Plant Layout
Facility Layout Planning
Product Layout
Process Layout
Fixed position layout
Cellular layout
Factors affecting location plant
Merit and Demerits
Plant Layout Principles
An Assembly line
U shaped assembly line
Assembly line balancing
Cellular layout and Group Technology
This was a presentation done team-wise in Manipal as part of our MBA assignments. The subject name was Operations Management and the presentation topics were different types of layouts. Our team got the topic Process Layout.
Plant Layout
Facility Layout Planning
Product Layout
Process Layout
Fixed position layout
Cellular layout
Factors affecting location plant
Merit and Demerits
Plant Layout Principles
An Assembly line
U shaped assembly line
Assembly line balancing
Cellular layout and Group Technology
This was a presentation done team-wise in Manipal as part of our MBA assignments. The subject name was Operations Management and the presentation topics were different types of layouts. Our team got the topic Process Layout.
Production Management
Types of plant Layout like production or line layout, Process layout, Fixed position or Location layout and combined layout.Along with its importance with example.
The module deals with overview of Production and Operation Management. It highlights the Definition, characteristics and objective of POM, also it focus on Production System.
method study is the branch of an industrial Engg. specially the sub branch of mechanical engg.
those who r the college students of engg. specially mechamnical 8mechanical can download this .it is very helpful for presentation purpose
Product Vs Service
Concept of Production
Scope of POM
Transformation Process
Product Design & Product Process
History of POM
Issues in POM
Product Design / Process
Facility Layout
Introduction
Layout planning is determining the best physical arrangement of resources within a facility.
It may be defined as a technique of locating machines, processes and plant services within the factory so as to achieve the right quantity and quality of output at the lowest possible cost of manufacturing.
Objective of a good Layout
Provide enough production capacity.
Reduce material handling costs.
Reduce congestion that impedes the movement of people or material.
Reduce hazards to personnel.
Increase employee morale.
Reduce accidents.
Utilize available space effectively & efficiently.
Different layouts for various manufacturing systems
3 three basic types of layout:
Process layout
Product layout
Fixed-Position layout
3 hybrid layouts:
Cellular Manufacturing
Flexible Manufacturing Systems
Mixed-model Assembly Lines
Method Study, Objective of method study, Pre-requisites for method study, Steps/basic procedure in method study, different method recording techniques,
Stores management is part of the overall function of materials management. In order, therefore, to understand the function of the former it is desirable to have a clear understanding of what materials management stands for.
According to Alford and Beatty “storekeeping is that aspect of material control concerned with the physical storage of goods.” In other words, storekeeping relates to art of preserving raw materials, work-in-progress and finished goods in the stores.
Production Management
Types of plant Layout like production or line layout, Process layout, Fixed position or Location layout and combined layout.Along with its importance with example.
The module deals with overview of Production and Operation Management. It highlights the Definition, characteristics and objective of POM, also it focus on Production System.
method study is the branch of an industrial Engg. specially the sub branch of mechanical engg.
those who r the college students of engg. specially mechamnical 8mechanical can download this .it is very helpful for presentation purpose
Product Vs Service
Concept of Production
Scope of POM
Transformation Process
Product Design & Product Process
History of POM
Issues in POM
Product Design / Process
Facility Layout
Introduction
Layout planning is determining the best physical arrangement of resources within a facility.
It may be defined as a technique of locating machines, processes and plant services within the factory so as to achieve the right quantity and quality of output at the lowest possible cost of manufacturing.
Objective of a good Layout
Provide enough production capacity.
Reduce material handling costs.
Reduce congestion that impedes the movement of people or material.
Reduce hazards to personnel.
Increase employee morale.
Reduce accidents.
Utilize available space effectively & efficiently.
Different layouts for various manufacturing systems
3 three basic types of layout:
Process layout
Product layout
Fixed-Position layout
3 hybrid layouts:
Cellular Manufacturing
Flexible Manufacturing Systems
Mixed-model Assembly Lines
Method Study, Objective of method study, Pre-requisites for method study, Steps/basic procedure in method study, different method recording techniques,
Stores management is part of the overall function of materials management. In order, therefore, to understand the function of the former it is desirable to have a clear understanding of what materials management stands for.
