Ktustudents - In: Layout

Module - I
LAYOUT
Design of layout of factories, Office, Storage area etc, on

consideration of facilities of working people, Storage facilities and
general equipment for amenities of working people – Product, Process
and combination layout – Systematic layout planning, Design of
Assembly lines, Line balancing methods.
1.1 FACTORY LAYOUT/PLANT LAYOUT

Layout of a factory is most important task for obtaining least
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total cost of material handling. For a good factory layout, it is most
essential to have minimum movement of workers and materials during
production.
Layout should be such that, it can be changed without much

difficulty due to expansion, diversification, change in product design
or technology.
‘Plant layout can be defined as the physical location or

configuration of departments, work-stations, and equipment in the
conversion process.’
It is defined as “Judicial selection of the location of the plants
and machines so as to facilitate uninterrupted and quick movements
of input materials through pre-determined cycle of operations till these
are transformed as outputs in the form of products and services with
minimum material management and handling, with maximum
efficiency and quality of operation leading to minimum overall cost
of the entire operations.
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1.2 Material Handling and Facilities Planning - www.airwalkbooks.com
1.2 OBJECTIVE OF FACTORY LAYOUT

1. Minimum material handling and maximum production
2. Flexibility of assembling
3. Facilitate manufacturing process
4. Efficient usage of man power
5. Good working conditions
6. Care for employee safety
7. Minimum production delay
8. Less capital investment
9. Easy supervision
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10. Better ventilation and illumination
1.3 ADVANTAGES OF EFFECTIVE LAYOUT

1. Improved in production process as a whole.
2. Higher production capacity.
3. Reduction in the amount of inventory.
4. More efficient usage of machinery and labour
5. Minimum material handling, and safe material handling.
6. Improved supervision
7. Short material flow and production cycle.
8. Less handling by skilled workers.
9. Safe, neat and clean layout.
10. Comfortable working with less mental or physical strain on
workers
11. No bottle neck.
12. Flexible to meet variations in output and varieties.

www.srbooks.org Layout 1.3
1.4 EFFECT OF BAD LAYOUT

1. Long production cycle
2. Stock control difficulties
3. Delay in production and delivery.
4. Poor house keeping
5. Crowded condition
6. Excessive material handling by skilled labors
7. Difficulty in supervision and control
8. Back tracking.
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9. Bottlenecks in production
10. Excessive temporary storage
11. Some machines will be heavily loaded and some will stay idle
for long time.
12. Obstacles in material flow.
1.5 DESIGN OF LAYOUT OF FACTORIES

Fig. 1.1 shows a design of layout of a factory. The factory’s
60% of area is covered by the production and assembly units. Where
as the 20% of area is covered by storage unit. Remaining 20% is
covered by the employee amenities.
These configurations may vary depending on the type of factory.

Since Fig. 1.1 is shown for a manufacturing plant, the maximum space
is allotted for production unit.
Certain factors which has to be considered for good factory

design are explained here.

Lo cke r for Em ployee
Toilet
T - Table
Ad m inistrative
O ffice T1 T2 T3 T4
P ath way
Pa rking
M edical
T8 T7 T6 T5 R oom
Assem bly
Shipping Unit
R eceiving
Productio n
A rea
Finished
Products
P arking
Raw P arts Parts
M a terials Pro cessing F inishing

F ig: 1.1 D esign of L ayou t of Facto ry
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1.5.1 Product
The type of factory to be constructed depends on the type of
product to be manufactured. The production process determines the
equipment, machinery and plant to be utilized in plant layout. For an
effective factory layout, the following aspects have to be considered.
1. Product design
2. Product specification
3. Quantity, rate of production and variety.
1. Product Design
Product design is essential for a large scale factory layout. For
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example, a change in product design may change the process of
manufacturing from casting to welding. Product design is also
necessary to determine the raw material storage space.
2. Product specification
The specified dimensions, limits and tolerances to which the
parts are to be produced often determine the kind of process or type
of machinery to be used.
For example, for turning a diameter of 10 mm, an ordinary lathe
may serve the purpose, but for the limit 0.001 mm, grinding or lapping
equipment is needed. For closer tolerances, rate of production will be
slow, so appropriate machine has to be fitted.
3. Quantity, Rate of Production and Variety

Quantity and variety of production determines the number of
machines required for total production. If the rate of production is
high, then the layout can be line or product layout.
Variety applies not only to products, but also to various styles,
types and models.

