Plant Layout (Ch-3)
Transcript of Plant Layout (Ch-3)
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Chap 3 - Facility /Plant/FactoryLayout:
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Facility Layout
Introduction Objectives & Principles Factors Affecting Layout Selection and
Design Types of Plant Layout Product Layout Process Layout
Fixed position layout or static layout;
Combination layout or Hybrid layout
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Definition
Plant layout refers to the arrangementof physical facilities such as machines,equipment, tools, furniture etc. in sucha manner so as to have quickest flowof material at the lowest cost and withthe least amount of handling in
processing the product from thereceipt of raw material to the deliveryof the final product.
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Introduction
Facility layout means planning: for the location of all machines, utilities,
employee workstations, customer service
areas, material storage areas, aisles,restrooms, lunchrooms, internal walls,offices, and computer rooms
for the flow patterns of materials and
people around, into, and within buildings infrastructure services such as the
delivery of line communications, energy,and water and the removal of waste waterall make up basic utilities.
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Locate All Areas In and AroundBuildings
Equipment
Work stations
Material storage Rest/break areas
Utilities
Eating areas Offices
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Objectives
Proper and efficient utilization of available floor space.
Reduce material handling costs Provide ease of supervision and
control.
Allow easy maintenance of machinesand plant.
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Objectives of Plant Layout Elimination of unnecessary
occupied areas.
Reduction of administrativeand indirect work. Improvement on control and
supervision. Better adjustment to changing
conditions. Better utilization of the
workforce, equipment andservices.
Reduction of material handling
activities and stock in process. Reduction on parts and quality
risks. Reduction on health risks and
increase on workers safety.
Economies in materials,facilitate manufacturing
process & handling of semi-finished & finishedgoods.
To provide adequate safetyto the workers from
accidents. To meet the quality &capacity requirements inthe most economicalmanner.
Provision of medicalfacilities & cafeteria atsuitable & convenient
places. To provide efficient
material handling system. .
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Types of Layout
i. Process layout or functionallayout or job shop layout;
ii. Product layout or line processing layout or flow-
line layout;iii. Fixed position layout or
static layout;
iv. Combination layout or Hybrid layout.
v. Cellular or Group Layouy
ProductLayouts
Fixed
Position
Layouts
Mixed Layouts Process Layouts
QuantityQuantity
Number of Different ProductsNumber of Different Products
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Manufacturing units
(a) Product or line layout: Under this, 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 without any
backtracking or deviation. Under this, machines are
grouped in one sequence. Therefore materials are fed
into the first machine and finished goods travel
automatically from machine to machine, the output of
one machine becoming input of the next.
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Suitability: Product layout is usefulunder following conditions:
Mass production of standardized products Simple and repetitive manufacturing
process Operation time for different process ismore or less equal Reasonably stable demand for the
product Continuous supply of materials
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Types of plant layout
Product layout-
Layout that uses standardized processingoperations to achieve smooth, rapid, high-volume flow
Here machines are arranged acc. To theneeds of product & in the same sequenceas the operations are necessary formanufacture. E.g. ‘back office’ of services
such as banks and insurancecompanies.
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Product (Assembly Line)Layouts
Product layouts are used to achieve asmooth and rapid flow of large volumesof products or customers through a
system.A job is divided into a series of
standardized tasks, permittingspecialization of both labor and
equipment.The large volumes handled by thesesystems usually make it economical toinvest huge amount of money inequipment and job design.
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Product (Assembly Line)Layouts…
For instance, if a portion of amanufacturing operation required thesequence of cutting, sanding, and
painting, the appropriate pieces of equipment would be arranged in thatsame sequence.
Operations are arranged in the
sequence required to make theproduct Product layouts achieve a high degree
of labor and equipment utilization.