According to Alford and Beatty “storekeeping is that aspect of material control concerned with the physical storage of goods.” In other words, storekeeping relates to art of preserving raw materials, work-in-progress and finished goods in the stores.
Layout planning is deciding on the best physical arrangement of all resources that consume space within a facility.
Decisions about the arrangement of resources in a business are not made only when a new facility is being designed; they are made any time there is a change in the arrangement of resources, such as a new worker being added, a machine being moved, or a change in procedure being implemented.
Layout planning is performed any time there is an expansion in the facility or a space reduction.
This is best for plant layout required for any firm and industry where material handling is one of founding pillar of plant layout
Here each type is explained in simple and effective manner with principles.
Material handling is also listed with principles and types of material handling
Similar to Different types of Production Layout (20)
manner, disposition, feeling, position, etc., with regard to a person or thing; tendency or orientation, especially of the mind: a negative attitude; group attitudes
”A systematic approach to identifying and eliminating waste (non-value-added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection.”
The main benefits of lean manufacturing are lower production costs; increased output and shorter production lead times, higher flexibility.
Work measurement: Job design determines the content of a job, and method analysis determines how a job is to be performed. Work measurement is concerned with determining the length of time it should take to complete the job. Job times are vital inputs for workplace planning, estimating labor costs, scheduling, budgeting and designing incentive systems.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
6th International Conference on Machine Learning & Applications (CMLA 2024)ClaraZara1
6th International Conference on Machine Learning & Applications (CMLA 2024) will provide an excellent international forum for sharing knowledge and results in theory, methodology and applications of on Machine Learning & Applications.
CW RADAR, FMCW RADAR, FMCW ALTIMETER, AND THEIR PARAMETERSveerababupersonal22
It consists of cw radar and fmcw radar ,range measurement,if amplifier and fmcw altimeterThe CW radar operates using continuous wave transmission, while the FMCW radar employs frequency-modulated continuous wave technology. Range measurement is a crucial aspect of radar systems, providing information about the distance to a target. The IF amplifier plays a key role in signal processing, amplifying intermediate frequency signals for further analysis. The FMCW altimeter utilizes frequency-modulated continuous wave technology to accurately measure altitude above a reference point.
Immunizing Image Classifiers Against Localized Adversary Attacksgerogepatton
This paper addresses the vulnerability of deep learning models, particularly convolutional neural networks
(CNN)s, to adversarial attacks and presents a proactive training technique designed to counter them. We
introduce a novel volumization algorithm, which transforms 2D images into 3D volumetric representations.
When combined with 3D convolution and deep curriculum learning optimization (CLO), itsignificantly improves
the immunity of models against localized universal attacks by up to 40%. We evaluate our proposed approach
using contemporary CNN architectures and the modified Canadian Institute for Advanced Research (CIFAR-10
and CIFAR-100) and ImageNet Large Scale Visual Recognition Challenge (ILSVRC12) datasets, showcasing
accuracy improvements over previous techniques. The results indicate that the combination of the volumetric
input and curriculum learning holds significant promise for mitigating adversarial attacks without necessitating
adversary training.
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
1. Four Main Types of Plant Layout
By Smriti Chand Plant Layout
Advertisements:
Keeping in view the type of industry and volume of production, the type of layout to be
selected is to be decided from the following:
1. Product or Line Layout
2. Process or Functional Layout.
3. Fixed Position Layout.
4. Combination type of Layout.
1. Product or Line Layout:
If all the processing equipment and machines are arranged according to the sequence of
operations of the product, the layout is called product type of layout. In this type of layout, only
one product of one type of products is produced in an operating area. This product must be
standardized and produced in large quantities in order to justify the product layout.
The raw material is supplied at one end of the line and goes from one operation to the next quite
rapidly with a minimum work in process, storage and material handling. Fig. 8.3 shows product
layout for two types of products A and B.
Advantages offered by Product Layout:
(i) Lowers total material handling cost.
