12-Objectives-Principles - Factors Influencing The Plant Layouts-08!10!2021 (08-Oct-2021) Material - I - 08!10!2021 - MEE1014 - Plant - L

MEE1014
INDUSTRIAL ENGINEERING AND MANAGEMENT
Dr SAMPATH KUMAR T
Associate Professor
School of Mechanical Engineering
VIT University
Sampath.thepperumal@vit.ac.in
9443964297
Dr T SAMPATH KUMAR, ASSOCIATE
13-09-2019 1
PROFESSOR - SMEC
Module V
Plant location and Plant layout:

Plant location –need - Factors – comparison – quantitative methods for
evaluation Plant layout: Objectives principles – factors influencing – tools and
techniques including computer based layout design – CRAFT, ALDEP,
CORELAP.

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PROFESSOR - SMEC
MODULE 4
Layout Planning
 Types of Layout
 Factors influencing product - Process
 Tools and Techniques for developing
Layout
 Developing and Analysis of plant
Layout
 Presenting the Layout – Office
Layout plot planning.
 Evaluation and Improvement of
Layout.
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“Plans are nothing; planning is everything”
– Dwight D. Eisenhower
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Layout
Long-range viewpoint and coordinating the facilities plan with the plans of the
other organizational units is very important.
A facilities layout strategy should emerge from the overall strategic plan.
Product, manufacturing, marketing distribution, management, and human resource
plans will be impacted by and will impact on the facilities layout.
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Dr T SAMPATH KUMAR, ASSOCIATE PROFESSOR - SMEC
Layout
Which comes first, the material handling system or the facility layout?
Many appear to believe the layout should be designed first and then the
material handling system should be developed. Yet, material handling decisions can
have a significant impact on the effectiveness of a layout.
For example, the following decisions will affect the layout:
1. Centralized versus decentralized storage of work-in-process (WIP), tooling,
and, supplies.
2. Fixed path versus variable path handling.
3. The handling unit (unit load) planned for the systems.
4. The degree of automation used in handling.
5. The type of inventory control, physical control, and computer control of
materials.
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Need for plant layout
1. Product design change

2. New product
3. Changes in volume demand
4. Facilities becoming obsolete
5. Frequent accidents
6. Poor work environment
7. Change in the location or concentration of markets
8. Cost reduction

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PROFESSOR - SMEC
Objectives of plant layout
• Minimising and controlling material handling and

transportation
• Elimination of bottle necks to meet free of raw material and
semi-finished goods
• Suitable design of work stations
• High material turnover through shorter cycle operation
• Minimization of return on investments
• Effective utilization of installed capacity and cubic space

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PROFESSOR - SMEC
Objectives of plant layout
• Minimization of waiting time for semi-finished products

• Safer and convenient environment
• Improved work methods
• Elimination of physical efforts
• Improved flexibility for changes in product design and future
expansion
• Effective utilisation of manpower resources

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PROFESSOR - SMEC
Principles of plant layout
1. Principle of overall integration
The best layout is one which integrates the man, materials, machinery and
supporting services in order to get the optimum utilisation of resources and
maximum effectiveness.
2. Principle of minimum distance
Minimum travel of man and materials- straight line movement should be
preferred.
3. Principle of flow
A good layout is one that makes the materials to move in forward direction
towards the completion stage. ie. There should not be any back tracking.
4. Principle of cubic space
Best layout is one which utilizes both vertical and horizontal space. The height
is also to be utilized effectively.

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PROFESSOR - SMEC
Principles of plant layout
5. Principle of satisfaction, security and safety

A good layout is one that gives due consideration to workers
safety and satisfaction and safeguards the plant and machinery
against fire, theft, etc.,
6. Principle of flexibility
The best layout is one which can be adapted and re-arranged at a
minimum cost and time.
7. Principle of minimum handling
A good layout is one that reduces the material handling to the
minimum

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PROFESSOR - SMEC
Advantages of Plant layout
• Minimum manual material handling.
• It reduces the number of accidents and better working
conditions.
• Minimize labour cost.
• Minimises the manufacturing cycle time.
• Enhances productivity.
• Minimises the movement between workcentres.
• Uniform and uninterrupted flow of materials and
production carried out as per predetermined time period
and with effectiveness.