1.5.2 Method of Production
Product methods are heart of a physical factory layout. Method

of production determines the machinery and equipment, and this
determines the entire factory. The production method depends on
number of aspects like.
 One production may depend on number of operations.
 Some may depend on number of machineries or other

production may depend on one machine.
It is therefore essential to take decision about the methods to

be used for the process, before attempts are made to plan a layout.
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Sequence of operations will influence the finial shape of the
layout.
It is very important and necessary to list the operations and the

order in which they are performed.
1.5.3 Machinery and Equipment
It is impossible to make a layout without the complete

information about the machinery and the equipment to be used in the
manufacturing process.
For proper arrangement of the machinery and good layout, we

must know the number of machines exactly. The number of machines
of a given type will determine not only their location in relation to
each other, but also their relationship for those equipments used in
preceding and following operations.
The equipment will also influence the layout as it needs

superstructure, feeder, hooker etc. The machine height decides the
height of the factory ceiling.

In addition, space must be left for moving in or out for the

changes to be made in layout in future. This is particularly a serious
problem, when columns and walls are nearer to elevators etc.
1.5.4 Material
Material has certain characteristics that may affect the layout.
The important properties that will influence are:
(i) Size
(ii) Shape and Bulk
(iii) Weight
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(iv) Conditions
(v) Special characteristics
 A large size product will need entirely a different setup for

processing as well as the movement of the product than
small size product.
 Long materials like bars, rods or pipes will create different

problems like storage etc.
 The product weight is also an essential factor, as one storey

buildings are suitable for heavy weight products.
 The condition of material may be solid or liquid or gaseous,

hard or soft, stiff or flexible, which influences the factory
layout.
 Some special characters like ductile or brittle or fragile,

some others may be volatile, flammable or explosive, have
to be considered, because they also influence the storage
area.

1.5.5 Movement
In movement of materials, material handling plays a vital role.
During planning, the man incharge of layout should see the flow which
may be straight line, towards completion, without back tracking (or)
cross flow. Unnecessary handling will result in damage of the material
and undue physical effort.
The movement can be of two factors, they are:
(i) Movement of material
(ii) Movement of man.
Movement of Material
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Major production work depends on the movement of materials.
Material handling is responsible for 90% of plant accident and 80%
of indirect labour charge and large percentage of product damage.
So it is necessary that factory layout should eliminate the
unnecessary and uneconomical handling to reduce the overall cost by
planning proper handling methods and equipments.
Movement of Man
A good layout provides easy movement of production workers,
indirect labors or supervisors. Workers must be able to get their work
conveniently.
Jumbled and crowded equipments do not permit access areas for
inspection or supervision which results in poor control over the
operations.
1.5.6 Employee facilities

Today industrial standards and act demands services like medical
facilities, canteen and cafeteria for food services, locker rooms and
lavatories as essential services.

There are some factors which contribute to employee working

condition are heat, light, ventilation, noise and vibration etc.
Employee’s facilities necessary for the comfort, convenience and
safe working must be provided at the time of lay out.
Good layout should take care of proper illumination, control of
noise, vibration and dust, arrangement of proper ventilation and
discharge of fumes and other harmful gases.
1.5.7 Services
The factory requires a wide variety of services which support
and keep the production going.
The services to be considered are:
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Piping:
For water, steam, oil, acids, coolants, lubricants, gases and
compressed air.
Drain:
Drainages are used for waste water, water solution, acid etc.
Exhaust and ventilation ducts:

For fumes, dusts, vapours etc.
Connection:
For electricity, transformers for higher voltage etc.
Supports
Foundation trusses, overhead beams for material handling etc.
Protection and segregation

Combustion, explosion, spillage, dirt and hazard, contamination,
delicate machines and instruments.

Conditioning
Filtered air, constant temperature, sound absorption, fire
protection, well maintained working area, sunlight window shield.
Movement
Super flexibility, services operating lift etc., special axis area,
fire exit area, etc.
1.5.8 Adaptability and Versatility

A proper factory layout must meet the emergencies and
variations from the normal operation without any difficulty. If normal
production is not done, then the following measures can be taken for:
(i) Determining an alternative route
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(ii) Providing standby equipment
(iii) Establishing bank (or) buffer stock
Versatility is the ability to handle a variety of different products.
Versatility depends on:
(i) Tools, equipments and machinery should be handled without any
fluctuation.
(ii) Supervision should be adjusted to operating conditions, hours of
work, reassignment of men to various jobs, changes in speeds of
equipment.
1.5.9 Location of factory

The management often faced with the problem of selecting a
new site for locating a new factory.
Very often, the cost of transportation of inputs and outputs to
the processing units or the market place are the critical parameters. In
such cases, the transportation method can be used for finding out the
lowest cost location.

