Professional Documents
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Plant Layout
Plant Layout
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Definition
Plant layout refers to the arrangement of physical facilities such as machines, equipment, tools, furniture etc. 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 receipt of raw material to the delivery of the final product.
The subject of plant layout not only covers the initial layout of machines and other facilities encompasses improvement in, or revisions of, existing layout in the light of subsequent developments in the methods of production.
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effectively.
utilization.
Improve productivity.
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Principles of Layout
Principle of minimum travel Principle of sequences Principle of usage
Principle of compactness
Principle of safety and satisfaction Principle of flexibility Principle of minimum investment.
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Types of layout
Process layout or functional or job shop layout. Product layout or line processing layout.
PROCESS LAYOUT
The process layout involves a grouping together of like machines in one department. For example : machines performing drilling operations are fixed in the drilling department
In this way there would be a heating department , painting department, casting department.
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Drilling
shop Electro plating shop Painting shop Assembly Finished goods storage
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Training Shop
(Lathes)
The distance between departments should be as short as possible. Machines should be grouped in accordance with the principle of sequence of operation within the department. Convenience for inspection. Convenience for supervision.
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Advantages Handle a variety of processing requirements Not vulnerable to equipment failures General-purpose equipment is less costly and is easier and less costly to maintain Possible to use individual incentive systems Scope for expansion as the capacity can be easily increased. Greater flexibility.
Disadvantages
Difficulty in the movement of material. Requires more space.
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Advantages
Reduction in material handling cost due to mechanization. Avoid production bottleneck. Economy in manufacturing time. Better production control. Require less floor area per unit of production. Work-in-progress is reduced and so on investment. Early detection of mistakes. Greater incentive to a group of workers to raise their level of performance.
Disadvantages
Product layout is known for its inflexibility. This is an expensive layout Difficulty in supervision.
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The worker identifies himself with the product and takes pride
in it when the work is complete. The high cost of, and difficulty in transporting a bulky product are avoided.
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Disadvantages
As the production period being very long so the capital investment is very high. Very large space is required for storage of material and equipment near the product. As several operations are often carried out simultaneously so there is possibility of confusion and conflicts among different workgroups.
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Raw Mat.
Forging Press
Heat Treatment
Proces s layout
Forging Press
Heat Treatment
F i n i s h e d O u t p u t
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2 3
Cell #1
Cell #2
Cell #3
1
Cell #4
1
2 4 3 3
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Advantages
Lower work-in-process inventories.
Reduced material handling costs Shorter flow times in production Improved visual control
Disadvantages
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