Plant/Facility Layout “Plant layout ideally involves allocation of space and arrangement of equipment in such a manner that overall operating costs are minimized. Plant layout refers to the arrangement of physical facilities such as machinery, equipment, furniture etc. with in the factory building in such a manner so as to have quickest flow of material at the lowest cost and with the least amount of handling in processing the product from the of material to the shipment of the finished product. Page 2Features of Plant Layout + Ease of working, maximum safety and minimum health hazards for people working in the plant + Minimum handling of materials * Reduced congestion of materials, machinery and men + Minimum damage and spoilage of materials + Flexibility with regard to changing production conditions Page 3Factors affecting Plant Layout 1. Plant location and building 2. Nature of Product 3. Plant Environment 4. Spatial Requirements 5. Repairs and Maintenance 6. Management Policy man Needs Page 4Factors affecting Plant Layout + Factory building - The nature and size of the building determines the floor space available for layout. While designing the special requirements, e.g. air conditioning, dust control, humidity control etc. must be kept in mind. Location of a plant greatly influences the layout of the plant. Topography, shape, climate conditions, and size of the site selected will influence the general arrangement of ‘the layout and the flow of work in and out of the building. * Nature of product - Production of heavy and bulky items need different layout as compared to small and light items. Similarly products with complex and dangerous operations would require isolation instead of integration of processes. * Plant Environment - Heat, light, noise, ventilation and other aspects should be duly considered, e.g. paint shops and plating section should be located in hall so that dangerous fumes can be removed through proper . Adequate safety arrangement should alse be made. ance - Machines should be so arranged that adequate space em for movement of equipment and people required for Page 5Factors affecting Plant Layout * Management policy - Various managerial policies relate to future volume of production and expansion, size of the plant, integration of production processes; facilities to employees, sales and marketing policies and purchasing policies etc. These policies and plans have positive impact in deciding plant layout. « Human needs - Adequate arrangement should be made for cloakroom, washroom, lockers, drinking water, toilets and other employee facilities, proper provision should be made for disposal of effluents, if any. + Type of machinery - General purpose machines are often arranged as per process layout while special purpose machines are arranged according to product layout. * Production Process - In assembly line industries, product layout is better. In job order or intermittent manufacturing on the other hand, process layout is desirable. Page 6Principles of Plant Layout . PRINCIPLE OF MINIMUM MOVEMENT PRINCIPLE OF FLOW PRINCIPLE OF SPACE PRINCIPLE OF SAFETY PRINCIPLE OF FLEXIBILITY PRINCIPLE OF INTERDEPENDENCE PRINCIPLE OF OVERALL INTEGRATION PRINCIPLE OF MINIMUM INVESTMENT Page 7Principles of Plant Layout + PRINCIPLE OF MINIMUM MOVEMENT - As far as possible materials and labour should be moved over minimum distances. « PRINCIPLE OF FLOW - The work areas should be arranged according to the sequence of operations so that there is continuous flow of materials without congestion. The layout should allow for easy movement of materials without interruption or delay. + PRINCIPLE OF SPACE - All available cubic space should be effectively used both vertically and horizontally. « PRINCIPLE OF SAFETY - There should be consideration for safety and convenience of workers. There should be built in provision for the safety and comfort. Page &Principles of Plant Layout + PRINCIPLE OF FLEXIBILITY - Layout should be designed in the manner that production facilities can easily be rearranged when it becomes necessary in future on account of expansion and technological advancement. + PRINCIPLE OF INTERDEPENDENCE Interdependent operations and processes should be located in close proximity to each other. + PRINCIPLE OF OVERALL INTEGRATION - All the plant facilities and services should be fully integrated into a single operating unit so as to maximize efficiency and minimize costs of production. * PRINCIPLE OF MINIMUM INVESTMENT - The layout should yield savings in fixed capital investment through optimum utilization of ilable facilities. Page 9Costs involved Costs of movement of materials from one work area to another Cost of space Cost of production delays Cost of spoilage of materials Cost of labour dissatisfaction and health risks Costs of changes required if the operational conditions change in the future. Cost of customer dissatisfaction due to poor service (quality, delivery, flexibility, responsiveness, cost) which may be due to poor Page 10Plant Layout : Types llThe production process normally determines the type of plant layout to be applied to the facility: + Fixed position plant layout Product stays and resources move to it. + Product oriented plant layout Machinery and Materials are placed following the product path. . i a ut (Functional Lr Machinery is placed according to what they do and materials go to them + Combined Layout Combine aspects of both process and product layouts Page 12product/ 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 from 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. (B) Product Layout Page 13Product Layouts + Product layouts are used to achieve a smooth and rapid flow of large volumes of goods or customers through a