PLANT LAYOUT DESIGN &

MATERIAL HANDLING
Ir. Florida Butarbutar, MT
Process Flow Diagram (PFD)

 The layout designer uses a PFD as the basis of initial plant layout.
The order of unit operations on the PFD (usually from top left to
bottom right of the drawing) is a good starting point for the layout
in space
 The lines of the PFD are labeled in such a way as to summerize the
mass and energy balance, with flows, temperatures, and
compositions of stream. The visual representation of the plan
interconections and mass and energy balance is the main purpose
of the drawing
Operation Process Chart

 DefenitionOperation process chart (OPC) is a diagram that illustrates the

process steps that will be experienced by raw materials regarding the sequence
of operations and checks from the start to become a complete product or as a
component, and also contains information needed for further analysis continued.
So in an operation process chart, only operations and checks are recorded,
sometimes at the end of the process the storage is recorded
 Operation Process Chart has several uses that can be noted. Its purpose is to be
able to know the need for machinery and its budgeting, to be able to estimate
the need for raw materials (by calculating efficiency in each operation /
inspection), as a tool to determine the layout of a factory, as a tool to determine
improvements to the way work is being used, as well as a tool for training work
Information from OPC

The information that can be obtained in the operation process chart is as follows:
 Raw materials and supporting materials needed (presented with horizontal arrow
lines).
 Operations needed on each component or part of raw material (presented in a
circle).
 Time needed in the process.
 Machines or equipment used in operations.
 Simbols on the OPC
 Operation Operational activities that occur when the workpiece change in nature,
both physical and chemical. Operation is the activity that most occurs in a process
that usually occurs in a machine or work station
 InspectionInspection activities on workpieces or equipment, both in terms of
quality and quantity. Inspection is usually done by comparing the object being
examined against a standard
 Transportation Transportation activities occur when workpieces, workers or
equipment experience a change of place that is not part of an operational process
 Delay-->Waiting activities, where the material is temporarily waiting for further
processing
 Storagethe activity of storing a workpiece for quite a long time.
Operation Process Chart
Routing Sheet

 Ordering production (routing sheet) is a tabulation of the steps involved in producing certain
components and the necessary details of related matters. The ordering of production becomes
important of production activities which is the collection of all data developed by the process
engineer and the main communication tool between the product engineer and the production
worker. This routing sheet is often referred to as a process sheet or operation sheet
 Routing sheet is useful to count the number of machines needed and to count the number of
parts that must be prepared in an effort to obtain the desired number of products. Data needed
in the calculation of this routing sheet is the order of operations of each component, name or
type of equipment used, scrap percentage and plant efficiency. The order of operations in the
routing sheet is based on the order of operations in the operation process map. Information
obtained from the calculation of the routing sheet is to find out the capacity of theoretical tools,
the number of units prepared, products with efficiency and the number of theoretical machines
 Table Routing sheet

Machine Product Scrap Losses Good Pieces Pieces To Be Efficiency Product Machine Required Machine Required Cycle Time
Per Hour Required Started Theory Actual

(A) (B) (C) (D) (E) (F) (G) (H)

 Explanation
A = Mechine Capacity
B = Scrap percentage
C = Desired Output
D = [100 / (100-B)] x C
E = [100 / Effisiency] x D
F=E/A
G = Rounding off F  rounding up value
Ex. F = 1,001 than G = 2
 H = Cycle Time ( From OPC )