Plant Layout m

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Plant Layout


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Plant layout is also known asfacilities layout. After theselection of factory site, the

factory building is constructedat the selected site.

Plant Layout


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Factory Layout is a broader

concept and it decides abouthousing of all the activities insidethe factory such as:

1. Office areas in whichadministrative department ishoused.

2. Plant area involves:

Distinction between FactoryLayout and Plant Layout


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b) Personal services like parking areas, time

keeper office, canteen and lunch room etc.

In relation to factory layout, plant layout isnarrow consideration and concentrates on anarrangement of production and services dept.

Along with the location and sequence ofmachines and equiupment .


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Minimize overall production time.

Utilize existing space mosteffectively.

Provide for employee

convenience, safety and comfort. Minimize material-handling cost.

To provide adequate safety to

the workers from accidents.

The objectives of plantlayout are:


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1.Type of Production System

2. Nature of Product Manufactured

3. Availability of total floor area

4. Arrangement of material handlingequipment

5. Possibility of future expansion

6.Type of Machines

Factors influencing layoutchoices:


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Types of Layout


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Process Layout or FunctionalPlant Layout

L L

L L

M M

M M

D D

D D

G G

G G

ASSEMBLY1

ASSEMBLY2

Product 2

Material 2

Material 1

Product 1

Common for a large variety ofproducts in batch volumes.

Similar processes are groupedtogether.

Inefficient: Long materialtransport routes from dept. todept. Work in progress is high.Tracking of orders can bedifficult.

Advantages: Specialist labour

and supervision. Flexibility asmaterial can be rerouted in anysequence.

e.g. Machine tools, custommade furniture etc.


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Product Plant Layout

A

SSEMBL

Y

L M D G

L M D G

L M D G

Mass production where variety is smalland production volumes are very high.

AKA flow or line layout.

More efficient, but less flexible thanfunctional layout.

Work in progress is minimised, and jobsare easily tracked.

Investment in specialised capitalequipment is high, so a reliable and steadydemand is required.

Very sensitive to machine breakdown ordisruption to material supply.

e.g. Textile, sugar, petroleum, paper andpulp, cement plants etc.


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Difference between Productlayout and Process Layout

Sr. No. Product Layout Process Layout

1. Duplication or repetition ofmachines

No duplication or repetition ofmachines

2. Breakdown of one machineinterrupts the entire productflow.

Breakdown of one machine doesnot interrupt the entire productflow.

3. Reduced material handlingcost due to straight lineproduction flow.

Cost of material handlingincreases due to backtrackingbetween the processes.

4. No problem of bottlenecks andidle-capacity.

Problem of bottlenecks i.e.waiting


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Difference between Productlayout and Process Laout

Sr.No.

Product Layout Process Layout

5. Do not require frequent

changes in machine set-up.

Frequent changes in machine

set-up.

6. It is relatively easy tocontrol.

Not easy to control.

7. Duplication of Machinesincreases investment.

As compared to productlayout less investment.

8. No specialization Specialization of supervisionis possible.


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Fully automated Plant layout

WIP Inventory

C


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1313

Assembly Line in a Car Factory


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1414


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1515


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Cellular Plant Layout

L M

D G

M M

D G

L L

L G

ASSEMBLY

CELL 3

ASSEMBLY

CELL 2

ASSEMBLY

CELL 1

AKA Group Technology

Each cell manufactures productsbelonging to a single family.

Cells are autonomous manufacturingunits which can produce finished parts.

Commonly applied to machined parts.Productivity and quality maximised.Throughput times and work in progresskept to a minimum.

Suited to products in batches andwhere design changes often occur.

Fi d P iti L t


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Fixed Position Layout:(Static Layout or Project

Layout)

PRODUCT

MATERIAL

MATERIAL

LABOUR

LABOUR

COMPONENTS

COMPONENTS

Fixed Position LayoutSingle large, high costcomponents or products. Product is static. Labour,tools and equipment come tothe work rather than viceversa. e.g. ship building ,

construction of dams andbridges etc.


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Fixed Position Layout


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Guess the diagram shows

which type of layout?


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Efficient layout makes manufacturingfunction smooth and efficient an reduces costof material handling and avoids bottlenecks

and minimization of production delays.

Economies in handling.

Effective use of available area.

Minimization of production delays.

Better supervision.

Improved utilization of labour.

Good working conditions.

Importance of plant layout:


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Smooth flow of production.

Maximum utilization of available

space. Minimum material handling.

Good working condition

Facilitates supervision andcontrol

Characteristics of goodlayout:


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Congestion of materials

Poor utilization of available space.

Excessive material handling distance.

Excessive maintenance time andxost.

Long production cycle time.

Characteristics of BadLayout:

Plant Layout m

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