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Facility layout
- 1. FACILITY LAYOUT Production AndOperation Management UNIT-3 4/28/2017 Prepared by: Divya Paulose 1
- 2. Plant Layout • Aplant Layout refers to the arrangement of machinery & other industrial facilities such as receiving & shipping departments, Employer amenities for achieving quickest and smoothest production at least cost. • The subject of plant layout not only covers the initial layout, but encompasses improvement in ,or revision of existing layout • According to Knowles & Thomson “Planning & arrangement of machinery & other industrial facilities & services for the first time in completely new plant for the improvement of layout already in use , in order to introduce new methods” 4/28/2017 Prepared by: Divya Paulose 2
- 3. Objectives of goodPlant Layout • Provide enough Production Capacity • Reduce material handling cost • Reduce hazards to personnel • Increase employee moral • Reduce accidents • Utilize available space • Provide ease of production • Provide ease of maintenance • Provide ease of supervision • Improve productivity • Allow high machine utilization 4/28/2017 Prepared by: Divya Paulose 3
- 4. Factors Influencing PlantLayout • General principles Plant layout is often a compromise between a number of factors such as: • The need to keep distances for transfer of materials between plant/storage units to a minimum to reduce costs and risks; • The geographical limitations of the site; • Interaction with existing or planned facilities on site such as existing roadways, drainage and utilities routings; • Interaction with other plants on site; • The need for plant operability and maintainability; • The need to locate hazardous materials facilities as far as possible from site boundaries and people living in the local neighborhood;4/28/2017 Prepared by: Divya Paulose 4
- 5. • The needto prevent confinement where release of flammable substances may occur; • The need to provide access for emergency services; • The need to provide emergency escape routes for on-site personnel; • The need to provide acceptable working conditions for operators. The most important factors of plant layout as far as safety aspects are concerned are those to: • Ensure safety within on-site occupied buildings; • Control access of unauthorized personnel 4/28/2017 Prepared by: Divya Paulose 5
- 6. Factors influencing FacilityLayout 4/28/2017 Prepared by: Divya Paulose 6
- 7. Materials • Type andsize of material influence facility layout • Type of raw material – solid, liquid, or heavy small or large. • Need for the storage and movement of raw material in plant till converting to final goods. • It require properly placed storage rooms, material movement/ material handling equipments. • The availability/scarcity of material is also affected by seasonal variations and market conditions. • It also involves initial cost and recurring cost. 4/28/2017 Prepared by: Divya Paulose 7
- 8. Product • Types ofproduct whether it is heavy or light, big or small, Liquid or solid in nature influence plant layout. • Sales/demand also influence plant layout. • i.e volume/quality are important factor. • The purpose is to have effective and efficient production of a product or product line 4/28/2017 Prepared by: Divya Paulose 8
- 9. Worker • Layout designershould consider type, position and requirements of employees. • employee safety is a major consideration. • Position of employee – stationery or moving. 4/28/2017 Prepared by: Divya Paulose 9
- 10. Machinery • Production isa combination and manipulation of Men, Materials and Machines. • These combination should result in high production rate. • To move the product and workers from work station to work station. • To move the product from work station to work station, keep machinery and workers constant. • To move the worker and the machine should move around product. 4/28/2017 Prepared by: Divya Paulose 10
- 11. Type of Industry INDUSTRY SyntheticAnalytical Conditioning Extractive 4/28/2017 Prepared by: Divya Paulose 11
- 12. Industry Intermittent Continuous 4/28/2017 Preparedby: Divya Paulose 12
- 13. Location • Plant siteinfluence the plant layout. Village site Urban site • Mode of transportation/depending on raw material and market Railways Trucks • Future demand expansion • Fuel required is also a constraint 4/28/2017 Prepared by: Divya Paulose 13
- 14. Managerial Policies • Thetop managements policies determines objectives and scope of the plant activities. Like the following ones: • Extent of automation • Desire for rapid delivery of goods to customers. • Making or buying a particular part. • Purchasing policy • Personnel policy 4/28/2017 Prepared by: Divya Paulose 14
- 15. Principles of PlantLayout • The principle of Minimum travel • The principle of sequence • The principle of usage • The principle of compactness • The principle of safety • The principle of satisfaction • The principle of minimum investment 4/28/2017 Prepared by: Divya Paulose 15
- 16. TYPES OF LAYOUT •Process layout or functional layout or job shop layout • Product layout or line processing layout or flow-line layout • Fixed position layout or static layout • Cellular manufacturing layout or group technology layout • Combination Layout or hybrid layout 4/28/2017 Prepared by: Divya Paulose 16
- 17. Process layout orjob shop layout • In Process layout similar machines and services are located together. • Therefore, in a process type of layout all drills are located in one area of the layout and all milling machines are located in another area. • A manufacturing example of a process layout is a machine shop. • Process layouts are also quite common in non-manufacturing environments. • Examples include hospitals, colleges, banks, auto repair shops, and public libraries. • A pictorial representation of a process type of layout 4/28/2017 Prepared by: Divya Paulose 17
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- 20. Advantages 4/28/2017 Prepared by:Divya Paulose 20 • Very high degree of variety in products is possible. • Flexibility and adaptability to changes is high. • Machine breakdowns do not cause crippling production stoppages. • Requires small maintenance crew. • Good level of variety, skills requirement and therefore higher job satisfaction. • Coordination and supervision is simpler as the processes are similar and the staff is skilled.
