The document discusses plant layout and material handling, detailing different layout types such as process, product, combination, and fixed position layouts. It emphasizes the importance of effective material handling systems, their classification, objectives, and principles, and explains various handling equipment like conveyors, industrial trucks, cranes, hoists, and robots. Key goals include minimizing costs and delays while maximizing safety and efficiency in the manufacturing process.

1. Plant Layout and Material
Handling
Prepared By : Patel Shreyash K.
Branch : M.E. (Production)
Pen No. : 170490728016
Subject : Production & Operation Management
SHRI SITARAMBHAI NARANJIBHAI PATEL INSTITUTE
OF TECHNOLOGY AND RESEARCH CENTRE
1Plant Layout and Material Handeling

2. Plant Layout
 A plant layout study is an engineering
study used to analyze different physical
configurations for a manufacturing plant.
It is also known as Facilities Planning and
Layout.
Plant Layout and Material Handeling 2

3. Classification of Layout
 Process layout
 Product layout
 Combination layout
 Fixed position layout
 Group layout
Plant Layout and Material Handeling 3

4. Process Layout
In a process layout, management groups
together machines that perform similar
functions. For example, it may put all of the
lathes together in one part of the factory. The
part that is being manufactured goes from
one process area to another process area as it
is manufactured. Hospitals typically follow a
process layout. Example, the maternity ward
is in an area where the hospital attends to all
aspects of the maternity process.
Plant Layout and Material Handeling 4

5. Product Layout
The product layout approach involves
setting up the production facilities around
the steps involved in manufacturing the
product. The product goes from one step
to another as it is manufactured. This is
the typical assembly line approach.
Example, in the manufacturing process of
a car, the car body goes from one stage of
production to the next.
Plant Layout and Material Handeling 5

6. Combination Layout
A combination of process and product
layouts combines the advantages of both
types of layouts. A combination layout is
possible where an item is being made in
different types and sizes. Here machinery
is arranged in a process layout but the
process grouping is then arranged in a
sequence to manufacture various types
and sizes of products.
Plant Layout and Material Handeling 6

7. Plant Layout and Material Handeling 7
Combination Layout

8. Fixed Position Layout
This is also called the project type of
layout. In this type of layout, the material,
or major components remain in a fixed
location and tools, machinery, men and
other materials are brought to this
location.
Plant Layout and Material Handeling 8

9. Material Handling
Materials handling can be also defined as
‘the function dealing with the preparation,
placing and positioning of materials to
facilitate their movement or storage .
Material handling is the art and science
involving the movement, handling and
storage of materials during different stages of
manufacturing. Thus the function includes
every consideration of the product except the
actual processing operation.
Plant Layout and Material Handeling 9

10. Material handling does not add any value
to the product but adds to the cost of the
product and hence it will cost the
customer more. So the handling should be
kept at minimum. Material handling in
Indian industries accounts for nearly 40%
of the cost of production
Plant Layout and Material Handeling 10

11. Objectives of Material
Handling
Minimize cost of material handling.
Minimize delays and interruptions by
making available the materials at the point
of use at right quantity and at right time.
Safety in material handling through
improvement in working condition.
Maximum utilization of material handling
equipment.
Lower investment in process inventory.
Plant Layout and Material Handeling 11

12. Principles of Material Handling
Systems
Planning principle: All handling
activities should be planned.
Space utilization principle: Make
optimum use of cubic space.
Unit load principle: Increase quantity,
size, weight of load handled.
Gravity principle: Utilize gravity to
move a material wherever practicable.
Safety principle: Provide for safe
handling methods and equipment.
Plant Layout and Material Handeling 12

13. Classification of Material
Handling Systems
 Conveyors
 Industrial Trucks
 Cranes and Hoists
 Containers
 Robots
Plant Layout and Material Handeling 13

14. Conveyors
Conveyors are useful for moving material
between two fixed workstations, either
continuously or intermittently. They are
mainly used for continuous or mass
production operations indeed, they are
suitable for most operations where the flow
is more or less steady. Conveyors may be of
various types, with rollers, wheels or belts to
help move the material along: these may be
power-driven or may roll freely.
Plant Layout and Material Handeling 14

15. Plant Layout and Material Handeling 15
Fig: Conveyors

16. Industrial Trucks
Industrial trucks are more flexible in use
than conveyors since they can move
between various points and are not
permanently fixed in one place. They are,
therefore, most suitable for intermittent
production and for handling various sizes
and shapes of material. There are many
types of truck petrol- driven, electric,
hand-powered, and so on.
Plant Layout and Material Handeling 16

17. Plant Layout and Material Handeling 17
Fig: Industrial Trucks

18. Cranes and Hoists
The major advantage of cranes and hoists
is that they can move heavy materials
through overhead space. However, they
can usually serve only a limited area. Here
again, there are several types of crane and
hoist, and within each type there are
various loading capacities. Cranes and
hoists may be used both for intermittent
and for continuous production.
Plant Layout and Material Handeling 18

19. Plant Layout and Material Handeling 19
Fig: Cranes and Hoists

20. Robots
Many types of robot exist. They vary in
size, and in function and maneuverability.
While many robots are used for handling
and transporting material, others are used
to perform operations such as welding or
spray painting. An advantage of robots is
that they can perform in a hostile
environment such as unhealthy conditions
or carry on arduous tasks such as the
repetitive movement of heavy materials.
Plant Layout and Material Handeling 20

21. Plant Layout and Material Handeling 21
Fig: Robots

22. Thank you
22Plant Layout and Material Handeling