Principles of Plant layout
Types of Plant layout
Process layout
Product layout
Cellular Manufacturing layout
fixed Position layout
Hybrid Layout
and their Advantages & disadvantages
Principles of Plant layout
Types of Plant layout
Process layout
Product layout
Cellular Manufacturing layout
fixed Position layout
Hybrid Layout
and their Advantages & disadvantages
Production Planning and Control
Objective of PPC
Classification/Functions of PPC
Levels of PPC
Factors determining Production Planning Procedures
Production Planning System
Factors Determining PC procedures
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
Production Planning and Control
Objective of PPC
Classification/Functions of PPC
Levels of PPC
Factors determining Production Planning Procedures
Production Planning System
Factors Determining PC procedures
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
Addis Ababa City Administration Technical, Vocational, Education And Training...Haileyesus Wondwossen
ย
Addis Ababa City Administration
Technical, Vocational, Education, And Training Agency
Bole Manufacturing College
Efficient Plant Layout Design Project For A Small Scale Garment Workshop
One of the most common industrial problems is proper use of man, material, and machines properly. Some organizations are thriving to solve this problem even educational institutes. The key idea of this project is proper to use or efficient use of resources with available area. So this project begins with analyzing the total area used by a college and I have found that the college has 31,719.685 m2 area, from this much amount of space building of 8562 m2, a road 5149 m2, a green area of 5900 m2 is used, so by rough calculation the collage will have 12,108.685m2 space but the collage need much more space than this because students need a playground for football, there is no entertainment center even tv room, there is no lab workshop building area for maximizing college aim finally there is 2 building this to be planted with this area. This calculation will give us the college must maximize its efficiency with minimum requirements and available resources. So, I begin to solve this illusion by reduction of three garment workshops into two workshops and freeing the remaining workshop. In the methodology part there is a calculation based on every machinery manual and ISO standard specification, some of the data also counts from the literature. But finally using the requirements I found that the plant needs to place one workshop for garments only so other departments can use the remaining. This is a great opportunity for the college to increase its efficiency. Also, from my sample point yearly graduating class is very minimum like 24.6% only in garments this tells us the college must change its policy by adding more departments depending on customer needs. Finally, I will recommend deeply analyzing every system for future better work and to fulfill the components or materials need to build the facility.
Addis Ababa City Administration, Bole Manufacturing College, Haileyesus Wondwossen
It gives the complete information about plant layout- objectives of plant layout-factors affecting plant layout- types of plant layouts-advantages and disadvantages of those layouts-methods of designing plant layout-computerised algorithms to design plant layout-geometric modelling of plant layout-soft wares available to design plant layouts-advantages of using soft wares for the preparation of plant layouts.
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.
Facilities Layout is the method of allocating machines & equipments, various production process and other necessary services involved in transformation process of products with the available space of the factory so as to achieve the greatest possible output of high quality at the lowest possible costs of manufacturing.
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2. Managerial Issues while selecting
a Layout
๏ Recognizing that many factors must be considered in
choosing how to layout a facility.
๏ Understanding the significant impact that choosing a
particular type of layout has on the firmโs ability to
compete in the market and its long-term success.
๏ Developing estimates of the investment costs of time
and money associated with installing a particular
layout.
๏ Attaining the goal of a smooth flow of material
through the process through the choice of a layout
that is both efficient and effective.
2
3. Types of Manufacturing Layouts
Layout Type
Process Similar operations are performed in a
common or functional area, regardless of
the product in which the parts are used.
Product
(Flow-shop layout)
Equipment/operations are located
according to the progressive steps required
to make the product.
Group Technology
(GT) or Cellular
Groups of dissimilar machines are brought
together in a work cell to perform tasks on a
family of products that share common
interests.
Fixed-Position The product, because of its size and/or
weight, remains in one location and
processes are brought to it.
3
5. Concept
๏ Many problems are similar, by grouping
similar problems, a single solution can be
found to a set of problems, thus saving
time and effort.
๏ A manufacturing philosophy in which
similar parts are identified and grouped
together to take advantage of their
similarities in design and manufacturing.
๏ A technique for identifying and bringing
together related or similar components in
order to take advantage of their
similarities in the production process.
