WORKSHOP

MANAGEMENT

COURSE CODE – ME 6313

TOPICS TO BE COVERED
1. WORKSHOP LAYOUT
2. TYPES OF PRODUCTION
3. WORK PLANNING
4. WORK MEASUREMENT
5. COST CALCULATIONS
6. QUALITY ASSURANCE AND
CONTROL
7. VEHICLE INSPECTIONS
8. MAINTENANCE OF WORKSHOP
EQUIPMENT
9. MATERIAL HANDLING
EQUIPMENT IN THE WORKSHOP
REFERENCES

 J. M. Apple, Plant Layout and Material

Handling, Macmillan, Latest Edition.
 C. B. Gordon, Production Handbook, Ronald,

latest Edition.
 H.E. Maynard, Industrial Engineering

Handbook, McGraw-Hill Book Company,

Latest Edition.
 J. J. Burbidge, Production Planning,

Heinemann, London, Latest Edition.

 Muther, Practical Plant Layout,
McGraw-Hill, Latest Edition.
 Lewis and Marron, Facilities and Plant

Engineering Hand Book McGraw-Hill,

Latest Edition.
 R. F. Clifton, Principle of Planned

Maintenance, Edward Arnold, Latest

Edition.
MODE OF ASSESSMENT

Test (CA) - 40%

Examination (SE) - 60%

Total - 100%
WORKSHOP LAYOUT
INTRODUCTION
Workshop layout is the most
effective positioning of men,
material and machines for
maximum coordination and
efficiency in a workshop.
The main aim of a proper
workshop layout is to utilize
all available resources in the
most efficient and
economical manner to
optimize production and
increase productivity.
OBJECTIVES OF LAYOUT
 To facilitate the manufacturing
process.
 To minimise the material handling.
 To maintain flexibility of

arrangement of operation
 To maintain high turn over of

works in process.
 To hold down investment in
equipment.
 To make economical use of floor

area.
 To promote effective utilization of

labour.
 To provide employee convenience

and comfort in doing the work.

 ADVANTAGES OF A GOOD PLANT
LAYOUT
A good plant layout has the
following advantages
The floor area is utilized in an

effective and optimum manner

The time required for material

handling is minimized
The overall production time is
reduced
Most of the paper work is

eliminated
The service of men, materials

and machines are utilized in

the most effective manner
Labour utilization is optimized
It helps in better supervision

and reduces confusion

Congestion due to a large

number of men, materials and

machines is avoided.
Productivity increases, resulting

in more profits to the

organization.
It promotes better planning
and effective control
It facilitates easy maintenance

of plant and equipment

DISADVANTAGES
Improper and unsystematic arrangement
of machines and equipment in a shop
has the following disadvantages
 Cost of materials handling rises
 Distance covered by the worker will be

more
 Improper layout results in more accident
 The plants space will not be
properly utilized
 Return on capital invested will be

less
 The raw material and in process

work will have to move longer

distance resulting in increased
production time and overall cost
and lesser productivity.
TYPES OF LAYOUT
1. Product or line layout
2. Process or functional
layout
3. Fixed position layout
4. Cellular (Group) layout
PRODUCT LAYOUT
 If the machines and processing
equipment are arranged according to
the sequence of operations of a
product, the layout is called product
layout.
 This type of layout is suitable in

manufacturing of one type of products

in large quantity. Separate layouts are
necessary for types of products.
 PRODUCT LAYOUT

Raw Finished
Station Station
Station Station
Station Station
Station
materials 1 22 33 44 item
or customer
Material Material Material Material

and/or and/or and/or and/or

labor labor labor labor

Used for Repetitive or Continuous Processing

6-
20
 A U-Shaped Production Line

In 1 2 3 4

Workers

Out 10 9 8 7

6-
21
a) Flujo en línea recta d) Flujo en “L”

b) Flujo en “U” d) Flujo circular ó en “O”

c) Flujo en serpentín e) Flujo en “S”

 ADVANTAGES OF PRODUCT
LAYOUT
 Production time is lower.
 Total materials handling cost is lower.
 Smaller floor area per unit of

production.
 Production control is simpler (fewer

controls and records needs)

 Greater incentive for the worker as a

team to raise productivity.