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PROFESSOR - SMEC
Factors influencing plant layout
• Type of production – Engineering industry, process industry

• Production system – Job shop, batch production, mass
production
• Quality requirements
• Availability of the total area
• Arrangement of material handling system
• Type of building – single or multi
• Future expansion plan
• Plant site – roads, highways, etc.,

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PROFESSOR - SMEC
Types of layout
• Line or product layout

• Functional or process layout
• Fixed position layout

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PROFESSOR - SMEC
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PROFESSOR - SMEC
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PROFESSOR - SMEC
Types of layout
Product or line layout:
In out
1 2 3 4
• Arranged according to the operation sequence
• Arranged in line shape or U-shape
• Suitable for mass production
• Suitable for continuous process industries such as
automobile, chemical, textile, sugar industries

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PROFESSOR - SMEC
Production Line Departments
The layout for a production line department is based on the processing sequence for
the part(s) being produced on the line.
Materials typically flow from one workstation directly to the next adjacent one.
Nice, well-planned flow paths generally result in this high-volume environment
(product layouts).
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Basic Layout Types
Production Line Departments
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• Advantages
1. It lowers the overall manufacturing time
2. Less space is needed for placing machines
3. There is minimum of handling and transportation
4. There is less work in process
5. Better utilization of machines and labour
6. It minimises counting and inspection
7. Smooth flow of materials
8. Elimination of cross handling

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PROFESSOR - SMEC
Disadvantages
1. When model or type changes, the layout of machinery also
require a change
2. All machines in the arrangement cannot be used to their
maximum capacity
3. Break down of one machine will causes all other machines to
remain idle
4. Future expansion is not possible

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PROFESSOR - SMEC
Basic Layout Types
Product Family Departments

The layout for a product family department is based on the grouping of parts to
form product families.
Non-identical parts may be grouped into families based on common processing
sequences, shapes, material composition, tooling requirements,
handling/storage/control requirements, and so on.
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Basic Layout Types
Product Family Departments
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Basic Layout Types
Process Departments
The layout for a process department is obtained by grouping like processes together
and placing individual process departments relative to one another based on flow
between the departments.
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Basic Layout Types
Process Departments
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Process or functional layout
1 2 3 4
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5 6
6v
7 8 9 10
Various sections such as store room, inspection dept, lathe, milling, broaching, shaper, drill, stock room, etc.,
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PROFESSOR - SMEC
• The machines in this layout are generally arranged on

functional basis
• This type is also called as an analytical layout
• This layout is more suitable when similar equipment's and
machines are grouped together and useful when low volume of
production is required

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PROFESSOR - SMEC
Advantages
1. In similar jobs and machines, supervision is simple
2. Less number of machines are required
3. Better control on precision or complicated process is
possible
4. Layout is flexible
5. Stoppage of machines does not affect the production

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PROFESSOR - SMEC
Disadvantages
1. Handling and back-tracking of materials is too much
2. More floor area is needed
3. Total production cycle time is more
4. Automatic devices for internal transportations are
costly
5. More training is essential to prepare the workers for
the job

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PROFESSOR - SMEC
Fixed Position or material Layout
• This layout is suitable for manufacturing huge

aircraft, ship vessel and pressure vessel, as the
product material are too heavy.
• This layout is also known as ‘static product layout’
• For these types of products it is convenient and
economical to bring the tools, machine and men to
the workplace.

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PROFESSOR - SMEC
Fixed Material Location Departments
In the case of fixed material location departments the workstations are brought to
the material.
The layout of the fixed material location department involves the sequencing and
placement of workstations around the material or product.
It is used in aircraft assembly, shipbuilding, and most construction projects.
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Basic Layout Types
Fixed Material Location Departments
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Fixed Position Layout
Advantage
1. Minimum investment
2. Assurance of continuity of operations
3. Less total production cost
4. Minimum material movement
5. Maximum flexibility
6. Production of different products on the same layout

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PROFESSOR - SMEC
Fixed Position Layout
Disadvantage
1. Machine and tools take more time to reach the work
place
2. Necessity of highly skilled workers
3. Low utilization of labour and equipment
4. Higher equipment handling cost
5. Requirement of complicated jigs and fixtures

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PROFESSOR - SMEC
Advantages of good plant layout
1. Reduced effort of the worker
2. Increased productivity
3. Easier access to equipment and facilities
4. Less maintenance cost
5. Flexibility for improvement and future expansion
6. Less in process inventory
7. Reduced material handling
8. Reduced manufacturing time
9. Increased output
10. Saving in floor space
11. Maximum utilisation of men and machine
12. Safety and health conditions to employees
13. Easier and better supervision
14. Neat appearance to work area, without confusion
15. Minimum capital investment
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PROFESSOR - SMEC
Characteristics of good layout
• Good material flow pattern

