FACILITIES

LAYOUT
PRESENTED BY
HIMA K JOSEPH
&
HALE P A
INTRODUCTION:-
A factory is a place where
all the industrial activities are housed. After
the selection of the factory site ,the factory
building is constructed at the selected site.
Factors like owned or hired
building ,new construction or readymade
building have a considerable effect on the
decision of the arrangement of departments
inside the factory.

Generally the activities are

divided in to following groups;
1.Office area in which the administrative
departments are housed.
2.Plant area which houses the following
activities;
a)production departments.
b)service ,,
3.Technical services:-
like receiving departments
store room,stockroom,tool
room, inspection
department, power house and
boiler room, material handling
equipment, shipping department etc.
4.Personal services:-
packing area, time
keeper’s office, canteen
and lunch room,
recreation room etc.

production & service

departments along with location and
sequences of machines and equipments.
IDEAL PLANT LAYOUT
 it is the arrangement of the production
process,storeroom,stock room, material
handling equipments ,employees services,
and all other accessories required for
facilitating the production in the factory.
 Effective utilization of men ,material
machine.
OBJECTIVES
I. Minimization of material handling.
II. Elimination of bottlenecks through
balancing of plant capacities.
III. High material turnover.
IV. Elimination of physical efforts required for
operative workers.
V. Effective utilization of man power
resources'.
VI. Effective utilization of installed capacity,
so return will high.
FACTORS AFFECTING PLANT
LAYOUT DECEISION
 Type of production
 Production system
 Scale of production
 Type of machine
 Type of building facilities
 Availability of total floor area
 Possibility of future expansion
 Arrangement of material handling equipment
MATERIAL FLOW SYSTEM
Men ,machine tend to remain static
while the materials move from one
workstation to another.
MATERIAL FLOW SYSTEM

VERTICAL
FLOW
HORIZONTAL
SYSTEM
FLOW
SYSTEM
HORIZONTAL FLOW SYSTEM
 Single storey building
 Starting point receiving(R) of raw materials
and terminal point shipment (S) of finished
goods.

R S
 VERTICAL FLOW SYSTEM
 Multi storey building.
 It is used where limited land area is available
and the processing is done on light materials
with the help of light machines.

4TH
FLOOR

3RD
FLOOR
-

2ND
FLOOR

GROUND S
FLOOR R
TYPES OF LAYOUT
1) PROCESS LAYOUT:-
It is called functional
layout. All machines performing similar
type of operations are grouped to one
location in the process layout.
Eg.milling machines, cutting machines .
Advantages;
1.Specilization in supervision is possible.
2.Individual incentives schemes can be
developed.
Disadvantages
1.The cost of material handling will increases.
2.The inspection cost is high.
Product layout
The machines are arranged in
sequence required by particular order. Arranged in
an sequential order.
Advantages
1.Reduced material handling cost due to straight line
production flow.
2.Maximum utilization of machine and labor capacity
through developing proper balance between them.
Disadvantages
1.The breakdown of one single machine in the
line interrupts the entire production flow.
2.They are less flexible than others.
mixed or combined layout:-
both are mutually exclusive.
A proper compromise reaping the benefits of
both the layouts is possible to some extent.
static product layout or project layout:-
the manufacturing operations
requires the movements of men ,materials
and machine .few inputs are static and
others are moving.
Cellular or group layout
machines are places in
groups. Each machines group makes a family
of parts which requires similar
treatment.computerised numerical control
machines are ;
1. flexible manufacturing module(FMM)
2. flexible manufacturing cell(FMC)
3. flexible manufacturing system(FMS)
4. flexible manufacturing line(FML)
Job shop layout
it is the process of job production, and
hence the system is very flexible.
 PLANT LAYOUT FACTORS
It is necessary to optimize these to have an ideal
layout.
1.Manpower factors
2.Machinery
3.Movement
4.Material
5.Waiting
6.Service
7.Factory building
8.Change related
LAYOUT DESIGN PROCEDURE

Determine the objectives/limitations

Collect the input data and study the

activities involved

Determine the flow of materials and

activity relationships

The said space relationship diagram is

modified
 Several alternative layout emerge as a
result

MANUAL METHODS
1.FLOW AND ACTIVITY ANALYSIS:
Design a sound layout plan, we require
both qualitative and quantitative data about
various affecting the plan like product
attributes, output volume and components
parts.
PROCESS CHART
a. Operation process chart
b.Flow process chart
operation process chart
it is a process chart which gives an
overall picture by recording in sequence only
the main operation(0) and inspection
Specify;
1.type the chart
2.job concerned and it is present or proposed
methods
3.Date of study and name of observer.
4.Where the chart begins and ends.
Flow process chart;
A process chart setting out the sequence of
the flow of a proceidureby recording all
events under review using the appropriate
process chart symbol.
2.Travel chart;
it is also called from to chart, since it
depicts the entire material flow amongst the
departments taken as a source and
destination
Merits
1.Useful tools of materials movement analysis.
2.Useful to locate activities.
3.Alternative flows and layouts could be compared.
4.Shows quantitative relationships and hence useful
in computerization and OR.
3.REL CHART
A:Absolutely essential
E:essential
I:important
O:ordinary
U: unimportant
X: not desirable
casting
A
forging I
E I
drilling E
X
A O
X
machinin
O O I
g U E I
U
I
U
metrolo O
I
gy U X
O A
electrics
O A
o
welding
o
inspectio
n
 SYSTEMATIC LAYOUT PLANNING
PROCEIDURE

INPUT DATA ACTIVITIES

MATERIAL ACTIVITY
FLOW RELATIONSHIP

RELATIONSHIP
CHART

SPACE
SPACE NEEDED AVAILABITY

---------------------------------------------------------------------
 RELATIONSHIP CHART

MODIFICATION PRATICAL
PROPOSALS CONSTRAINTS

LAYOUT
ALTERNATIVES

---------------------------------------------------------
-
EVALUATION
QTM LAYOUT
• It applied to layout problem.
• Linear programming
• Transportation problem
• Assignment technique
• Dynamic programming
• Waiting line method and simulation.
COMPUTERIZED RELATIVE
ALLOCATION OF FACILITIES
TECHNIQUE
It is called CRAFT.
It is an integrative programmed which is
continued till the further reduction of cost is
not possible.
It is mainly heuristic algorithm.
COMPUTERIZED RELATIONSHIP
LAYOUT PLANNING(CORELAP)
 It can input of scale of output
 Length to width ratio
 Pre assignments of departments.
AUTOMATED LAYOUT DESIGN
PROGRAMMED
 This algorithm is constructed using the
facilities data and placing the departments.
 The input consists of the data regarding the
no, area,length,width of departments ,REL
chart etc.
THANK
YOU……………
….