5
6. Group Technology Layout
๏ Definition of Group Technology
โGroup technology is the technique of
identifying and bringing together related
or similar parts in a production process in
order to utilize the inherent economy of
flow production methods.โ
V. B. Solaja,Institute of Machine Tools, Belgrade, Yugoslavia
6
7. Group Technology Layout
๏ Group Technology layout is also called
manufacturing cell layout.
๏ Example:
โฆ A plant producing 10,000 part numbers may be able
to group the parts into 50 or 60 families. Each family
would possess similar design and manufacturing
characteristics.
โฆ Hence, the processing of each member of a given
family would be similar, and this results in
manufacturing efficiencies in the form of:
๏ Reduced set-up,
๏ Lower in-process inventories,
๏ Better scheduling,
๏ Improved tool control,
๏ Standard process plan.
7
8. 8
Job Shop prior to GT
Drilling
D D
D D
Grinding
G G
G G
G G
Milling
M M
M M
M M
Assembly
A A
A A
Lathing
Receiving and
shipping
L
L L
L L
L L
L
9. 9
Job Shop using 3 GT Cells
Cell 3
L M G G
Cell 1 Cell 2
Assembly
area
A A
L M DL
L M
Shipping
D
Receiving
G
11. GT Layout - Benefits
๏ Benefits
โฆ Implied reduction of necessary control
โฆ Reduced material handling
โฆ Reduced set-up time
โฆ Reduced tooling
โฆ Reduced in-process inventory
โฆ Reduced expediting
โฆ Increase operator expertise
โฆ Improved human relations.
11
12. GT Layout - Limitations
๏ Disadvantages
โฆ Reduced shop flexibility
โฆ Possible reduced machine utilization
โฆ Possible extended job flow times
โฆ Possible increased job tardiness.
๏ Implementation Issues
โฆ Reorganization - machine layout need
reorganization every so often.
โฆ Work cell supervision - supervisors must be
expert in several field (milling, turning,
grinding, etc.) represented in the cell.
โฆ Shop floor control / production planning - cell
concept leads to unbalanced workload on
machines.
12
13. 13
GT Layout โ
Analysis
1. Identify families of
parts with similar
flow paths
2. Group machines
into cells based on
part families
3. Arrange cells so
material
movement is
minimized
4. Locate large
shared machines
at point of use
In Out
Worker 1
Worker 2
Worker 3
S
L
HM
VM
G
VM
L
Final
inspection
Finished
part
14. GT Layout โ
Load Distance Analysis Example
๏ Each department is 10 feet by 10 feet,
distances are rectilinear, which of the
following two layouts is better?
Layout A Layout B
3 8
7 4
1 10
9 2
6 5
4 7
10 1
2 9
5 6
8 3
14
17. Solution (1/2)
๏ Compute the total travel for each product
through each layout alternative.
Product
Department
Processing
Sequence
Distance per
Product (feet)
Layout A
Distance per
Product (feet)
Layout B (feet)
A 1 5 4 10 30+30+10= 70 30+30+10= 70
B 2 6 3 9 20+40+30= 90 20+10+10= 50
C 2 10 1 9 10+10+10= 30 10+10+10= 30
D 1 7 8 10 10+20+20= 50 10+50+30= 90
E 2 5 6 9 10+10+10= 30 10+10+10= 30
F 1 7 4 10 10+10+10= 30 10+10+10= 30
17
18. Solution (2/2)
๏ Compute total distance traveled per
month by each product through each
layout alternative.
Units per Distance per Product Distance per Month
Product Month Layout A Layout B Layout A Layout B
A 1000 70 70 70,000 70,000
B 2000 90 50 180,000 100,000
C 3000 30 30 90,000 90,000
D 1000 50 90 50,000 90,000
E 2000 30 30 60,000 60,000
F 4000 30 30 120,000 120,000
Totals 570,000 530,000*
18
19. Factors that influence Layout
๏ Factors that influence layout
โฆ Volume, weight of items to be produced.
โฆ Nature of the service to be provided.
โฆ Cost of the building to house the operation.
โฆ The product mix that must have a facility.
โฆ The fragility of the product or component.
19
20. Types of Manufacturing Layouts
Layout Type
Process Similar operations are performed in a
common or functional area, regardless of
the product in which the parts are used.
Product
(Flow-shop layout)
Equipment/operations are located
according to the progressive steps required
to make the product.