• Straight Aisles
• Minimum back-tracking of flow path
• Operations related to each other
• Minimum manual handling
• Good house keeping
• Engagement of workers fully
• Minimum re-handling material

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PROFESSOR - SMEC
Layout Procedures
In designing layouts, the procedures can be classified into two main categories:
1. Construction type layout methods basically involve developing a new layout
“from scratch”, and
2. Improvement procedures generate layout alternatives based on an existing
layout.
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Apple’s Plant Layout Procedure
1. Procure the basic data

2. Analyse the basic data
3. Design the productive process
4. Plan the material flow pattern
5. Consider the general material handling plan
6. Calculate equipment requirements
7. Plan individual workstations
8. Select specific material handling equipment
9. Coordinate groups of related operations
10. Design activity interrelationships
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Apple’s Plant Layout Procedure
11. Determine storage requirements

12. Plan service and auxiliary activities
13. Determine space requirements
14. Allocate activities to total space
15. Consider building types
16. Construct master layout
17. Evaluate, adjust, and check the layout with the appropriate persons
18. Obtain approvals
19. Install the layout
20. Follow up on implementation of the layout
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Reed’s Plant Layout Procedure
1. Analyse the product or products to be produced

2. Determine the process required to manufacture the product
3. Prepare layout planning charts
4. Determine workstations
5. Analyse storage area requirements
6. Establish minimum aisle widths
7. Establish office requirements
8. Consider personnel facilities and services
9. Survey plant services
10. Provide for future expansion
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Reed calls the layout planning chart, “the most important single phase of the entire
layout process”.
It incorporates the following:

1. Flow process, including operations, transportation, storage, and inspection
2. Standard times for each operation
3. Machine selection and balance
4. Manpower selection and balance
5. Material handling requirement
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Muther’s Systematic Layout Planning (SLP)
Procedure
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Procedure
The systematic layout planning (SLP) procedure uses as its foundation the activity
relationship chart.
Based on the input data and an understanding of the roles and relationships between
activities, a material flow analysis (from-to-chart) and an activity relationship
analysis (activity relationship chart) are performed.
From the analyses performed, a relationship diagram will be developed.
The next two steps involve the determination of the amount of space to be assigned
to each activity.
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Procedure
Departmental service and area requirement sheets would be completed for each
department.
Once the space assignments have been made, space templates are developed for
each planning department and the space is “hung on the relationship diagram” to
obtain the space relationship diagram.
Based on modifying considerations and practical limitations, a number of layout

alternatives are developed and evaluated. The preferred alternative is
then recommended.
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Procedure – Key Inputs
Input What ? Why?

Product Material What will be produced
or distributed
Quantity Volume Shipping volume and
space required
Routing Process Sequence How will they be
processes?
Supporting Services With what? Backing for the
process
Time When and How long? Seasonal, Cut off time,
etc.,
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Three Fundamentals of SLP
The three fundamentals of SLP are

• Relationship between activities
• Space for each activity
• Adjustments
• Relationships and
• Space
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Four Phases of SLP
A. Location
B. Arrangement
 Layout Types
o Job
o Batch
o Assembly Line
o Continuous Flow
C. Detailed Arrangement
D. Installation
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Repeating Pattern
Input
Input PQRST and
Layout Types Output
Activity Areas
Relationships
and Space Space
Required Relationship
Diagram
Adjustments for
Fit and Function Preliminary
Layout
Arrangement
Modifications
and limitations Alternative
layouts
Evaluations and
Approval
Layout plan
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Procedure
I. Determine the Activity areas and feature requirements
• All activities
• PQRST
II. Develop a form to material flow chart
• Equivalent Material
III. Develop a non flow relationship chart
• Supervision, Inspection
• Staffing
• Ventilation
• Power requirements etc.,
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Procedure
IV. Develop a combined flow and non flow relationship chart
V. Rating system and Weighting System
VI. 80 20 rule
VII. A & E are next to each other
IV. Determine space requirement for each activity area
IV. Current Space
V. Get well and or
VI. Future
VII. Create a space relationship diagram
VIII.Importance of closeness
IX. Relativity reasons and Importance
X. Initial relationship diagram
XI. Develop block diagram
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Procedure
IV. Find alternatives
IV. Create a detailed level facility layout
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SLP – In a Capsule
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Preference of layout
When Product layout is preferred