- 21. Disadvantages Higher flow timesof products due to: Intermittent flows of the material More numerous machine set-ups. Production planning and control is more complex; much paper work is necessary. Worker skills need to be high in order to complete all components of the job. Higher inventories of basic raw materials may be necessary due to much uncertainty of demand. Higher work-in-process inventories due to necessary intermediate storages, if the machine and labor utilization is to be at a satisfactory level and if the flow times of the products are to be at acceptable levels. More handling of materials. 4/28/2017 Prepared by: Divya Paulose 21
- 22. PRODUCT LAYOUT • Productlayouts are found in flow shops (repetitive assembly and process or continuous flow industries) • Flow shops produce high-volume, highly standardized products that require highly standardized, repetitive processes. • Resources are arranged sequentially, based on the routing of the products. • In theory, this sequential layout allows the entire process to be laid out in a straight line, which at times may be totally dedicated to the production of only one product or product version. • The flow of the line can then be subdivided so that labor and equipment are utilized smoothly throughout the operation. 4/28/2017 Prepared by: Divya Paulose 22
- 23. A U-Shaped ProductionLine 4/28/2017 Prepared by: Divya Paulose 23
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- 25. PRODUCT LAYOUT Advantages • Highvolume • Low unit cost • Low labor skill needed • Low material handling • High efficiency and utilization • Simple routing and scheduling • Simple to track and control Disadvantages • Lacks flexibility • Volume, design, mix • Boring for labor • Low motivation • Low worker enrichment • Can not accommodate partial shut downs/breakdowns • Individual incentive plans are not possible 4/28/2017 Prepared by: Divya Paulose 25
- 26. FIXED POSITION LAYOUT •Fixed-position layouts are typical of projects in which the product produced is too fragile, bulky, or heavy to move. • Ships, houses, and aircraft are examples. • The product remains stationary for the entire manufacturing cycle. • Equipment, workers, materials, and other resources are brought to the production site. • The workers called to the work site are highly skilled at performing the special tasks they are requested to do. For instance, pipefitters may be needed at one stage of production, and electricians or plumbers at another. • The wage rate for these workers is much higher than minimum wage. 4/28/2017 Prepared by: Divya Paulose 26
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- 28. Cellular Layouts • CellularManufacturing –Layout in which machines are grouped into a cell that can process items that have similar processing requirements. A product layout is visible inside each cell. • Group Technology –The grouping into part families of items with similar design or manufacturing characteristics. Each cell is assigned a family for production. This limits the production variability inside cells, hence allowing for a product layout. 4/28/2017 Prepared by: Divya Paulose 28
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- 30. 4/28/2017 Prepared by:Divya Paulose 30 -1111 -1111 222222222 - 2222 Assembly 3333333333 - 3333 44444444444444 - 4444 Lathe Lathe Mill Mill Mill Mill Drill Drill Drill Heat treat Heat treat Heat treat Gear cut Gear cut Grind Grind
- 31. 4/28/2017 Prepared by:Divya Paulose 31 • Group Technology Layout Similar to cellular layout Part Family W Part Family X Part Family Y Part Family Z Assemble Y,W Assemble X,Z Final Product
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- 33. Facility Design Considerations •Nature and Objectives of Service Organization • Land Availability and Space Requirements • Flexibility • Security • Aesthetic Factors • The Community and Environment 4/28/2017 Prepared by: Divya Paulose 33
- 34. The importance ofa layout: • An efficient layout on the manufacturing function: • It makes it smooth and efficient. • Operating efficiencies, such as economies in the cost of handling materials, • Minimization of production delays and • Avoidance of bottlenecks” - all these depend on a proper layout. • An ideally laid out plant reduces manufacturing costs through reduced materials handling, • Reduced personnel and equipment requirements and reduced process inventory. 4/28/2017 Prepared by: Divya Paulose 34
