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layout Quality and Cost of the product Safety Lead-time It is a strategic decision which is dynamic by nature
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Objectives of Plant layout improved Productivity Improvement of QCD (lead-time) Space utilization min loss of material due to mix-up or spillage Safety Easier and less handling
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Less inventory, smooth flow, no stagnancy Better working conditions Flexibility Equipment on wheels
Need to look at Layout occurs due to: 1. New plant 2. Change in product design 3. New product 4. Obsolescence of facilities 5. Change in the production system (output characteristics) 6. Change in the safety standards 7. Improvement
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Principles of Layout 1. Principle of Minimum movement Principle of Flow The process flow diagram unidirectional without backtracking 2. Principle of Space Inventory on chutes mezzanines
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3. Principle of Safety and health (isolate the process, easy evacuation, contain the pollution, provide specific safety measures) 4. Principle of Flexibility Equipment on wheels 5. Principle of Interdependence Customer and supplier closer
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6. Principle of Overall integration Men, machines, space and materials 7. Principle of Min investment Min space, min inventory, maximum utilization of all resources
Symptoms Of Bad Layout 1. Congestion of material and men on the floor 2. Bottlenecks 3. Mental and physical strain on operatives, frequent tension between operatives, between operatives and supervisors 4. Frequent accidents
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5. Mat. handling by skilled operatives 6. Frequent mix up in material and subsequent rework 7. Delayed deliveries to the customers
Layout Factors 1. Material factor design, variety, quantity of product, nature of material like physical state, hazard, operations and their sequence 2. Man factor: no of workers & supervisors, safety, man power utilization, service and help 3. The machinery factor includes the process, production equipment, tools and their utilization
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4. The movement factor include inter and interdepartmental movement and handling at various operations, storage and inspections, material handling equipment 5. The waiting factor - includes permanent and temporary storage, delays and their location 6. The service factor service related to employee facilities, material, equipment maintenance
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What Are Conventional Types Of Layout: Line Layout/product layout, Process/function layout, Static/fixed position Layout
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1 2 4
P Q R
FUNCTION/PROCESS LAYOUT
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R/M
STATIC LAYOUT
Product Layout [Line Layout] Product focused Equipment as per sequence of operations & one machine for one operation Material moves from machine to machine Suitable for mass production Function Layout [Process Layout] Process focused
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Equipment as per process/function, material moves from department to department in batches Suitable for batch production
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Fixed Position [Static] Layout Material does not move Suitable for one off production
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Group Technology Layout Synthesis of line layout and function layout general purpose machines arranged according to line layout Cell Layout, family of items is processed in one cell Suitable for JIT production Cell Layout is also suitable for FMS production.
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MAJOR ASSEMBLY
SUB ASSEMBLY I
SUB ASSEMBLY II
A1 A2 B1
C1 C2 C3 D1 D2
A3 A4 C4 D3 D4
C5 B2 A5 D5
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M1 CELL B
M2
M1
M2 M3
CELL C
M5
M4
M2 M3
M1
M1
M2 M3
CELL A M4 M5
CELL D
M5
D4
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STATION II
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CELL LAYOUT
MASS
BATCH
ONE OFF
JIT
LESS
HIGH
DEPENDS ON PRODUCT NA
LESS
AUTOMATIC
SEMI AUTO
BETTER LOW
BETTER LOW
HIGH HIGH
HIGH
DOUBTFUL
BETTER
HIGH
INCENTIVE SYSTEM
GROUP
INDIVIDUAL
INDIVIDUAL
PRODUCTIVTY INCENTIVES
EQUIPMENT ARRANGEMENT
FLEXIBLE
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Process of preparation for layout/ layout change 1. Draw flow diagram of the process 2. Collect information about layout factors study what materials go in to the process. By 80 20 rule identify critical items for layout 3. Keep principles of layout in mind 4. Prepare templates or models for machines 5. Prepare a floor plan for the shop floor 6. Set lay out objectives
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7. Use layout tools like Templates Models Computers Process Chart Flow diagram Machine data cards 8. Prepare layout for various sections
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9. Prepare several options of detailed layout 10.Discuss with user departments 11.Recommend 12.Implement 13.PDCA
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OFFI CES
DIS PA TC H
ST ORE
P RT MA TL W P I
I N K S P A C K I N G
pres s N PT G L NE I R/ M S T 0 R E
N ec s k 0.5T
pres s S
Sh oulde s r 1.0 T
pres s B
Bottoms 1.0 T
s litting
s litting
O F F I C E S Q C
B O D Y S T O C K
B 1
B 2
B O D Y
pack
pack
M A N EN N CE I T A
1 7/01/0 4
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O F ICES F
S TO RE
sli W IP PRT
PRINT DONE
ma inte nan ce
S lit I cut TIN P LA TE S TORE S lit II cut
P TG LINE B B S N
B 1 B 2 P
pm
qc
P P
SH OU LD R E S
U DER IN S N PECTI O N
F IN IS HED GO O D S
I N K S
D IS P A TCH
L AY OUT - AFTER
17/ 01/ 04
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