2. (ii) There is less work in processes.
(iii) Better utilization of men and machines,
(iv) Less floor area is occupied by material in transit and for temporary storages.
(v) Greater simplicity of production control.
(vi) Total production time is also minimized.
Limitations of Product Layout:
(i) No flexibility which is generally required is obtained in this layout.
(ii) The manufacturing cost increases with a fall in volume of production.
(iii) If one or two lines are running light, there is a considerable machine idleness.
(iv) A single machine break down may shut down the whole production line.
(v) Specialized and strict supervision is essential.
2. Process or Functional Layout:
The process layout is particularly useful where low volume of production is needed. If the
products are not standardized, the process layout is more low desirable, because it has creator
process flexibility than other. In this type of layout, the machines and not arranged according to
the sequence of operations but are arranged according to the nature or type of the operations.
This layout is commonly suitable for non repetitive jobs.
Same type of operation facilities are grouped together such as lathes will be placed at one place,
all the drill machines are at another place and so on. See Fig. 8.4 for process layout. Therefore,
the process carried out in that area is according to the machine available in that area.
3. Advantages of Process Layout:
(i) There will be less duplication of machines. Thus, total investment in equipment purchase will
be reduced.
(ii) It offers better and more efficient supervision through specialization at various levels.
(iii) There is a greater flexibility in equipment and man power thus load distribution is easily
controlled.
(iv) Better utilization of equipment available is possible.
(v) Break down of equipment can be easily handled by transferring work to another
machine/work station.
(vi) There will be better control of complicated or precision processes, especially where much
inspection is required.
Limitations of Process Layout:
(i) There are long material flow lines and hence the expensive handling is required.
(ii) Total production cycle time is more owing to long distances and waiting at various points.
(iii) Since more work is in queue and waiting for further operation hence bottle necks occur.
(iv) Generally, more floor area is required.
(v) Since work does not flow through definite lines, counting and scheduling is more tedious.
(vi) Specialization creates monotony and there will be difficult for the laid workers to find job in
other industries.
3. Fixed Position Layout:
This type of layout is the least important for today’s manufacturing industries. In this type of
layout the major component remain in a fixed location, other materials, parts, tools, machinery,
man power and other supporting equipment’s are brought to this location.
The major component or body of the product remain in a fixed position because it is too heavy or
too big and as such it is economical and convenient to bring the necessary tools and equipment’s
to work place along with the man power. This type of layout is used in the manufacture of
boilers, hydraulic and steam turbines and ships etc.
Advantages Offered by Fixed Position Layout:
4. (i) Material movement is reduced
(ii) Capital investment is minimized.
(iii) The task is usually done by gang of operators, hence continuity of operations is ensured
(iv) Production centers are independent of each other. Hence, effective planning and loading can
be made. Thus total production cost will be reduced.
(v) It offers greater flexibility and allows change in product design, product mix and production
volume.
Limitations of Fixed Position Layout:
(i) Highly skilled man power is required.
(ii) Movement of machines equipment’s to production centre may be time consuming.
(iii) Complicated fixtures may be required for positioning of jobs and tools. This may increase
the cost of production.
4. Combination Type of Layout:
Now a days in pure state any one form of layouts discussed above is rarely found. Therefore,
generally the layouts used in industries are the compromise of the above mentioned layouts.
Every layout has got certain advantages and limitations. Therefore, industries would to like use
any type of layout as such.
Flexibility is a very important factory, so layout should be such which can be molded according
to the requirements of industry, without much investment. If the good features of all types of
layouts are connected, a compromise solution can be obtained which will be more economical
and flexible.
Important Types of of Plant Layout (with
advantages and disadvantages)
By Smriti Chand Industries
Advertisements:
5. Some of the important types of plant layout are: A. Product or line layout, B. Process or
functional layout, C. Layout by stationary material!
(A) Product or Line Layout:
Product or Line Layout is the arrangement of machines in a line (not always straight) or a
sequence in which they would be used in the process of manufacture of the product. This type of
layout is most appropriate in case of continuous type of industries where raw materials is fed at
one end and taken out as finished product at the other end. For each type of product a separate
line of production will have to be maintained.