1. Product variety is few
2. Production quantity is high for long period
3. Application of time and motion study is possible
4. Equipment balance is possible
5. Inspection study during operation is minimum
6. Continuous handling of the product is possible

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PROFESSOR - SMEC
When process layout is preferred

1. Varieties of products are many
2. Method of time and motion study is difficult
3. Equipment balance is not possible
4. Inspection study during operation is high
5. Difficulty in mechanical handling exist
6. Same machine is needed for more than one
operations

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PROFESSOR - SMEC
When fixed position layout is preferred
The size and weight of the product restricts the use of

continuous mechanical handling devices

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Tools and techniques for developing layout
• Operation process chart

• Flow diagram
• String diagram
• Travel chart (From-to-chart)

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Operation process chart
• This is a graphical representation of sequence of

operations, transportations, inspection, delays and
storage occurring during manufacturing.
• This chart gives information regarding the distance
moved and time required for various activities such as
transportations, delays and inspection.
• The various symbols are used for the activities.

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PROFESSOR - SMEC
Operation process chart

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PROFESSOR - SMEC
Flow diagram
• The flow diagram aids the visualisation of the

movement of material on the existing layout
• The path of movement between the two locations
and the frequency of movement can be visualised
by this flow diagram
• The movement of material is recorded on the
layout diagram (suitable scale of the floor layout
diagram)
• This shows the back-tracking and excessive
movement of materials
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PROFESSOR - SMEC
Flow diagram
• Objectives of flow diagram

1. To show clearly the steps in manufacturing
2. To eliminate or reduce back-tracking
3. To eliminate or reduce excessive travel
4. To eliminate points of traffic congestion
5. To improve plant layout

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PROFESSOR - SMEC
Flow diagram
Wood processing

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PROFESSOR - SMEC
Flow diagram

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PROFESSOR - SMEC
String diagram
• The movement of workers at regular intervals

between a number of points in working area with or
without material
• A string diagram is a plan or model (to scale) on
which a thread is used to trace and measure the path
of workers, materials, or equipment during a
specified sequence of events. It also shows the
frequency of movement between various points

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PROFESSOR - SMEC
String diagram
• Objectives of string diagram

To determine and eliminate or reduce
1. Back-tracking
2. Excessive travel
3. Points of traffic congestion

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PROFESSOR - SMEC
String diagram

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PROFESSOR - SMEC
String diagram
• Advantages
1. Useful for complex movement
2. Back-tracking bottle necks and under-utilized paths
are indicated
3. Existing path of movement is traced
4. Economical route can be easily compared for
different pattern of movements
5. Movement of operator, materials and equipment's
are studied
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PROFESSOR - SMEC
Travel Chart
• It is an analytical technique used to assemble in

compact form and a large quantity of data in matrix
form.
• This chart is similar to a mileage chart used in road
maps to indicate the distance in kilometres between
destinations

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PROFESSOR - SMEC
Travel Chart

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Use of Travel Chart
• To analyse material movements

• To compare layouts and to measure layout efficiency
• To shorten manufacturing cycles
• To lower labour costs
• To show dependency of one area on another
• To make economical use of floor space
• To show inter-relationship of product lines

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PROFESSOR - SMEC
Layout planning procedure
1. Fixing the objectives of plant
2. Collection of necessary data
3. Formulation of overall plan
4. Determining nature of manufacturing operation
5. Developing the techniques in accordance with plant layout and preparing
charts, diagrams and templates for it
6. Deciding the building requirements in respect of floor space, floor load
capacities, ceiling heights, location of partitions, sizes and location of
doors and windows
7. Deciding the location of service activities, keeping in view the facility of
the manufacturing process and the convenience of workers
8. Determining the sequence of machines and then stabilising them
9. Drafting the outlines of manufacturing center
10. Arrangement of finance according to plan
11. Preparation of layout drawings and test production-run
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PROFESSOR - SMEC
Before a new layout can be designed
or an old one is corrected
The facts that should be obtained are

1. About products – ie. about material, qualities and output
2. About process – ie. about operations and their sequence
through operation process chart
3. About existing layout through flow process chart and flow
diagram
4. About existing machines and material handling equipment
5. About the space available for the work place and machines
6. About the receiving, storing and outgoing areas

