FACILITIES AND PROCESS PLANNING

(PLANT LAYOUT AND MATERIAL HANDLING)

PLANT

- A place where men, materials, money, machinery etc. are brought together
for manufacturing the products

PLANT LOCATION
1 To select a proper geographic region 2 To select a specific site within the region

IDEAL PLANT LOCATION - One where unit cost of production and distribution are at the minimum and
where the prices and volume of sales will brig the maximum profits

SOURCES FOR THE INFORMATION OF THE PLANT LOCATION

1 3 4 7 Chamber of commerce 2 Local government officials Local commercial banks 4 State government agencies Utilities companies 5 Bureau of labour statistics Regional and local development agencies

FACTORS INFLUENCING THE PLANT LOCATION

1 Availability of raw materials 3 Nearness to market 5 Availability of labour 7 Climatic and atmospheric conditions 9 Availability of capital 11 Community attitude 13 Existence of related industries 2 Nearness to raw materials 4 Transport facilities 6 Availability of power and fuel 8 Availability of water 10 Land 12 Business and commercial facilities 14 Others (local bye laws, taxes etc.)

SELECTION OF PLANT SITE

1 Availability of cheap land and expansion facility 2 Cost of leveling the land and soil conditions 3 Cost of construction materials 4 Facilities for the upkeep and general maintenance 5 Facilities for housing the workers, conveyance etc. 6 Facilities for transport of materials 7 Cost of laying the water supply and sewage facilities 8 Cost of installation of electricity and other facilities 9 Possibilities for disposing waste 10 Restriction by the Town Planning Department local bye laws

LOCATION OF A PLANT URBAN LOCATION ADVANTAGES

1 2 3 4 5 6 7 8 Better transport facilities Skilled and unskilled labour suppy Better education facilities Better banking facilities Adequate police and fire protection Greater amenities (Hospital, shopping etc.) Availability of power and water Good advertising value

RURAL LOCATION ADVANTAGES

1 2 3 4 5 6 7 8 Cheap land Facilities for future expansion Low wages, rents, taxes etc Lower cost of living Less fire hazard No congestion in housing No restrictions such as in Municipalities Less labour trouble

DISADVANTAGES
1 2 3 4 5 6 Higher price of land Development difficult and expensive Various municipal restrictions Higher cost of living Ill effect of overcrowding Higher wages, rents, taxes etc.

DISADVANTAGES
1 2 3 4 5 6 7 Restricted supply of skilled labour Less attraction on country site Housing difficulties Lack of social amenities Lack of communication facilities Poor educational facilities Scarcity of power and water supply

CONSIDERATION IN FACILITIES PLANNING AND LAYOUT

1 2 3 4 5 6 Production equipment Handling equipment Auxiliary equipment Space Land Buildings

FACILITIES DESIGN PROCEDURE

(The steps may not follow in a specific order)

1 3 5 7 9 11 13 15 17 19

Procure basic data Design production process Consider general material handling plan Plan individual work areas Coordinate groups of related operations Determine storage requirements Determine space requirements Consider building types Evaluate, adjust, and check the layout Install layout

2 4 6 8 10 12 14 16 18 20

Analyze the basic data Plan material flow pattern Calculate equipment requirements Select specific material handling equipment Design activity relationship Plan service and auxiliary activities Allocate activity areas to total space Consider the master layout Obtain approval Follow up on implementation of layout

PLANT CAPACITY DEFINITION

- The maximum rate of output attainable over a specified period of time with latest product specification, work force and equipment

MEASUREMENT OF CAPACITY
1 By the rate of output per unit of time (Eg. Tonnes / month, barrels/month etc.) 2 In terms of Units of input (Used in service industries. Eg. Calculation of the student credit hours is the capacity of the department) Example : In a shop there are 4 machines used to work for 8 hours with 85% efficiency each. What is the capacity of the work center? Answer : 4 machine x 8 hours per machine x 0.85 = 27.2 hours

BALANCING IN PLANT CAPACITY The balance in the capacity of the various units and equipment is achieved by an effective selection of equipment, thereby a uniform flow of work The bottle neck of the equipment should be considered Improper balance means over capacity or under capacity. This should be avoided while designing a plant layout

INTEGRATION OF EQUIPMENT AND CAPACITY To obtain continuity in the flow of work and maximum capacity, there should be proper integration of production machines. It involves 1 2 3 4 Machine time Inventory of materials and stock Interruption and emergencies Varying the rate of output

SERVICEABILITY
A good plant location and layout is to provide room for maintenance and services relating to machinery It includes additional space, space for access to machines, motors, pumps and different service processes and service equipment The plant serviceability includes the distribution of auxiliary service lines. The major service lines are: 1 Water, electricity 2 Seam for process and heating 3 Lubricating oil 4 Gas 5 Acid 5 Fuel 7 Other process liquid 8 Sewage and waste disposal While laying down these auxiliary service lines, they need following considerations: 1 Economical considerations 2 Readily accessible to equipment located at any position 3 Installation out of the way of other facilities. Such service lines should not disturb conveyors walking aisles or the production floor 4 Safety concepts for personnel, equipment and material.

