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Facility Layout - Production and Operation Management
The document discusses the importance and principles of facility layout in manufacturing plants, highlighting the need for efficient arrangement of machinery and resources to ensure smooth production processes. It outlines various factors influencing plant layout, such as the type of product, machinery, workers, and industry type, and details different layout types including process, product, fixed position, cellular manufacturing, and combination layouts. The document emphasizes that layout design is critical for maximizing productivity, reducing costs, and ensuring safety and employee satisfaction.
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Facility Layout - Production and Operation Management
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- 2. Introduction • When anew plant is erected, the question of the placement of machinery at different places, the location of stores, inspection cabins, tool rooms, maintenance wings, heat treatment chambers, toilets, canteens, cranes other equipments. • In a properly laid out plant, the movement of materials from the raw material stage to the end product stage is smooth and rapid
- 3. Introduction • It differsfrom plant to plant from location to location and from industry to industry. • The initial layout is almost never final or permanent . Changes do take place in production design, production methods and the size of the plant. Such changes necessitate a revision of the existing layout
- 4. Meaning, Definition andScope • Plant Layout refers to the arrangement of machinery, equipment and other industrial facilities for achieving quickest and smooth production. • More Simple Definition Given by Knowles & Thomson ⚬ Planning and arranging manufacturing machinery, equipment and services for the first time in completely new plants. ⚬ The improvements in layouts already in use in order to introduce new methods and improvements in manufacturing procedures.
- 5. Objectives of aGood Layout • Provide enough production capacity • Reducing Material handling costs • Utilize labour efficiently • Improve employee morale • Reduce accidents • Provide ease of supervision • Allow ease of maintenance • Improve productivity
- 6. Factors Influencing FacilityLayout • The pattern of layout varies from industry to industry, location to location and plant to plant. Different type of of layout are in use; • Primarily, the layout of a plant is influenced by the relationship among materials, machinery and men. • Other factors - such as type of product, the type of workers, the type of industry and management policies - also influence the layout. • Some of the factors which influence layout are explained following.
- 7. Factors Influencing FacilityLayout • Materials ⚬ The type of raw materials used i.e., whether the raw materials are liquid or solid, light or heavy, small or large; and ⚬ The availability or scarcity of materials even when this is affected by seasonal variations and market conditions. • Product ⚬ A layout is designed with the ultimate purpose of producing a product. type of product - product is heavy or light, big or small, liquid or solid and its position in relation to the plant location influence the layout.
- 8. Factors Influencing FacilityLayout • Worker ⚬ The layout designer should also consider the type, position and requirements of employees. ⚬ Employee facilities such as health and related services, feeding related services, locker rooms etc. • Machinery ⚬ The type of product, the volume of its production, the type of process and management policy determines the size and type of the machinery to be installed which, In turn, influences the plant layout. ⚬ Product is the combination and manipulation of men, materials and machines
- 9. Factors Influencing FacilityLayout • Type of Industry ⚬ The type of industry and the method of the manufacturing process exercise a significant influence on plant layout. ￭ Synthetic ￭ Analytical ￭ Conditioning ￭ Extractive (a processes that involve different activities that lead to the extraction of raw materials from the earth (such as oil, metals, mineral and aggregates)) • Location ⚬ The size selected for the location of a plant influences its layout in more than one way. i.e. size, transportation, expansion
- 10. Factors Influencing FacilityLayout • Managerial Policies ⚬ Management Policies significantly influence plant layout ￭ The volume of production and provision for expansion ￭ Making or Buying a particular component ￭ Purchasing Policy ￭ Personeel Policies
- 11. Principles of Layout •The Principle of Minimum Travel • Principle of Sequence • Principle of Usage • Principle of Compactness • Principle of Safety and Satisfaction • Principle Flexibility • Principle of Minimum Investment
- 12. Types of Layout •Process Layout or Functional Layout or Job Shop Layout • Product Layout or Line processing layout or flow line payout • Fixed Position layout or static layout • Cellular Manufacturing Layout or Group Technology Layout • Combination layout or hybrid layout
- 13. Process Layout orFunctional Layout or Job Shop Layout • Process layout involves a grouping together of like machines in one department • E.g.- Machines performing drilling operations are grouped in the drilling department, casting operations are grouped in the casting department, same like painting department, heating department soo on.. • e.g. Engine lathes
- 14. While Grouping machinesaccording to the process type, certain principles must be kept in mind • The distance between departments needs to be as short as possible with a view to avoding long distance movements • Department themselves should be located in accordance with the principle of sequence of operations. • Convenience for Inspection
- 15. Product Layout • Aproduct layout involves the arrangement of machines in one line depending on the sequence of operations. • While Grouping machines should be done, on product line, keeping in mind the following principles ⚬ All the machine tools or other items of equipment must be places at the point demanded by the sequence of operations ⚬ There should be no points where one line crosses another line. ⚬ All the operations, including assembly, testing and packagin should be included in the line.
- 16. Fixed Layout • Infixed position layout major components remain in a fixed location.
- 17. Cellular Manufacturing (CM)Layout • CM layout groups all machineries into cells, which function some what like a produce layout.
- 18. Combined Layout (OrGroup Technology Layout or Hybrid Layout) • A combination of the product and process layouts,
- 19. Special Arrangements forParticular Types of Plant
- 20. Revision of Layout •Reasons for Revision ⚬ Expansions ⚬ Technological advancements ⚬ Improvement in the layout