P u rc ha se
M an ag er B illing A c cou nts C hief
D e pa rtm en t D e pa rtm en t Ac counta nt
V IP
W a iting
P u rc ha se A u ditin g R o om
C h ie f D e pa rtm en t
D e pa rtm en t
A u dito r
C on ference
C o nfe re nc e R oo m :2 R oo m
S ta tion ary
R o om / S to res P re s ide n t
S e cu rity
D e pa rtm en t
R e ce ptio n
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M ed ic al C h airm a n
R o om /
R e st R oo m
P a rk ing E n tra nce V IP P a rking
Fig: 1.2 O ffice La you t
Layout is also influenced by the size and shape of the plot,

climatic conditions and by the laws of the areas where the plot is
located. Plant layout will also have a bearing on the method of
acquiring and storing fuel and power. Some locations will have facility
of purchasing power from central station, but in other locations, they
have to provide layout for generation of power.

1.6 DESIGN LAYOUT FOR OFFICE/ADMINISTRATIVE

OFFICE
Fig. 1.2 shows the layout of office. The general office normally
consists of the executives, personnel, purchases, accounts, sales,
advertising and public relations departments.
The location, arrangement and accommodation vary widely
between the functional types of offices and location of each of these
departments should be planned just like any other operation. In general,
in most companies, offices are all combined into one area for easy
communication among each personnel.
The offices for services, production and personnel may be
located within the production area but admin office should be separated
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because there are large number of outside visitors are frequently
coming to the administrative offices.
In case the offices are to share building housing plant activities
such as warehouse, store, shipping etc., it is often desirable to place
the office on the upper floor. This makes the lower floors for factory
or warehouse purposes. Normally the top floor gives better light and
has less noise from factory (or) warehouse activities carried on the
same building.
1.6.1 Considerations for office layout

The most important considerations for office layout are:
1. Relationship between different departments
2. Flow of information
3. Communication
4. Conference rooms.

1. Relation between different departments

Administrative office and sales office usually have to
accommodate outside visitors. The appearance of the office leaves an
impression on visitors and influences their goodwill towards the
company.
Purchasing and personnel office also receive visitors
continuously.
2. Flow of information
The organisation chart shows clearly how the information flows
from one division to another, the level of responsibility, where the
information originates and its ultimate destination. It provides
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reasonably good solution to the problem of determining the relative
positions of the department in the building.
3. Communication
The volume of communication - written, oral, by telephone or
in person, provides another key to the determination of best
arrangement of the auxiliary departments.
The quantity of communication will decide the nearness between
the various departments and those departments, between which the
flow is maximum, should be placed closer than the others.
4. Conference Rooms
The size and frequency of visit of conference room to be held
will determine the amount of floor space to be set aside for conference
rooms. Advanced consideration to this requirement will assure better
location and more adequate space for conference rooms.

1.6.2 Suggestions for office layout
1. In placing the department, sections, working units, etc., remember

that a straight line is the shortest distance between two points
and then, as nearly as is practical to have the flow of work.
Conform to this principle.
2. Remember that office floor space must be conserved, but not at

the expense of appearance, production or comfort.
3. Place related departments nearer to each other.
4. Aisles should be at least 3 feet wide.
5. Group minor activities around major ones so that when more
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space is needed, the major function will be taken care of first.
6. The type of work to be done is the basis for departmentalizing

the office work.
7. Work should come to employees rather than they go for it.
8. Employees’ place of working need at least 50 to 75 square feet

of working space.
9. An orderly and attractive appearing office induces respect of

visitors and efficiency on the part of employee.
10. Place offices of executives largely concerning with administrative

control and operations so that they may be able to maintain close
supervision over their departments.
1.6.3 File Department

Spacing between rows of filing cabinets which face one another
may be planned at a minimum of 40 to 80 inches. These are the
minimum dimensions to be used where high floor-space cost must be
considered.

When file drawers open at one side of an aisle, a 3-foot

minimum space may be allowed where 24.5 inch depth files are used
and 40 inches for 28.5 inch depth files.
1.6.4 Storage room and stationery room

 Inactive transfer cases and storage boxes require aisles
having a minimum of 4 feet.
 When open shelves are used for binders, old records, etc, a
minimum space of 30 inches is sometimes used for economy
of space.
 In stationary rooms, open shelves are used with a 3 foot
minimum width to be workable.
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1.7 STORE LOCATION AND LAYOUT
Stores are reservoirs to keep the production line adequately
supplied with raw and semifinished materials required.
Stores safeguard the materials from losses due to pilferage,
unauthourised use and deterioration due to weather, moisture, heat,
improper handling and obsolescence.
1.7.1 Location of Store

While locating the stores, the following criteria has to be
considered.
1. Stores are at convenient location.
2. Unnecessary Movement of employee should be restricted by
providing them with proper materials from the nearest stores at
right time.
3. Location should be such a way that it does not require long hauls
of large volume of materials.