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Characteristics of ProductLayouts
Special-purposeequipment areused
Changeover isexpensive andlengthy
Material flow is
continuous
Material handlingequipment is fixed
Planning, schedulingand controlling
functions are relativelystraight-forward
Production time for aunit is relatively short
In-process inventory is
relatively low Little direct
supervision is required
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Product or Line Layout
ProductA
ProductB
ProductC
Step 1
Step 1
Step 1
Step 2
Step 2
Step 2
Step 3
Step 3
Step 3
Step 4
Step 4
Step 4
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Raw
materials
or customer
Finished
itemStation
2
Station
2Station
3
Station
3Station
4
Station
4
Material
and/or
labor
Station
1
Material
and/or
labor
Material
and/or
labor
Material
and/or
labor
Used for Repetitive or Continuous Processing
Product Layout
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Drilling Grinding Milling Weilding
Planer
lathe
AssemblePaintInspectionQuality
In
Out
Workers
A U-Shaped Production Line
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A U-Shaped Production Line
Advantage: more compact, increased communication
facilitating team work, minimize the material handling
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Product oriented plant layout Advantages:
Reduced materialhandling activities.
Work In Processalmost eliminated.
Minimum
manufacturing time. Simplification of theproduction planningand control systems.
Tasks simplification. Labor specialization High utilization of
labor and equipment Short processing
time High rate of output
Disadvantages:
No flexibility inthe productionprocess.
High capitalinvestment.
Every workstationis critical to theprocess.- The lackof personnel orshut down of amachine stops thewhole process.
Monotonous work.
Require largecapital investment Creates dull,
repetitive jobs
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2.Process oriented plant layout (FunctionalLayout)
Layout that can handle varied processingrequirements
Here all machines performing similar type of operations are grouped together at one locationin the process layout. Thus here facilities are
grouped together acc. To their functions.Personnel and equipment to perform the samefunction are allocated in the same area.
E.g. all drilling machines are located at oneplace known as drilling section.
The different items have to move from one area toanother one, according to the sequence of operationspreviously established
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Process (Job Shop) Layouts Used when the operations system must
handle a wide variety of products in relativelysmall volumes (i.e., flexibility is necessary)
Designed to facilitate processing items orproviding services that present a variety of processing requirements.
The layouts include departments or otherfunctional groupings in which similar kinds of
activities are performed. A manufacturing example of a process layout
is the machine shop, which has separatedepartments for milling,grinding, drilling, and
so on.
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Characteristics of ProcessLayouts
General-purpose equipment is used
Changeover is rapid
Material handling equipment is flexible
Operators are highly skilled
Technical supervision is required
Planning, scheduling and controllingfunctions are challenging
Production time is relatively long
In-process inventory is relatively high
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Dept. A
Dept. B Dept. D
Dept. C
Dept. F
Dept. E
Used for Intermittent processing
Process Layout(functional)
Process Layout
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Process layout-
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Dept. AD DDD
Dept. BP p
P p
Dept. DG G
G G
Dept. CW WW W
Dept. F
A A
A A
Dept. EL LL L
Used for Intermittent processing Job Shop or Batch
Process Layout
ProductA
RM –A
RM-B
Product B
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Manufacturing units
(b) Process or functional layout
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Process Layout
Gearcutting
Mill Drill
Lathes
Grind
Heattreat
Assembly
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444
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111
444
111
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4 4 4 4 4
3 3 3 3 3 3
2 2 2 2 2
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Manufacturing units
(b) Process or functional layout
Advantages: Process layout provides thefollowing benefits
a) Lower initial capital investment in machines and equipments. Thereis high degree of machine utilization, as a machine is not blocked for a
single product b) The overhead costs are relatively low c) Change in output design and volume can be more easily adapted to
the output of variety of products d) Breakdown of one machine does not result in complete work
stoppage
e) Supervision can be more effective and specialized f) There is a greater flexibility of scope for expansion.