DISADVANTAGES OF PRODUCT
LAYOUT
Duplication of the processing
equipments and machine tools.
Investment cost more
Not flexible for switching over

to new products or change in

the design
In the event of breakdown of
even one machine the production
of whole section stops
In case of group incentive plan

an efficient worker may be loser

due to less efficient worker. All
workers may not work
wholeheartedly.
PRODUCT LAYOUT SHOULD BE PREFERRED, IF

 Product variety is few or one only

 Production quantity of each

variety is large for considerably

long period
 There is possibility of time and

motion studies to determine rate

of work.
There is possibility of
equipment balance.
Inspection requirement during

operation is minimum
Continuous handling by

mechanical means of the

product.
PROCESS LAYOUT
 If the equipment are not
arranged according to the
sequence of operations, but are
arranged according to the nature
or type of the operations, it is
called process layout.

Therefore, in this layout all the
lathes will be placed in a
section or department, all the
drilling machine in another
department or section, all the
milling machine in third
department and so on.
Machine shop process layout
Receiving Grinders-
Mills
Raw matl.

storage Assem-
bly

Drills
Planers

Finished
Inspec- goods
Lathes Automatics tion storage

Part A
Part B

30
 ADVANTAGES OF PROCESS
LAYOUT
Totalinvestment cost is less
because of fewer duplication of
the equipments
Some layout could be used for

even a new product or the old

product with some change in
design. So it is more flexible.
In the even of breakdown of
some machine the production
will not halt because another
machine can be used.
Greater incentive for individual

workers
Inspection is easier so better

control of the process.

DISADVANTAGES OF PROCESS
LAYOUT
Higher material handling cost
because of back tracking and
zig – zag movement of the
semi – finished product.
Longer production – cycle
 Production control is difficult,
because at a time many work pieces
may be under process on different
machines with different sequences
of operations. So routing, scheduling
and dispatching become complex
 Inspection is costlier
 Labour cost is higher because skilled

labourer is employed to handle

PROCESS LAYOUT SHOULD BE
PREFERRED, IF
 There are many varieties of

products
 There is relatively small quantity

of each variety.
 Time and motion study is difficult
 It is difficult to achieve

equipment balance
 The inspection requirement during
operation is very high
 The use of mechanical handling

means to shift the work from one

work – station to other work station
is difficult due to weight and size of
the work.
 There is frequency necessity to use

the same machine for two or more

operations
FIXED – POSITION LAYOUT
 Inthis layout, the largest
component of a product has a
fixed position and other parts of
the product, man and equipments
are all brought to this component
for other operations, assembly etc.
On this largest parts.
It is mainly used in ship- building,
automobile industry, railway wagon
building industry etc.
In automobile industry for example,
the chassis is kept at place and
other parts such as wheels, steering,
clutch etc are brought from different
section of the plant and fitted over
the chassis.
ADVANTAGES OF FIXED –
POSITION LAYOUT
 Capital investment for layout is minimum.
 Great flexibility with respect to Product

design, Product mix and production

volume
 Workers identify themselves with the

particular product.
 Job enlargement possibility is greatest in

this types of layout

DISADVANTAGES OF FIXED -
POSITION LAYOUT
 Since the same workers are

involved in more operations,

skilled and versatile workers are
required. The necessary
combination of skills may be
difficult to find and high pay
levels may be necessary.
 Movement of people and
equipment to and from the work
site may be expensive.
 Equipment utilization may be low

because the equipment may be

left at a location where it will be
needed again in a few days rather
than moved to another location
where it would be productive
FIXED – POSITION LAYOUT
SHOULD BE PREFERRED IF

 Product’ssize or weight is
prohibitive of use of continuous
mechanical handling devices
CELLULAR (GROUP) LAYOUTS
Layout in which machines are
grouped into a cell that can
process items that have similar
processing requirements.
 Cellular Manufacturing Layout

Heat Gear
-1111 Lathe Mill Drill -1111
treat cut

Heat
222222222 Mill Drill Grind - 2222

Assembly
treat

Heat
3333333333 Lathe Mill Grind - 3333
treat

44444444444444 Mill Drill Gear - 4444

cut
 ADVANTAGES
· Increased machine utilization
· Supports the use of general
purpose equipment
· Shorter travel distances and
smoother flow lines than for
process layout
Common tooling required for many
products (fewer setups)
Tooling can be justified since many

products require it (more volume

when products are grouped)
Minimized material handling
Simple production schedule
 LIMITATIONS
· General supervision is required
· Higher skill levels required of
employees than for product layout
· Depends on balanced material flow
through the cell; otherwise, buffers
and work-in-process storage are
required
Lower machine utilization than for
process layout
Increased set-up costs
Less flexibility than functional

departments