This type of layout is most suitable in case of metal extraction industry, chemical industry, soap
manufacturing industry, sugar industry and electric industry. It should be noted that this method
is most suitable in case of mass production industries.
Following diagram clearly explains product layout:
In the above diagram there are two products A and B for which separate lines of production have
been maintained. Kimbaii and Kimbaii jr. have given a simple diagram to explain this type of
layout in the book “Principles of Industrial organisation”.
According to Shubin and Madeheim, product layout is suitable where:
(i) large quantity of standardized products are produced;
(ii) the standardized products are to be processed repetitively or continuously on the given
production facilities;
(iii) there must be sufficient volume of goods processed to keep the production line actively
occupied,
(iv) there should be greater interchangeability of the parts; and (v) to maintain good equipment
balance each work station must employ machines or equipment’s of approximately equal
capacities. Similarly to maintain good labour balance, each work station must require an equal
amount of work to be performed.
Advantages of Product Layout:
(1) Removal of obstacles in production:
Product layout ensures unrestricted and continuous production thereby minimising bottlenecks in
the process of production, this is because work stoppages are minimum under this method.
(2) Economies in material handling:
6. Under this method there are direct channels for the flow of materials requiring lesser time which
considerably eliminate back-tracking of materials. On account of this, cost of material handling
is considerably reduced. This is greatly helpful in achieving desired quality of the end product.
(3) Lesser manufacturing time:
Under this method (as already pointed), backward and forward handling of materials is not
involved, it leads to considerable saving in manufacturing time.
(4) Lesser work in progress:
On account of continuous uninterrupted mass production, there is lesser accumulation of work in
progress or semi-finished goods.
(5) Proper use of floor space:
This method facilitates proper and optimum use of available floor space. This is due to non-
accumulation of work in progress and overstocking of raw materials.
(6) Economy in inspection:
Inspection can be easily and conveniently undertaken under this method and any defect in
production operations can be easily located in production operations. The need for inspection
under this method is much less and can be confined at some crucial points only.
(7) Lesser manufacturing cost:
On account of lesser material handling, inspection costs and fullest utilisation of available space,
production costs are considerably reduced under this method.
(8) Lesser labour costs:
Due to specialisation and simplification of operations and use of automatic simple machines,
employment of unskilled and semi-skilled workers can carry on the work. The workers are
required to carry routine tasks under this method. This leads to lesser labour costs.
(9) Introduction of effective production control:
Effective production control on account of simple operation of this method can be employed
successfully. Production control refers to the adoption of measures to achieve production
planning.
Disadvantages of Product Layout:
(1) Lesser flexibility:
7. As work is carried in sequence and process arranged in a line, it is very difficult to make
adjustments in production of operations. Sometimes, certain changes under this method become
very costly and impractical. On account of this drawback, this method is not suitable in the
production of goods which are subject to quick style and design changes.
(2) Large investment:
Under this method, machines are not arranged in accordance with functions as such similar type
of machines and equipment is fixed at various lines of production. This leads to unavoidable
machinery duplication resulting in idle capacity and large capital investment on the part of the
entrepreneur.
(3) Higher overhead charges:
Higher capital investment leads to higher overheads (fixed overheads) under this method. This
leads to excessive financial burden.
(4) Interruption due to breakdown:
If one machine in the sequence stops on account of breakdown, other machines cannot operate
and work will be stopped. The work stoppage may also take place on account of irregular supply
of material, poor production scheduling and employee absenteeism etc.
(5) Difficulties in expanding production:
Production cannot be expanded beyond certain limits under this method.
(6) Lack of specialisation in supervision:
Supervision of different production jobs becomes difficult under this method as there is absence
of specialised supervision as the work is carried on in one line having different processes and not
on the basis of different departments for different specialised jobs. Under this method a
supervisor is supposed to have detailed knowledge of all the machines and processes which leads
to absence of specialisation in the process of supervision.
(7) Under-utilisation of machines:
As has already been pointed out, separate set of one type of machines is fixed at different lines of
production. Usually, these machines are not properly and fully utilised and there remains idle
capacity in the form of under utilised equipment.