- 35. The plant layoutadvantages is concerned. Some of these advantages are: •Economies in Handling Nearly 30% to 40% of the manufacturing cost is accounted for, by materials handling. Every effort should, therefore, be made to cut down on this cost. Long distance movements should be avoided and specific handling operations must be eliminated. 4/28/2017 Prepared by: Divya Paulose 35
- 36. •Effective Use ofAvailable Area Every inch of the plant area is valuable, especially in urban areas. Efforts should therefore be made to make use of the available area by planning the layout properly. Some steps for achieving this end are: location of equipment and services in order that they may perform multiple functions; Development of up-to-date work areas. operator job assignments for a full utilization of the labor force. 4/28/2017 Prepared by: Divya Paulose 36
- 37. •Minimization of ProductionDelays Plant layout is a significant factor in the timely execution of orders. An ideal layout eliminates such causes of delays as shortage of space, long-distance movements of materials, spoiled work and thus contributes to the speedy execution of orders. •Improved Quality Control Timely execution of orders will be meaningful when the quality of the output is not below expectations. To ensure quality, inspection should be conducted at different stages of manufacture. An ideal layout provides for inspection to ensure better quality control. 4/28/2017 Prepared by: Divya Paulose 37
- 38. •Minimum Equipment Investment Investmenton equipment can be minimized by planned machine balance and location, minimum handling distances, by the installation of general purpose machines and by planned machine loading. •Avoidance of Bottlenecks Bottlenecks refer to any place in a production process where materials tend to pile up or are produced at a speed, less rapid than the previous or subsequent operations. Bottlenecks are caused by inadequate machine capacity, inadequate storage space or low speed on part of the operators. The results of bottlenecks are delays in productions schedules, congestion, accidents and wastage of floor area. 4/28/2017 Prepared by: Divya Paulose 38
- 39. • Better ProductionControl Production Control is concerned with the production of the product of the right type, at the right time and at a reasonable cost. A good plant layout is a requisite for good production control and provides the production control officers with a systematic basis upon which to build organization and procedures. • Better Supervision A good plant layout ensures better supervision in two ways: 1.Determining the number of workers to be handled by a supervisor and 2.Enabling the supervisor to get a full view of the entire plant at one glance. 4/28/2017 Prepared by: Divya Paulose 39
- 40. • Improved Utilizationof Labor Labor is paid for every hour it spends in the factory. A good plant layout is one of the factors in effective utilization of labor. It makes possible individual operations, the process and flow of materials handling in such a way that the time of each worker is effectively spent on productive operations. • Improved Employee Morale Employee morale is achieved when workers are cheerful and confident. This state of mental condition is vital to the success of any organization. Morale depends on: (a)Better working condition; (b)Better employee facilities; (c)Reduced number of accidents; (d)Increased earnings. 4/28/2017 Prepared by: Divya Paulose 40
- 41. • Improved Utilizationof Labor Labor is paid for every hour it spends in the factory. A good plant layout is one of the factors in effective utilization of labor. It makes possible individual operations, the process and flow of materials handling in such a way that the time of each worker is effectively spent on productive operations. • Improved Employee Morale Employee morale is achieved when workers are cheerful and confident. This state of mental condition is vital to the success of any organization. Morale depends on: (a)Better working condition; (b)Better employee facilities; (c)Reduced number of accidents; (d)Increased earnings. 4/28/2017 Prepared by: Divya Paulose 41
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