4. Arrangement of storage area should permit the use of mechanical

handling facilities.
5. Sufficient and proper space should be provided for store staff as
well as store records.
1.7.2 Planning of store layout

(i) A separate room near the store room has to be allotted for
unaccepted materials till they are approved.
(ii) Minimum handling materials.
(iii) Sufficient spacing between two lanes of racks etc.
(iv) Protection facilities to prevent from theft, damage, fire etc.
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(v) Transporting devices like trollies, fork lifts, trucks, conveyors,
gravity feed, etc., can be utilized without any obstacles.
(vi) Material has to be stored separately based on their characteristics
like inflammable items, tyres and other rubber items and welding
electrodes.
(vii) Sufficient space should be left for future expansion.
(viii) Adequate and clear lighting arrangement should be made.
(ix) Layout should encourage ‘First In First Out’ policy.
1.7.3 Layout of store

Fig. 1.3 shows the layout of store. The main elements of store
that need to be considered are: Raw material, Temporary storage,
Special storage facilities
Raw material storage

In this unit of storage, the raw materials are stored. These are
used for making the products like pig iron in a steel plant, raw cotton
in a textile mill. These are stored as per the type of materials.

U sually it shou ld b e
in sep ara te bu ilding
C h an ging S p ecial
S ta tion ary W a ste a nd
R o om for S to ra ge
S to re s S crap
Produ ction Fa cility
M aterials
S ta ff (Flam m able &
E xplosive s)
C o m p one nts
Tem p ora ry a nd S u b A sse m b ly
S to ra ge S to ra ge
Tools
R o om
A p pro ved
Fina l P rod uct
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Raw
P a ckaging A d m inistratio n M aterials
D e spatch O ffice:1
A re a E n tra nce (R ece iving)
P a rking P a rking
Fig: 1.3 Layout o f Stores
Temporary storage
When a particular raw materials are used and the job is
completed, no further need will be required for the storage of that
particular item. Storing this raw material in store room and having it
issued occasionally proves as wasted effort. The temporary storage
arrangement of these kind of materials at the point of use itself
eliminates some of the material handling works and checking.
Special storage facility
Certain kind of materials such as paints, oil, acids, gas cylinders,
chemicals, flammable and explosive substances require special storage
facility which may have to be built outside the plant building or
separate section for it with proper handling method.

1.8 AMENITIES OF WORKING PEOPLE

The success of an organisation depends upon many facts like
efficient management, better planning, good market, efficient personnel
etc. But most important factor of all is employees.
Certain facilities which will give good impression on working
environment are listed below.
1. Lockers, washrooms and toilets.
2. Food services and drinking water
3. Medical services, dispensary, first aid.
4. Good working conditions which include
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(i) Light
(ii) A/C (comfortable temperature)
(iii) Fresh air
(iv) Minimum noise
(v) Use of colours
(vi) Safety.
5. Special services
(i) Banking and loan facility
(ii) Trade union activity
(iii) Insurance program
(iv) Personal advisory activity
(v) Training programme
(vi) Education for children of employees.
(vii) Creches, common meeting rooms
(viii) Recreation programme - Games/Sports/Cinema.

To provide facilities in satisfactory manner, management will

have to go for careful planning at the beginning of process itself.
Most of these activities require certain office space which can
be estimated in terms of the company’s total employment and rate of
turnover.
1.9 TYPES OF LAYOUT

There are four basic types of layouts and they are:
1. Product layout
2. Process layout
3. Fixed position layout
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4. Cellular layout
1.9.1 Product layout

This type of layout is generally used when a product having
standard features is to be produced in large volumes. The production
process thus involves in repetitive tasks to be performed on items
which are arranged in a sequence. The specialized machines and
P ro du ct A
F
R
I
A 1 2 3 4 5 6 N
W
I
P ro du ct B S
M
H
A
1 2 3 4 5 6 E
T
D
E
R
12 11 10 9 8 7 G
I
O
A
O
L
13 14 15 16 17 18 D
Fig: 1.4 A Pictorial R epresentation of Pro du ct L ayou t

equipments are arranged one after the other in the order of sequence
required in production process, such that a production line is formed
by them as shown in Fig. 1.4. This production line is often called as
the assembly line.
Advantages of product layout

(i) Low unit cost due to high volume.
(ii) Delays are reduced.
(iii) Smooth, simple, logical and direct flow.
(iv) Low material handling cost per unit.
(v) Less skill is required for personnel.
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(vi) Inspection can be reduced.
(vii) Effective supervision and control.
(viii) Less work in process.
Disadvantages of product layout

(i) Less machine utilization.
(ii) Less flexible.
(iii) Machine stoppage stops the line.
(iv) Higher investment on equipments.
Application of product layout

The various applications of the product layout are listed as
follows:
(i) It is used when production volume of individual product is more.
(ii) It permits continuous material handling using materials or
products employing mechanical methods.