(B) Functional or Process Layout:
It is just the reverse of product layout. There is a functional division of work under this method.
For example, lathes are fixed in one department and welding activities are carried in another
8. department of the factory. The salient features of this type of layout are based on Frederick W.
Taylor’s concept of ‘functional organisation’.
This method is generally adopted for producing different varieties of unlike products. This is
particularly adopted tor job order industries like engineering, ship building and printing etc. The
following diagram shows that raw material travels through various process or departments from
lathes passing through mills, grinders, drills, welding, inspection, finishing, and assembly and to
finished product.
Advantages of Process Layout:
(1) Maximum utilisation of machines:
This method ensures fuller and effective utilisation of machines and consequently investment in
equipment and machines becomes economical.
(2) Greater flexibility:
Changes in the sequence of machines and operations can be made without much difficulty. This
is because the machines are arranged in different departments in accordance with the nature of
functions performed by them.
(3) Scope for expansion:
Production can be increased by installing additional machines without much difficulty.
(4) Specialisation:
As has already been pointed out that under this method, specialised machines are used for
performing different production operations. This leads to specialisation.
(5) Effective utilisation of workers:
Specialised workers are appointed to carry different type of work in different departments. This
leads to effective and efficient use of their talent and capabilities.
(6) More effective supervision:
As the machines are arranged on the basis of functions, performed by them, the specialised and
effective supervision is ensured by the specialised knowledge of supervisors. Each supervisor
can perform his task of supervision effectively as he has to supervise limited number machines
operating in his department.
(7) Lesser work stoppages:
9. Unlike the product method, if a machine fails, it does not lead to complete work stoppage and
production schedules are not seriously affected. Due to breakdown in one machine, the work can
be easily transferred to the other machines.
Disadvantages of Process Layout:
(1) Coverage of more floor area:
Under this method, more floor space is needed for the same quantum of work as compared to
product layout.
(2) Higher cost of material handling:
Material moves from one department to another under this method, leading to the higher cost of
material handling. The mechanical devices of material handling cannot be conveniently
employed under this method on account of functional division of work. Material has to be carried
by applying other methods from one department to another, resulting into higher cost of material
handling.
(3) Higher labour costs:
As there is functional division of work, specialised workers are to be appointed in different
departments for carrying specialised operations. The appointment of skilled worker leads to
higher labour costs.
(4) Longer production time:
Production takes longer time for completion under this method and this leads to higher
inventories of work-in-progress.
(5) Difficulties in production, planning and control:
Due to large variety of products and increased size of the plant, there are practical difficulties in
bringing about proper coordination among various areas (departments) and processes of
production. The process of production, planning and control becomes more complex and costly.
(6) Increased inspection costs:
Under this type of layout more supervisors are needed and work is to be checked after every
operation which makes the process of supervision costlier.
(C) Layout by Stationary Material:
This type of layout is undertaken for the manufacture of large parts and assemblies. In this case,
material remains fixed or stationary at one place, men and equipment are taken to the site of
10. material. This is suitable in case of ship building, locomotives and heavy machinery industries
etc.
Advantages:
(a) Economies in transformation:
As the work is carried at one place and material is not taken from one place to another, this leads
to savings in transformation costs.
(b) Different jobs with same layout:
Different projects can be undertaken with the help of same layout.
(c) Production in accordance with specifications:
The jobs can be performed in accordance with the specifications given by the customers.
(d) Scope for flexibility:
It provides maximum flexibility for various changes in production processes and designs of the
products.
Disadvantages:
(a) Immobility of material:
As material is fixed at one place, this leads to certain difficulties in arranging specialised
workers, machines and equipment for the job.
(b) Large investment:
This method is time consuming and costlier as compared to first two methods.
(c) Unsuitable for small products:
This method is not suitable for producing and assembling small products in large quantities. In
actual practice, it has been observed that a judicious combination of three types’ viz., product,
process and stationary material layout is undertaken by different organisations. This is done with
the view to enjoy the advantages of all the methods.