Manufacturing units
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Manufacturing units
(b) Process or functional layout
Disadvantages: Product layout suffers from followingdrawbacks
a. Material handling costs are high due to backtracking b. More skilled Labour is required resulting in higher cost. c. Time gap or lag in production is higher d. Work in progress inventory is high needing greater storage space
e. More frequent inspection is needed which results in costly supervision
Suitability: Process layout is adopted when 1. Products are not standardized 2. Quantity produced is small 3. There are frequent changes in design and style of product 4. Job shop type of work is done 5. Machines are very expensive
Thus, process layout or functional layout is suitable for job order production involvingnon-repetitive processes and customer specifications and non standardized
products, e.g. tailoring, light and heavy engineering products, made to order
furniture industries, jewelry.
o r o o ro ro o
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o r o o ro ro ofactors Product layout Process layout
1. nature Sequence of facilities Similar aregp2gether
2. Machines
utilization
Not to full capacity Better utilization
3. product standardized diversified
4. Processing time less more
5. Material handling less more
6. inventory High WIP Low WIP
7. breakdown Can’t tolerate Can tolerate
8. Productioncentre
simple complex
9.flexibilty low high
10. floor space Requires less more
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(c) Fixed Position or Location Layout
In this type of layout, the major product being produced isfixed at one location. Equipment Labour and components aremoved to that location. All facilities are brought and arrangedaround one work center. This type of layout is not relevant for small scale entrepreneur. The following figure shows a fixed
position layout
Stationary layout- Layout in which the
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Stationary layout- Layout in which theproduct or project remains stationary, andworkers, materials, and equipment are
moved as needed. E.g. construction of DAMS.
The product, because of its size and/or
weight, remains in one location andprocesses are brought to it.
Fi d P iti L t
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Fixed-Position Layouts In fixed-position layouts, the item being
worked on remains stationary, andworkers, materials, and equipment aremoved as needed.
Fixed-position layouts are used in large
construction projects (buildings, powerplants, and dams), shipbuilding, andproduction of large aircraft and space
mission rockets. Fixed-position layouts are widely used for
farming, firefighting, road building, homebuilding, remodeling and repair, anddrillin for oil.
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PRODUCT
MATERIAL
MATERIAL
LABOUR
LABOUR
COMPONENTS
COMPONENTS
•
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Fixed Position Layout or Static Layout
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Fixed Position Layoute.g. Shipbuilding
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(c) Fixed Position or Location Layout
Advantages a) It saves time and cost involved on the movement
of work from one workstation to another.
b) The layout is flexible as change in job design andoperation sequence can be easily incorporated.
c) It is more economical when several orders indifferent stages of progress are being executed
simultaneously. d) Adjustments can be made to meet shortage of materials or absence of workers by changing thesequence of operations.
(c) Fixed Position or Location Layout
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(c) Fixed Position or Location Layout
Disadvantages: Fixed position layout has the followingdrawbacks
Production period being very long, capital investment isvery heavy
Very large space is required for storage of material andequipment near the product.
As several operations are often carried out simultaneously,
there is possibility of confusion and conflicts amongdifferent workgroups.
Suitability: The fixed position layout is followed in followingconditions
Manufacture of bulky and heavy products such as
locomotives, ships, boilers, generators, wagon building,aircraft manufacturing, etc. Construction of building, flyovers, dams. Hospital, the medicines, doctors and nurses are taken to the
patient (product).
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(d) Combined layout Certain manufacturing units may require all three processes namely
intermittent process (job shops), the continuous process (mass production shops) and the representative process combined process[i.e. miscellaneous shops]. In most of industries, only a productlayout or process layout or fixed location layout does not exist.Thus, in manufacturing concerns where several products are
produced in repeated numbers with no likelihood of continuous
production, combined layout is followed. Generally, a combinationof the product and process layout or other combination are found, in practice, e.g. for industries involving the fabrication of parts andassembly, fabrication tends to employ the process layout, while theassembly areas often employ the product layout. In tablet,manufacturing plant, the machinery manufacturing tablet is arrangedon the product line principle, but ancillary services such as Heating,Ventilation and Air-Conditioning (HVAC)heating, the power house, the water treatment plant etc. are arrangedon a functional basis.
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Cellular Manufacturing (CM)Layouts
Cellular manufacturing is a type of layout in which machines are groupedinto what is referred to as a cell.
Groupings are determined by theoperations needed to perform work fora set of similar items, or partfamilies that require similarprocessing.
