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.
In every operational management field Layout is the very import concept which in should know. Even if u r a student or a worker you should know the process/flow of layouts.
In every operational management field Layout is the very import concept which in should know. Even if u r a student or a worker you should know the process/flow of layouts.
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.
Principles of Plant layout
Types of Plant layout
Process layout
Product layout
Cellular Manufacturing layout
fixed Position layout
Hybrid Layout
and their Advantages & disadvantages
Material management is a scientific technique, concerned with Planning, Organizing & Control of flow of materials, from their initial purchase to destination.
Inventory generally refers to the materials in stock. It is also called the idle resource of an enterprise. Inventories represent those items, which are either stocked for sale or they are in the process of manufacturing or they are in the form of materials, which are yet to be utilized.
Production planning, routing, scheduling, Activating, MonitoringDarshan Shah
First Plan Your Work and then Work on Your Plan.
1. Planning is deciding in advance what to do, how to do it, when to do it and who is to do it.
Planning bridges the gap from where we are, to where we want to go. It makes it possible for things to occur which would not otherwise happen.
2. Routing may be defined as the selection of path which each part of the product will follow, which being transformed from raw material to finished products.
Routing determines the most advantageous path to be followed from department to department and machine to machine till raw material gets its final shape.
3. Scheduling determines the program for the operations. Scheduling may be defined as ‘the fixation of time and date for each operation’ as well as it determines the sequence of operations to be followed.
4. Activating is concerned with the starting the processes. Activating is ‘release of orders and instruction for the starting of production for any item in acceptance with the route sheet and schedule charts’.
5. Monitoring is related to report daily the progress of work in each shop in a prescribed proforma and to investigate the causes of deviations from the planned performance.
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.
Principles of Plant layout
Types of Plant layout
Process layout
Product layout
Cellular Manufacturing layout
fixed Position layout
Hybrid Layout
and their Advantages & disadvantages
Material management is a scientific technique, concerned with Planning, Organizing & Control of flow of materials, from their initial purchase to destination.
Inventory generally refers to the materials in stock. It is also called the idle resource of an enterprise. Inventories represent those items, which are either stocked for sale or they are in the process of manufacturing or they are in the form of materials, which are yet to be utilized.
Production planning, routing, scheduling, Activating, MonitoringDarshan Shah
First Plan Your Work and then Work on Your Plan.
1. Planning is deciding in advance what to do, how to do it, when to do it and who is to do it.
Planning bridges the gap from where we are, to where we want to go. It makes it possible for things to occur which would not otherwise happen.
2. Routing may be defined as the selection of path which each part of the product will follow, which being transformed from raw material to finished products.
Routing determines the most advantageous path to be followed from department to department and machine to machine till raw material gets its final shape.
3. Scheduling determines the program for the operations. Scheduling may be defined as ‘the fixation of time and date for each operation’ as well as it determines the sequence of operations to be followed.
4. Activating is concerned with the starting the processes. Activating is ‘release of orders and instruction for the starting of production for any item in acceptance with the route sheet and schedule charts’.
5. Monitoring is related to report daily the progress of work in each shop in a prescribed proforma and to investigate the causes of deviations from the planned performance.
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
he physical arrangement of production facilities. It is the configuration of departments, work centers and equipment in the conversion process. It is a floor plan of the physical facilities, which are used in production.
Need for Capacity Planning
Type of Capacity
Roles of forecasting in Capacity Planning
Facility Layout Planning
Product Layout
Process Layout
Fixed position layout
Cellular layout
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2. Definition
Plant layout refers to the arrangement of
physical facilities such as machinery,
equipment, furniture etc. within the factory
building so as to achieve the right quantity
and quality of output at the lowest possible
cost of manufacturing.
3. Importance
Minimizing material, Time and cost.
Easy production flow.
Economic use of building.
Effective utilization of man power.
Provides for employee’s convenience, safety,
comfort at work.
Maximum exposure to natural light and ventilation.
4. Type’s
Plant layout may be of four types:
(a) Product or line layout
(b) Process or functional layout
(c) Fixed position or location layout
(d) Combined or group layout
5. Production or Line layout
Machines and equipments are arranged in one line
depending upon the sequence of operations required for
the product. The materials move form one workstation to
another sequentially.
6. ADVANTAGE
Low cost of material handling, due to straight and short route and
absence of backtracking.
Smooth and uninterrupted operations.
Continuous flow of work.
DISADVANTAGE
Breakdown of one machine will hamper the whole production
process
Lesser flexibility as specially laid out for particular product.
Heavy overhead charges.
SUITABILITY
Mass production of standardized products
Simple and repetitive manufacturing process
paper, rubber, automobiles, food processing and electronics etc.
7. Process Layout
In this type of layout machines of a similar
type are arranged together at one place.
8. ADVANTAGE
Breakdown of one machine does not result in complete work
stoppage.
Change in output design and volume can be more easily
adapted.
The overhead costs are relatively low.
DISAVANTAGE
Material handling costs are high due to backtracking.
More skilled labor is required resulting in higher cost.
Time gap or lag in production is higher.
SUITABILITY
Products are not standardized.
Quantity produced is small.
tailoring, furniture industries, jewelry.
9. Fixed Position or Location Layout
In this type of layout, the major product being
produced is fixed at one location. Equipment
labor and components are moved to that
location.
10. ADVANTAGE
It saves time and cost involved on the movement of work from
one workstation to another.
The layout is flexible.
DISADVANTAGE
Very large space is required for storage of material and
equipment.
there is possibility of confusion and conflicts among different
workgroups.
SUITABILITY
Manufacture of bulky and heavy products such as locomotives,
ships, aircrafts, etc.
Construction of building, flyovers, dams.
11. Combined Layout
A combination of process & product layout is
known as combined layout.
Manufacturing concerns where several
products are produced in repeated numbers
with no likelihood of continuous production,
combined layout is followed.
12. For Example
Industries involving the fabrication of parts
and assembly, fabrication tends to employ
the process layout, while the assembly areas
often employ the product layout.
In soap, manufacturing plant, the machinery
manufacturing soap is arranged on the
product line principle, but ancillary services
such as heating, the manufacturing of
glycerin, the water treatment plant etc. are
arranged on a functional basis.