(iii) It does not utilize the same machine or equipment for more than
one operation.
(iv) It is suitable for producing standardized products.
(v) It is useful when inspection needed while carrying out a series
of operations.
1.9.2 Process layout
This layout is also known as job shop layout. Process layout is
particularly suitable when different products are produced in lots or
batches. Process layout is very commonly found in service set-ups
such as banks, post offices, universities, libraries, hospitals etc. A
pictorial representation of a process layout is shown in Fig. 1.5.
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A
B
Sh ear
Sh ear
Sh ear
A
B
M ill
M ill
M ill
B
D rill
D rill
D rill
B
Pa ck
Pa ck
Pa ck
B
Sh earin g M illin g D rilling Pa cking

Se ction Se ction Se ction Se ction
Fig: 1.5 A P icto rial Representation of Process Layout
As shown in Fig. 1.5, in process type of layout all drills are

located in one area of the layout and all milling machines are located
in another area.
Advantages of process layout

(i) Better machine utilization.
(ii) Highly flexible in allocating personnel as well as equipment.

(iii) Change in product design and process design can be incorporated

easily.
(iv) Diversity of tasks for personnel.
Disadvantages of process layout

(i) Increased work in process.
(ii) Longer production line.
(iii) Increased material handling.
(iv) Critical delays can occur, if the part obtained from previous
operation is faulty.
Application of process layout
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The various applications of the process layout are listed as
follows:
(i) It is used when production volume of individual product is less.
(ii) It is mostly used in discontinuous production.
(iii) It permits continuous material handling by using considerable
amount of materials or products employing mechanical methods.
(iv) It utilizes the same machine or equipment for two or more
different operations.
(v) It produces numerous varieties of products mostly when special
orders are made.
(vi) It is useful when more inspections are needed while a series of
operation are being carried out.
1.9.3 Fixed location layout

This type of layout is used when the product is very bulky, heavy,
large or has a fixed position. Here, the product is kept at a fixed position
and all other materials such as component, tools, machines, workers etc.

D rill
W eld S h ea r
Job
G rin d A ssem bly
P a in t
Fig: 1.6 A P ictorial R epresentatio n of Fixed L ocation Layou t
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are brought and arranged around it. Then assembly or fabrication is
carried out. For example, in the construction of a building, dam, plant
etc. this layout is used. A pictorial representation of a fixed location
layout is shown in Fig. 1.6.
Advantages of fixed location layout
(i) Movement of material is reduced.
(ii) Highly flexible, can accommodate changes in product design,

product mix, and production volume.
(iii) Promotes pride and quality, because an individual can complete

the whole job.
Disadvantages of fixed location layout
(i) Skilled persons are required.
(ii) May result in increased space and greater work in process.
(iii) Personnel and material movements are increased.

Application of fixed position layout

The various applications of the fixed position layout are listed
as follows:
(i) It is used when only lesser items are manufactured.
(ii) It is used when the operation requires only tools or simple
machines.
(iii) It is useful when transferring cost of bulk amount of material is
high.
(iv) It is helpful when labour skill is dependent on his capability.
1.9.4 Cellular type layout
KTUStudents.in G rind Lathe D rill
A
S
S
Lathe D rill Press E
M
B
L
Y
Lathe D rill Press
Flow path of G ro up 111


Fig: 1.7 A Pictorial Representation o f Cellu lar Type o f Layout
This type of layout is based on the grouping of parts to form

product or part families. Similar products such as standard bolts or

nuts can be grouped into families based on common processing

sequences, shapes, tooling requirements etc. The processing particular
product family are arranged together and placed in a manufacturing
cell. This type of layout is used where various products have to be
manufactured in medium to large quantities.
A pictorial representation of cellular type layout is shown in
Fig. 1.7.
Advantages of cellular type layout

(i) Higher utilization of machine.
(ii) Offers some benefits of both product and process type layout.
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(iii) Smoother flow lines and shorter travel distances are expected than
the process layout.
Disadvantages of cellular type layout

(i) Requirement of flow balance in each cell.
(ii) Greater labour skills required.
5. Applications of cellular layout

The various applications of cellular layout are listed as follows:
(i) It is used when different parts of the products are produced.
(ii) It is suitable for producing various items having varying size and
shapes.
(iii) It is used in work areas having easily moveable machine tools.
(iv) It is used when more items are produced in sequence but not in
bulk.
(v) It is used when the production of the product does not depend
on its capacity.