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Cellular Manufacturing (CM)Layouts…
These relate to the grouping of equipmentand include faster processing time, lessmaterial handling, less work-in-process
inventory, and reduced setup time.
Used when the operations system musthandle a moderate variety of products in
moderate volumes
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‘Cellular’ Plant Layout
L M
D G
M M
D G
L L
L G
ASSEMBLY
CELL 3
ASSEMBLY
CELL 2
ASSEMBLY
CELL 1
• AKA ‘Group Technology’
• Each cell manufactures products
belonging to a single family.
• Cells are autonomous manufacturing
units which can produce finished parts.
• Commonly applied to machined parts.
• Often single operators supervising CNC
machines in a cell, with robots for
materials handling.
• Productivity and quality maximised.
Throughput times and work in progresskept to a minimum.
• Flexible.
• Suited to products in batches and where
design changes often occur.
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Cellular Manufacturing Layout
-1111 -1111
222222222 - 2222
A s s e m b l y
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
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Cellular Layout
Process (Functional)
LayoutProcess (Functional)
Layout Group (Cellular) LayoutGroup (Cellular) Layout
Similar resources placed
together
Resources to produce similar
products placed together
T T T
M
M M T
M
SG CG CG
SG
D D D
D
T T T CG CG
T T T SG SG
M M D D D
M M D D D
A cluster
or cell
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P-Q Analysis
ProductLayouts
Fixed
Position
Layouts Mixed Layouts Process Layouts
QuantityQuantity
Number of Different ProductsNumber of Different Products
B i L t F t
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Basic Layout Formats
Group TechnologyLayout
Similar to cellular layout
Part Family W Part Family X
Part Family Y
Part Family Z
Assemble Y,W Assemble X,Z
FinalProduct
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Cellular Manufacturing Layout or Group Technology Layout
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Dimension Process Cellular
Number of movesbetween departments
many few
Travel distances longer shorter
Travel paths variable fixed
Job waiting times greater shorter
Amount of work inprocess
higher lower
Supervision difficulty higher lower
Scheduling complexity higher lower
Equipment utilization Lower? Higher?
Process vs. Cellular Layouts
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Hybrid (mixed) Layouts
Actually, most manufacturing facilities usea combination of layout types.
An example of a hybrid layout is where
departments are arranged according to thetypes of processes but the products flowthrough on a product layout.
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Hybrid (mixed) Layouts… For instance, supermarket layouts are
fundamentally of a process nature, andhowever we find most use fixed-pathmaterial-handling devices such as roller-type conveyors both in the stockroom andat checkouts, and belt-type conveyors atthe cash registers.
Hospitals also use the basic process
arrangement, although frequently patientcare involves more of a fixed-positionapproach, in which nurses, doctors,medicines, and special equipment are
brought to the patient.
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Combined Layout or Hybrid Layout for Gear Manufacturing
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LAYOUT
Factory building: The nature and size of the building determines the
floor space available for layout. While designing the specialrequirements, e.g. air conditioning, dust control, humidity controletc. must be kept in mind.
Nature of product: product layout is suitable for uniform productswhereas process layout is more appropriate for custom-made
products. Production process: In assembly line industries, product layout is better. In job order or intermittent manufacturing on the other hand, process layout is desirable.
Type of machinery: General purpose machines are often arranged as
per process layout while special purpose machines are arrangedaccording to product layout
FACTORS INFLUENCING
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LAYOUT Repairs and maintenance: machines should be so arrangedthat adequate space is available between them for movementof equipment and people required for repairing the machines.
Human needs: Adequate arrangement should be made for cloakroom, washroom, lockers, drinking water, toilets andother employee facilities, proper provision should be madefor disposal of effluents, if any.
Plant environment: Heat, light, noise, ventilation and other aspects should be duly considered, e.g. paint shops and
plating section should be located in another hall so thatdangerous fumes can be removed through proper ventilationetc. Adequate safety arrangement should also be made.
Thus, the layout should be conducive to health and safety of employees. It should ensure free and efficient flow of menand materials. Future expansion and diversification may also
be considered while planning factory layout.