FACILITY LAYOUT

PREPARED BY:
1. MALVIKA UPADHYAY. 2. PRATISHTHA GOHIL.

3. DIPALI GOHIL.
4. AKASH PATEL.

SUBMITTED TO: RAVI SIR

FLOW OF PRESENTATION
Definition Of Plant Layout.

Introduction Of Plant Layout.

Types Of Layouts. Group Technology Benefits. Group Technology : Transition From Process Layout. Comparison Of Product and Process Layouts. Factors Affecting Plant Layout. Features of good Layout. Objectives/ Importance of ideal plant Layout.

INTRODUCTION OF LAYOUT
Plant layout planning includes decisions regarding the physical allocation of the economic activity centers in a facility. An economic activity center is any entity occupying space. The objective of plant layout planning is a more effective work flow at the facility, allowing workers and equipment being more productive. Facility layout techniques apply to the case where several physical means have to be located in a certain area, either industrial processes or services. The objective of the chapter is not only Plant layout but re-layout also (most common situation for a company).

DEFINITIONS OF PLANT LAYOUT

Definition: A technique of locating machines, processes and plant services within the factory in order to secure the greatest possible output of high quality at the lowest possible total cost of production. By F.G. Moore: A good layout is one which allows materials rapidly and directly for processing. This reduces transport handling, clerical and other cost down per unit, space requirements are minimized and it reduces idle machines and idle man time.

WHY RE- LAYOUT ?

The reasons for a re-layout are based on 3 types of

changes:
Changes in production volumes.

Changes in processes and technology.

Changes in the product. The frequency of the re-layout will depend on the requirements of the process.

REASONS FOR RE- LAYOUT

Symptoms that allow us to detect the need for a re-layout:
Congestion and bad utilization of space. Excessive stock in process at the facility. Long distances in the work flow process. Simultaneous bottle necks and workstations with idle time. Qualified workers carrying out too many simple operations. Labor anxiety and discomfort. Accidents at the facility. Difficulty in controlling operations and personnel.

TYPES OF LAYOUTS
There are 4 types of layout
Process layouts:
Group similar resources together

Hybrid / Cellular layouts:

Combine aspects of both process and product layouts

Product layouts:
Designed to produce a specific product efficiently

Fixed-Position layouts:
Product is two large to move; e.g. a building

PROCESS LAYOUT
It is also called functional layout. In this type of layout all machines and equipments which perform the same functions are grouped together. This set up is ideal for batch production.
In service facility(business) hospitals provide good example of process based or functional layout.

The wards and departments provide specific medical care, like the surgical ward looks after the surgery cases, and the other wards looks after for their specialty works. Process layouts aims at minimizing the costs of interdependent movement.

PROCESS LAYOUT
General purpose machines are arranged in no particular sequence, as the processing requirements and sequence are different for the various types of products to be manufactured. These machines include the lathe machine, drilling machine, milling machine, grinding machine which handle different types of process requirements. It is also called as a machine shop or job shop or intermittent manufacturing.

PROCESS LAYOUT
General purpose & flexible resources

Lower capital intensity & automation

Higher labor intensity

Resources have greater flexibility

Processing rates are slower Material handling costs are higher Scheduling resources & work flow is more complex Space requirements are higher

PRODUCT LAYOUT
It is also referred to as the flow line layout. In this layout, equipment and work processes are arranged in the progressive steps in which the product is made. The work flow in effect follows a straight line.
Automobile production on an assembly lines, chemical plant, cement factory and a steel plant are all examples of such layouts. The layout is particularly suited for flow and continuous production process structures.

PRODUCT LAYOUT
Specialized equipment High capital intensity & wide use of automation Processing rates are faster Material handling costs are lower

Less space required for inventories

Less volume or design flexibility

FIXED POSITION LAYOUT

In fixed position layout, the product stays fixed at a

particular location because of its bulk and size, and worker

teams and equipment move to the work site to work on it.

Examples of such layouts are ship buildings yards, bridge

construction sites and so on.

CELLULAR LAYOUT OR HYBRIDE OR GROUP LAYOUT

Combine elements of both product & process layouts Maintain some of the efficiencies of product layouts Maintain some of the flexibility of process layouts Groups of items with similar processing requirements are identified and separate manufacturing cells are formed for each group, which contain required machines in the desired sequence. The process of identification of similar groups is called as Group Technology (GT). Examples: Grocery stores

GROUP TECHNOLOGY BENEFITS

Better human relations Improved operator expertise Less in-process inventory and material handling Faster production setup

GROUP TECHNOLOGY: TRANSITION FROM PROCESS LAYOUT

Grouping parts into families that follow a common sequence of steps
Identifying dominant flow patterns of parts families as a basis for location or relocation of processes Physically grouping machines and processes into cells

Factors affecting Plant Layout

The final solution for a Plant Layout has to take into

account a balance among the characteristics and

considerations of all factors affecting plant layout, in order

to get the maximum advantages.

The factors affecting plant layout can be grouped into 8 categories: Materials Machinery Labor

FEATURES OF GOOD LAYOUT

1. 2. 3. 4. 5. 6. Sufficient space Adequate safety and security of workers Minimum Material handling task and cost Proper storage facility Easy execution, supervision and control Flexibility

Objectives/Importance of Ideal Plant Layout

A good Plant layout strives to attain the following objectives:
Minimization of Material Handling Elimination of bottlenecks through balancing of Plant Capacities High Material turnover through shorter operating cycle Effective utilization of installed capacity so that returns on the investments may be maximized. Effective utilization of space of the factory area Effective utilization of Manpower resources through elimination of idle time Elimination of unnecessary physical hard work. Avoidance of industrial accidents Better working conditions for the employees like lighting, ventilation, control of noise and vibration etc.