1.9.5 Difference between product layout and process layout

No Features Product layout Process layout
1. Nature of It is suitable for It is suitable for
product standardized products. non-standardized
products.
2. Production It is meant for mass It is meant for
volume production and less moderate production
job variety since and more job variety
similar machines are since similar machines
arranged according to are arranged in one
the sequence of location for
operation required for manufacturing the
manufacturing the product.
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product.
3. Utilization of The equipments are The equipments are
workers and not utilized fully and utilized fully and
equipments effectively as effectively as they can
machines and workers be used on different
are specialized for parts or products.
specific parts.
4. Initial Higher initial Lower initial
Investment investment for investment for
machines and machines and
equipments. equipments.
5. Space It requires less space It requires more space
for same amount of for same amount of
production. production.
6. Flexibility Work flexibility is less Work flexibility is
which makes changes more which makes
in operation quite changes in operation
impossible to manage. easily manageable.

No Features Product layout Process layout

7. Effect of Breakdown of one Breakdown of one
breakdown machine disturbs the machine affects
whole production. operation over that
particular department.
8. Manufacturing Time required for Time required for
time manufacturing product manufacturing product
is less. is more.
9. Control and Production planning Production planning
coordination and control is simple and control is difficult
since it needs less since much effort is
effort for coordination. needed for
coordination and parts
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have to be sent
through a number of
departments at
different locations.
1.10 SYSTEMATIC LAYOUT PLANNING (SLP)

Systematic layout planning is an organized way to conduct
layout planning. It consists of a framework of phase, a pattern of
procedures and a set of conventions for identifying, rating and
visualizing the element and areas involved in planning.
Every layout resets on three fundamentals.
1. Relationships
The relative degree of closeness desired (or) required among
things.
2. Space
The amount, kind and shape or configuration of the things being
laid out.

3. Adjustment
The arrangement of things into a realistic best fit.
1.10.1 Elements of systematic layout planning
1. Degree of Activity interrelationship

In order to identify which activity should be located where, a
classification of degrees of closeness has been established along with
code to identify each.
A - Absolute necessary
E - Especially important
I - Important
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O - Ordinary
U - Unimportant
A closeness code is shown in table 1.1
Table 1.1 Colour code
Value Closeness Code

A Absolute necessary Red
E Especially important Orange
I Important Green
O Ordinary Blue
U Unimportant None
X Undesirable Brown
The common parameters considered for relationship rating are:

1. Flow of material
2. Degree of personal contact
3. Degree of communication

4. Share personnel/space
5. Supervision or control
6. Noise, dust, dirt, fumes hazards
7. Unsafe or umpleasent conditions
8. Facility of material handling.
2. Activity Relationship Chart

It is a cross section from where the relationship between each
activity and other activities can be recorded for construction of an
activity relationship chart.
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C o de R e ason
1 Flow of m ate ria ls

1 . O ffic e s
0 2 E a se o f su pe rvis ion
4 E 3 C o m m o n pe rso n ne l
2 . Fo re m a n
1 S 0
4 C o nta ct n ece ssary
5 0 3 U
3 . C o nfere nc e R oo m 5 C o nven ie nce
U 4 1 U
6
U 2 1 U
4 . P a rcel P o st
U U 2 1 U 7
5 . P a rts S h ip m en t 0 U 2 0 U 8
U 4 U U 2 1 U 9
6 . R e pa ir an d S ervice U U U 2 1
10
P a rts E U U U 2
3 U U 1 C o de R e ason
7 . S e rvice A rea
U 1 A
A A b so lu te ly n ec es s ary
E 4 U 1
8 . R e ce ivin g E E s pe c ia lly im po rta nt
U 3 U
I Im p ortan t
9 . Tes ting A
E 1 O O rd in ary c lo se n es s O K
3 U U n im po rta nt
1 0. G en era l S to rag e
X U n de sirab le
Fig. 1.8 A ctiv ity relationship cha rt

While deciding degree of closeness, care and judgement should

be assigned. While evaluating activity relationships for N activity, they
N N  1
are . Along with closeness rating other than U, a numerical
2
code ‘N’ is provided to obtain closeness.
3. Activity relationship diagram
In activity relationship 8 7
5
diagram, each activity is represented A
by an equal sized square. The I I
A
squares are connected by number of E 0
10 9 6
lines to the closeness rating. The
0
squares are shifted around until the 0
KTUStudents.in
0 0 0 0
proper relationship between activities
2 3
is obtained Fig. 1.9 shows activity 4 0 0
relationship diagram. E
0
(Note: Normally the chart is drawn 0
1
with colour code as explained in
table. 1.1) Fig: 1.9 A ctivity Relatio nship
D iagrams
4. Space relationship diagram

Space relationship diagram is obtained by trail and error of
activity relationship diagram. Fig. 1.10 shows an output of space
relationship diagram.