Group Technology
(GT) or Cellular
Groups of dissimilar machines are brought
together in a work cell to perform tasks on a
family of products that share common
interests.
Fixed-Position The product, because of its size and/or
weight, remains in one location and
processes are brought to it.
20
21. Process Layout
๏ Grouping together of machines and/or workers
doing similar tasks.
๏ Applicable to both manufacturing and non
manufacturing operations.
๏ Advantages
โฆ Flexibility: equipment and personnel can be used
where they are needed.
โฆ Smaller investment in equipment: duplication is not
necessary unless volume is large.
โฆ Expertise: supervisors for each department become
highly. knowledgeable about their functions
โฆ Diversity of tasks: changing work assignments make
work more satisfying for people who prefer variety.
21
22. ๏ Disadvantages
โฆ Lack of process efficiency: backtracking and long
movements may occur in the handling of materials.
โฆ Lack of efficiency in timing: workers must wait
between tasks.
โฆ Complication of production planning and control.
โฆ Cost: workers must have broad skills and must be
paid higher wages than assembly line workers.
โฆ Lowered productivity: because each job is different it
requires different setups and operator training.
22
23. Product Layout
๏ Applicable to both manufacturing and non
manufacturing operations.
๏ Arrange machines and/or workers in
accordance with the sequence of operations for
a given product or service.
๏ Advantages of flow-line layout
โฆ Reduces materials handling.
โฆ Accommodates small amounts of work in process.
โฆ Reduces transit times.
โฆ Simplifies production planning and control systems.
โฆ Simplifies tasks, enabling unskilled workers to learn
task quickly.
23
24. ๏ Disadvantages of product layout
โฆ Lack of process flexibility.
โฆ Lack of flexibility in timing: the product can not flow
through the line faster than the slowest task can be
accomplished unless that task is performed at several
stations.
โฆ Large investments: special-purpose equipment and
duplication is required to offset lack of flexibility in
timing.
โฆ Dependence of the whole on each part: a breakdown
of one machine or absence of enough operators to
staff all work stations may stop the entire line.
โฆ Worker fatigue: workers may become bored by the
endless repetition of simple tasks.
24
25. GT Layout
๏ Group Technology layout is also called
manufacturing cell layout.
๏ Example:
โฆ A plant producing 10,000 part numbers may be able to
group the parts into 50 or 60 families. Each family would
possess similar design and manufacturing characteristics.
โฆ Hence, the processing of each member of a given family
would be similar, and this results in manufacturing
efficiencies in the form of:
๏ Reduced set-up,
๏ Lower in-process inventories,
๏ Better scheduling,
๏ Improved tool control,
๏ Standard process plan.
25
26. ๏ Advantages
โฆ Implied reduction of necessary control
โฆ Reduced material handling
โฆ Reduced set-up time
โฆ Reduced tooling
โฆ Reduced in-process inventory
โฆ Reduced expediting
โฆ Increase operator expertise
โฆ Improved human relations.
26
27. ๏ Disadvantages
โฆ Reduced shop flexibility
โฆ Possible reduced machine utilization
โฆ Possible extended job flow times
โฆ Possible increased job tardiness.
๏ Implementation Issues
โฆ Reorganization - machine layout need reorganization
every so often.
โฆ Work cell supervision - supervisors must be expert in
several field (milling, turning, grinding, etc.)
represented in the cell.
โฆ Shop floor control / production planning - cell concept
leads to unbalanced workload on machines.
27
28. Fixed Position Layout
๏ Manufacturing and non-manufacturing operations
of bulky or fragile products, e.g., ships and planes.
๏ Move machines and/or workers to the site;
products normally remains in one location for its
entire manufacturing period.
๏ Advantages of fixed position layout
โฆ Reduces movement of work items; minimizes damage or
cost of moving.
โฆ More continuity of the assigned work force (since the item
does not go from one department to another). This reduces
the problems of re-planning and instructing people each
time a new type of activity is to begin.
28
29. ๏ Disadvantages of fixed position layout
โฆ Since the same workers are involved in more
operations, skilled and versatile workers are required.
The necessary combination of skills may be difficult to
find and high pay levels may be necessary.
โฆ Movement of people and equipment to and from the
work site may be expensive.
โฆ Equipment utilization may be low because the
equipment may be left at a location where it will be
needed again in a few days rather than moved to
another location where it would be productive.
29