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PROFESSOR - SMEC
The following steps are taken
to make a good layout
• A detailed material flow pattern should developed
• A material handling method should be decided
• Work area plans should be prepared
• All panning and activities should be coordinated
• A master plant layout is laid
• The newly laid plant layout is evaluated
• The plant layout is installed
• Necessary changes are made to see that the
production is satisfactorily done
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PROFESSOR - SMEC
Revising plant for technological advance
Technological advancements can be classified as

follows
1. Increase in mechanization of industry
2. Development in fuel and energy
3. Development in industrial processes
4. Development in materials
5. Improvement in product design
6. Development in scientific management

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PROFESSOR - SMEC
Reasons for inefficient layout in existence
Some reasons for poor layout are as follows

1. Under qualification
2. Overall centralized control
3. Inadequate facilities
4. Unsuited building for the layout
5. Over specialization of plant facilities and layout
6. Making product design changes
7. Inefficient plant maintenance practice
8. Ignorance of industrial research
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PROFESSOR - SMEC
Procedure for improvement and revision
Layout for revising the plant needs the following steps
1. Determination of objectives
2. Compilation of the layout drawings of the present plant
3. Formulation of the cost analysis study to help the layout
analysis
4. Flow diagram analysis, flow process chart, flow process
chart, handling analysis and knowledge of service activities
5. Development of improved flow diagram and process chart
with a final detailed drawing of the revised layout

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PROFESSOR - SMEC

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MEE1014

INDUSTRIAL ENGINEERING AND MANAGEMENT

Plant location and Plant layout:

Dr T SAMPATH KUMAR, ASSOCIATE

13-09-2019 Dr T SAMPATH KUMAR, ASSOCIATE PROFESSOR - SMEC 4

1. Product design change

Dr T SAMPATH KUMAR, ASSOCIATE

• Minimising and controlling material handling and

Dr T SAMPATH KUMAR, ASSOCIATE

• Minimization of waiting time for semi-finished products

Dr T SAMPATH KUMAR, ASSOCIATE

Dr T SAMPATH KUMAR, ASSOCIATE

5. Principle of satisfaction, security and safety

Dr T SAMPATH KUMAR, ASSOCIATE

Dr T SAMPATH KUMAR, ASSOCIATE

• Type of production – Engineering industry, process industry

Dr T SAMPATH KUMAR, ASSOCIATE

• Line or product layout

Dr T SAMPATH KUMAR, ASSOCIATE

Product or line layout:

Dr T SAMPATH KUMAR, ASSOCIATE

Production Line Departments

Dr T SAMPATH KUMAR, ASSOCIATE

Dr T SAMPATH KUMAR, ASSOCIATE

Product Family Departments

Product Family Departments

13-09-2019 Dr T SAMPATH KUMAR, ASSOCIATE 26

• The machines in this layout are generally arranged on

Dr T SAMPATH KUMAR, ASSOCIATE

Dr T SAMPATH KUMAR, ASSOCIATE

Dr T SAMPATH KUMAR, ASSOCIATE

• This layout is suitable for manufacturing huge

Dr T SAMPATH KUMAR, ASSOCIATE

Fixed Material Location Departments

Dr T SAMPATH KUMAR, ASSOCIATE

Dr T SAMPATH KUMAR, ASSOCIATE

• Good material flow pattern

Dr T SAMPATH KUMAR, ASSOCIATE

1. Procure the basic data

11. Determine storage requirements

1. Analyse the product or products to be produced

It incorporates the following:

From the analyses performed, a relationship diagram will be developed.

Based on modifying considerations and practical limitations, a number of layout

Input What ? Why?

The three fundamentals of SLP are

When Product layout is preferred

Dr T SAMPATH KUMAR, ASSOCIATE

When process layout is preferred

Dr T SAMPATH KUMAR, ASSOCIATE

When fixed position layout is preferred

The size and weight of the product restricts the use of

Dr T SAMPATH KUMAR, ASSOCIATE

• Operation process chart

Dr T SAMPATH KUMAR, ASSOCIATE

• This is a graphical representation of sequence of

Dr T SAMPATH KUMAR, ASSOCIATE

Dr T SAMPATH KUMAR, ASSOCIATE

• The flow diagram aids the visualisation of the

• Objectives of flow diagram

Dr T SAMPATH KUMAR, ASSOCIATE

Dr T SAMPATH KUMAR, ASSOCIATE

Dr T SAMPATH KUMAR, ASSOCIATE