PROCEDURE FOR SERVICEABILITY OF LAYOUT

Determine what exact service required Establish peak load service Coordinated plan of the layout man, the builder, architect and the plant engineer Erection & Installation

FLEXIBILITY
While planning the industrial layout, sufficient care must be taken to provide space for future expansion, alteration and possible development Demands for future flexibility can be made successfully if they are anticipated in the initial planning Some important METHODS TO OBTAIN FLEXIBILITY are as follows: 1 Provide a large size bay 2 Permit alternative arrangement for equipment 3 Providing clear heights for production and storage 4 Installation of utilities for electricity and sprinklers on a grid 5 Provision for uniform lighting for the entire plant 6 Locating light fixtures, sprinklers, unit heaters et, between beams 7 Providing quick utility connections for distribution lines 8 Use of movable partitions 9 Installing a slope between ground level and floor level 10 Provision for future balconies 11 Design of adequate floor load capacities for future needs 12 Adequate storage space 13 Use of flexible material handling equipment 14 Planning adequate utilities and service facilities 15 Equipment with built in lugs or skid supports for reallocation

EQUIPMENT REQUIREMENT
Selection of equipment requires not only forecast of the market for the product but also a thorough knowledge of the material, effort and times for its erection and development The production facilities equipment are classified into the following categories: 1 Manually operated equipment 2 Semi automatic equipment 3 Fully automatic equipment The equipment may also be classified according to the standardization and the degree of specification as follows: 1 2 3 4 5 Standard machinery (Eg. Lathe, drilling machine etc.) Universal machinery Multi operation machinery Single purpose machinery Unit type machinery

ADVANTAGES OF STANDARD MACHINES ARE: 1 2 3 4 5 6 7 Initial investment is less Plant capacity can be expanded easily Applicable to wide range of uses Adaptable to changes in the design of the product Breakdown period of machine is comparatively short Replacement parts are easily available The resale value is higher than that of specialized machinery

ANALYSIS IN SELECTION OF EQUIPMENT

WHY THE SELECTION OF EQUIPMENT IS IMPORTANT?

It depends on the process followed in any industry It is the basic step in the development of the plant The cost of production and the quality of the product are influenced by the machine selection Poor selection of equipment is the major drawback in the progress of the firm

The equipment selection is to be done especially when,

Production capacity is to be expanded Radical changes in the design of the product Technological improvements THE PROCEDURE FOR THE SELECTION OF EQUIPMENT 1 2 3 4 5 6 Identify the process for which the equipment is to be selected Choose the equipment Design the special tools along with the selection of equipment Do the motion analysis and time study Specify the required sequence of operations of the process Do a pilot study and development before satisfactory production on commercial basis

FACTORS AFFECTING THE SELECTION OF SPECIFIC EQUIPMENT

1 2 3 4 5 6 7 8 Kind of operations Quality and degree of precision needed Anticipated future changes in the product design Volume of production determined by the forecast of demand Available equipment beyond plant capacity Anticipated production rates by various capacity machine units Attainment of maintenance balance capacity in the equipment Kind of layout whether product or process layout

N
Where,

( T / 60 ) ( P / HC )

N - Number of machines required T - Standard time for the operation in minutes P - Production required per day of standard number of hours H - Standard number of hours per day C - Factor of use for equipment, normally taken as 0.85 EXAMPLE : A firm plans to manufacture screws by using Lathe. It is estimated that each screw requires 20 minutes of machine time and 900 screws are to be made in a shift. Each shift operates for 8 hours. Assume that 80% of machine hours can be used. Determine the number of lathes to be purchased. SOLUTION :

N = (T/60) (P/HC) = (20/60) {(900/(8*0.85)}

= 44.11 = 45 Lathes

SPACE REQUIREMENT FACTORS AFFECTING THE SPACE DETERMINATION 1 I GENERAL 2 PRODUCTION 3 BUILDINGS 4 COST

GENERAL FACTORS
1 2 3 4 5 6 7 Space for production and service Sales forecast Technological advances Possible changes in production Master / Long range / Expansion plans Flexibility Number of employees

II PRODUCTION FACTORS
1 2 3 4 5 6 7 8 9 10 11 Size and nature of product Method of production Nature and number of process Work standards Production efficiency Scrap percentage Number and size of the machine Flow pattern Number of operators Handling methods and equipment Storage requirement

III BUILDING FACTORS

1 2 3 4 5 6 7 8 Type and construction of plot Floor load capacity Infrastructure Aisles Condition of soil Column spacing Utilities Plot size

IV COST FACTORS
1 2 3 Capital investment Interest Economic trends

LOBOUR REQUIREMENT AND SELECTION

Right person with right quality and capacity is needed Skilled, unskilled, technical, managerial and supporting staff Number of persons required Type of the plant is having the influence on the selection of labour Cautious people with presence of mind (Eg. Nuclear plant) Staffing problems will affect the companys objectives

SELECTION PROCEDURE
1 Walk in interviews 2 Recommendations through friends and relatives 3 Advertisement 4 Public and private employment agencies etc.

MANNING TABLE
It consists of different jobs with the number of operating trainees on hand Future requirements for personnel are also available No. of employees needed = Future requirements available people Management can anticipate personnel needs with the help of this table

REFERENCES : 1 Plant layout and Material handling by K.R. Govindan