system. Product layout sets up production equipment along a product-flow line, and the work in process moves along this line past workstations. It efficiently produces large numbers of similar items. {Begin Work flow =e lend} ii i _.. Finished cediatiae —_ Materials Materials / Materials Materiats _/ and/or labor and/or labor and/or labor andor labor LAR Nagata,Product Layouts * eg. ina paper mill, bamboos are fed into the machine at one end and paper comes out at the other end. The raw material moves very fast from one workstation to other stations with a minimum work in progress storage and material handling. © eg. chemicals, sugar, paper, rubber, refineries, cement, automobiles, food processing and electronics etc. WS WS?) WS3) WS4 WSS OUT A product layou! in a paper manufacturing operation WAY 4 Page 15Product Layouts Advantages A high rate of output Low unit cost due to high volume Low material-handling cost per unit A high utilization of labor and equipment Smooth and uninterrupted operations Continuous flow of work Optimum use of floor space Shorter processing time or quicker output ess congestion of work in the process fective inspection of work moduction control Disadvantages Morale problems due to repetitive stress injuries. Highly susceptible to shutdowns Preventive maintenance, the capacity for quick repairs, and spare-parts inventories are necessary expenses High initial capital investment in special purpose machine Breakdown of one machine will hamper the whole production process Lesser flexibility as specially laid out for particular product. Page 16process Layout Process layout groups machinery and equipment according to their functions. In this type of layout machines of a similar type are arranged together at one place. E.g. Machines performing drilling operations are arranged in the drilling department, machines performing casting operations be grouped in the casting department. Therefore the machines are installed in the plants, which follow the process layout. Page 17Process Layouts * Process layouts are designed to process items or provide services that involve a variety of processing requirements. Process Layout Product Layout (functional) (sequential) Used for Intermittent Processing Used for Repetitive Processing Job Shop and Batch Processes Repetitive and Continuous Processes Page 18Process Layouts The grouping of machines according to the process has to be done keeping in mind the following principles — 1. The distance between departments should be as short as possible for avoiding long distance movement of materials. 2. The departments should be in sequence of operations 3. The arrangement should be convenient for inspection and supervision eg. tailoring, light and heavy engineering products, made to order furniture industries, jewelry. a el ee AL |[iowcsn | Rapaee’||_Ripore_|| Boom Wee] Goan agrees || RopersProcess Layouts Advantages Disadvantages = There is high degree of machine utilization, asa " In-process inventory costs can machine is not blocked for a single product be high = Change in output design-and volume can be * Material handling costs are high more easily adapted to the output of variety of == More skilled labour is required products resulting in higher cost. = Not vulnerable to equipment failures. = Time gap or lag in production is Breakdown of ane machine does not result in higher complete work stoppage = Work in progress inventory is =) Supervision can be more effective and high needing greater storage specialized space gre is a greater flexibility of scope for = More frequent inspection is n needed which results in costly supervision Page 20Fixned-P osition Layout + A fixed-position layout places the product in one spot, and workers, materials, and equipment come to it. * In this type of layout, the major product being produced is fixed at one location. Equipment labour and components are moved to that location. All facilities are brought and arranged around one work center. This type of layout is not relevant for small scale entrepreneur. E.g. - shipbuilding (C) Fixed-PositicFixed-Position Layouts * In fixed-position layouts, the item being worked on remains stationary, and workers, materials, and equipment are moved about as needed. + Fixed-position layouts are widely used in farming, firefighting, road building, home building, remodeling and repair, and drilling for oil. In each case, compelling reasons bring workers, materials, and equipment to the “product's” lacation instead of the other way around. . Manufacture of bulky and heavy products such as locomotives, boilers, generators, wagon building, aircraft ing, etc. Construction of building, flyovers, dams. Page 22Fixed-Position Layouts (D) Fixed-Position Layout 497 ae ' a St Material resourcesixed-Position Layouts Advantages Disadvantages = Saves time and cost in movement + Capital investment is quite heavy = Flexible as changes in job design can be * Very large space is required for storage easily incorporated of materials and equipment = More economical when several orders in * As several operations are carried different stages are executed simultaneously, possibility of confusion + Adjustments can be made to meet and conflicts are high shortage of materials or absence of workers. Page 25customer Oriented Layout + Customer-oriented layout arranges facilities to enhance the interactions between customers and a service. [)Custemer-Oired Layout vet bot Page 26Combination Layouts * Combine aspects of both process and product layouts. + Supermarket layouts are essentially process layouts, yet we find that most use fixed-path material-handling devices such as roller- type conveyors in the stockroom and belt-type conveyors at the cash registers. Page 27Thank you Page 28