that the
following steps be taken in his “systematic plan of attach”:
1. Analyze the product to be produced.
2. Determine the process required to manufacture the product.
3. Prepare layout planning charts.
4. Determine work stations.
5. Analyze storage area requirements.
6. Establish minimum aisle widths.
7. Establish office requirements.
8. Consider personnel facilities and services.
9. Survey plant services.
10. Provide for future expansion.
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Rashmi S, Dept. of IEM, JSSATE-B

16. Systematic Layout Planning Procedure (Muther 1961)
Systematic layout planning is an organized way to conduct layout
planning, it consists of a framework of phases, a pattern of procedures and
a set of conventions for identifying , rating and visualizing the elements
and areas involved in a plan.
SLP is a framework of four planning phases:
•Analysis
•Search
•Evaluation
•Selection
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Rashmi S, Dept. of IEM, JSSATE-B

17. October 5, 2020
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Rashmi
S,
Dept.
of
IEM,
JSSATE-B

18. Each layout rests on three fundamentals
 RELATIONSHIPS –
Degree of closeness desired among things
 SPACE –
The amount, kind, shape of configuration of the things to be
laid out
 ADJUSTMENTS –
Arrangement of things into a realistic best fit
These are the heart of any layout plan regardless of products,
processes or size.
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Rashmi S, Dept. of IEM, JSSATE-B

19. There are 20 steps in SLP Pattern:
 Procure data
 Analyze data
 Design production process
 Design material flow pattern
 Select/ design material handling plan
 Calculate requirement of equipments
 Plan work areas
 Select material handling equipments
 Plan group of related operations
 Design activity relationship
• Calculate space requirements
• Plan service activities
• Calculate total space requirements
• Allocate activities to space
• Consider building types
• Construct model layout
• Evaluate, adjust, and check layout
• Justify
• Install
• Nurture layout
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Rashmi S, Dept. of IEM, JSSATE-B

20. The activity relationship diagram also called the Affinity analysis diagram in the facility layout.
“An activity relationship chart (ARC) is a tabular means of displaying the closeness rating among
all activities or departments.
In general, there are 6 closeness rating are used” This rating is named as “A, E, I, O, U, And X”
This rating has a specific meaning attached to it.
Activity Relationship diagram
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Rashmi S, Dept. of IEM, JSSATE-B

21. Rating symbols
 Following is the rating symbols with the meaning
 A Is Absolutely necessary
 E is especially Important
 I am Important
 O is Ordinary
 U is unimportant
 X should be i
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Rashmi S, Dept. of IEM, JSSATE-B

22. October 5, 2020
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Rashmi S, Dept. of IEM, JSSATE-B

23. October 5, 2020
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Rashmi S, Dept. of IEM, JSSATE-B

24. Reasons codes:
Reasons codes are used for finding the volume or importance of a
relationship to the rating symbol. Following are some of the reasons
codes;
 Same table
 Flow of materials
 Service
 Inventory control
 Volume
 Flow of parts
 Cleanliness
 Communications
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Rashmi S, Dept. of IEM, JSSATE-B

25. Rule of thumb:
 These rules of thumb are used for assigning code to any activity
relationship diagram, you shouldn’t violate these rules otherwise the
facility layout will not be that effective.
 Used few “A” And “X” relationships <5%
 No more than 10% of “E” Relationships in the activity relationship
diagram.
 “I” should be used less than 15%
 No more than 20% should be “O” relationships.
 About 50% of the relationships should be “U”
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Rashmi S, Dept. of IEM, JSSATE-B

26. Contd…
 The basic purpose of the activity relationship diagram is to ensure that
the facility you are designing has the minimal distance between the
two facilities that are important for each other.
 One activity can’t be performing if the previous activity has not been
done.
 Like, first you do welding then painting, what if you send a piece of
metal to paint first and then to the welding? So, the basic purpose is
to place facilities closer and to reduce cycle time.
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Rashmi S, Dept. of IEM, JSSATE-B

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References
 Facilities Planning, Third Edition By JAMES A. Tompkins
 Plant Layout And Materials Handling By James M. Apple
 Facility Planning & Layout Design by Chandrashekar
Hiregoudar, B Raghavendra Reddy