5 8 7
A A E
E
0
9 6
10
0 0 0
0 0
0
0
4 2 3
0
0 0 0 E
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Fig: 1.10 S pa ce A ctivity
R elationship D iagram s
1.10.2 Systematic layout planning pattern

It begins with ‘input’ as the possible type of layout. The output
of this section is a list of ‘Activity areas’ which include departments,
cells, work group, product value streams, breakouts, shipping etc.
The second section shows the relationships to be honored by the
layout (i.e) flow of materials.
Once flow of material is identified, then space required and
available space will be calculated. The outcome of this section is space
relationship diagram.
The next section is modification and limitation in which the
space relationship diagram is used. The outcome of this section is
alternative layout.
Analysing all the alternatives, final layout plan will be approved.
Fig. 1.11 shows the SLP procedure.

SL P Pattern o f Procedures
Input (P Q R ST)
1 &
Types o f Layo ut Activity-
Areas
ip s
ti on sh
R e la Flow of M aterials
2 & Othe rs
R e latio nship s R e latio nship
D ia gram
ce
Spa
Sp ace R equ ired
3 & Available Sp ace
R e latio nship
D ia gram
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nt
s tm e
A d ju
M odification s Plan x
4 & y
z
Lim itation s Alterna tive
Layouts
Evaluation
5 &
Ap proval
Layout P lan
for th is P hase
Fig: 1.11 SLP Pattern and Proced ure
1.11 DESIGN OF ASSEMBLY LINES

Assembly line balancing is the problem of assigning operations
in work stations along with the assembly line, in such a way that the
assembly assignment is optimal.
Assembly lines balancing is used to balance the work loads on
an assembly lines. This is required to increase the efficiency and
reduce the operating cost of the line.

A well balanced assembly line reduces wastes such as operator

idleness, the need of fluctuating operators, stock and faulty products.
Assembly lines are popular in mass production of automobiles.
In this system, the raw material enters and moves progressively
through a series of workstations to get processed into the desired
product.
The problem of optimising the divisions of task among
workstations is known as line balancing problem.
Assembly lines are classified as
1. Single mode assembly line
Used in mass production of a single product.
KTUStudents.in
2. Multi-model assembly line
Used when significant difference exists in production process of
each model. It is used in batch production.
1.12 LINE BALANCING

Line balancing is an important technique for any production
system to achieve efficiency and economy.
Line balancing can be defined as, “a production strategy that
involves setting an intended rate of production for required material
to be fabricated within a particular time frame. In addition, effective
line balancing requires assuring that every line segment’s production
quota can be met within the time frame using the available production
capacity.
1.12.1 Terms used in line Balancing
1. Work Element
A rational division of total work.

2. Total work content

Total work content is aggregate amount of total work. Total
work content time is the time required to perform the total work
content.
3. Work station
Different stations at which works are carried out. Each work
station is responsible for a predetermined work.
4. Operation time
The time required to complete the work allotted at each station
is known as operation time.
5. Cycle time
KTUStudents.in
Time available at each station to perform the work is known as
cycle time.
Cycle time = Operation time + Idle time.
1.12.2 Line Balancing Methods
1. Heuristic Approach
Heuristic means ‘Serving to find out’. Heuristic approach is used
for problem solving, decision making or control. These are generally
thumb rules and adopt logical analysis, common sense and past
experience.
Balancing the line
In line balancing problems, tasks are assigned among workers at
assembly line stations so that performance times are made as equal as
possible.
Steps for solving problem are:
(i) Define tasks

Task represents small group of works that can be assigned to a
workstation.

(ii) Sequencing the task

As the task can be performed in a specific sequence, predecessor
and successor tasks are identified.
(iii) Minimum Number of Workstations
Calculate the minimum number of workstations required to
produce desired output.
(iv) Assign task to each station
For this purpose several combinations are possible. Optimize and
assign work to each station.
(v) Evaluate effectiveness and efficiency
Find layout which is effective and which yields desired capacity.
KTUStudents.in
It is efficient if it minimizes ideal time.
1.12.3 Helgeson and Burnie Method
This method is also known as "Ranked positional weight
technique."
The steps for this method are given below.
1. Develop a procedure diagram.
2. Determine the positional weight for each operation corresponding
to the time of the longest path from the beginning of the
operation through the remainder of the network.
3. Rank the work elements based on the positional weight. Work
element with highest positional weight is ranked first.
4. Assign work elements to the work stations, where the elements
of highest positional weight and rank, are first assigned.
1.12.4 Balancing Losses
Balancing loss is the amount of idle time on the line caused by
uneven division of work among operators (or) work stations, and
expressed as a percentage of actual production time of the line.

When two or more operators are working on a line or in a group,

it is often difficult to arrange them to be allocated with the same
amount of work.
Thus the management should make effort to reduce any
imbalance which may be present in the flow line.
The imbalance can be reduced by,
1. Changing the nature of the product/work.
2. Rearranging the work allocation between the operations to get
more work load.
3. Change the number of operators in the sequence.
4. Improve the method by using more heavily load operators.
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5. Divide the task into a number of self-contained operators.
Problem 1.1 Available production for an available day is 380
minutes and the output after production is 450 items. How much times
it takes for a cycle?
Given:
T  380 min/day
Q  450 items
To find
‘C’  Cycle time.
Solution:
T
C
Q
T  380 min
 380  60
 22800 sec

22800
C
450
C  50.66 sec/item
Problem 1.2: Consider the previous problem, for which the work
content is 180 seconds, find the number of work stations and calculate
balancing loss.
Given
Q  450
T  380 min
So, C  50.66 sec
 t  180 sec
KTUStudents.in
To find:
Nmin  ?
Balancing loss
Solution:
Out put  Total work content
Number of work stations Nmin 
Production time
Qt

T
t T
Nmin  C
C Q
180 Q 1
 
50.66 T C
Nin  3.5
Approximately
Nmin  4

Nmin  C   t 4 50.66  180

Balancing losses  
Nmin  C 4 50.66
 11.17 %
Problem 1.3: Time consumed at each station for a job is shown in
the table below.
Station Nos. 1 2 3 4 5 Total

Time (min) 3 3.5 4 6 3 18
(i) Find the line balancing efficiency and balancing loss.
(ii) How to improve line balance?
Solution:
KTUStudents.in
Total time at workstations = 18 min
[. . . Maximum time (6
No. of work stations  Nmin  5
min at station 4) should
Cycle time  C  6 min be taken as C]
Total time at work stations 18
 Line balance efficiency    100
Nmin  C 56
 60 %
Balancing loss = 40% (i.e.) 100  60  40
To improve line balance

Let us split 4th station as 4A and 4B.
New Stations 1 2 3 4A 4B 5 Total

Time (min) 3 3.5 4 3 3 3 18
. .
[ . Nmin  6
18
Line balance efficiency   75 %
64 C  4]
Balancing loss = 25% 100  75  25
Hence new arrangement is improved.

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Module - I

Design of layout of factories, Office, Storage area etc, on

1.1 FACTORY LAYOUT/PLANT LAYOUT

Layout should be such that, it can be changed without much

‘Plant layout can be defined as the physical location or

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1.2 OBJECTIVE OF FACTORY LAYOUT

1.3 ADVANTAGES OF EFFECTIVE LAYOUT

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1.4 EFFECT OF BAD LAYOUT

2. Stock control difficulties

3. Delay in production and delivery.

4. Poor house keeping

6. Excessive material handling by skilled labors

7. Difficulty in supervision and control

10. Excessive temporary storage

12. Obstacles in material flow.

1.5 DESIGN OF LAYOUT OF FACTORIES

These configurations may vary depending on the type of factory.

Certain factors which has to be considered for good factory

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3. Quantity, Rate of Production and Variety

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1.5.2 Method of Production

Product methods are heart of a physical factory layout. Method

 One production may depend on number of operations.

 Some may depend on number of machineries or other

It is therefore essential to take decision about the methods to

It is very important and necessary to list the operations and the

1.5.3 Machinery and Equipment

It is impossible to make a layout without the complete

For proper arrangement of the machinery and good layout, we

The equipment will also influence the layout as it needs

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In addition, space must be left for moving in or out for the

The important properties that will influence are:

(ii) Shape and Bulk

(v) Special characteristics

 A large size product will need entirely a different setup for

 Long materials like bars, rods or pipes will create different

 The product weight is also an essential factor, as one storey

 The condition of material may be solid or liquid or gaseous,

 Some special characters like ductile or brittle or fragile,

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1.5.6 Employee facilities

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There are some factors which contribute to employee working

Exhaust and ventilation ducts:

Protection and segregation

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1.5.8 Adaptability and Versatility

1.5.9 Location of factory

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P a rk ing E n tra nce V IP P a rking

Fig: 1.2 O ffice La you t

Layout is also influenced by the size and shape of the plot,

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1.6 DESIGN LAYOUT FOR OFFICE/ADMINISTRATIVE

1.6.1 Considerations for office layout

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1. Relation between different departments