Product Layout

SUBMITTED BY:HARPREET SINGH DIVYA NIGAM ARCHANA Singh Mamta Singh

Meaning of Layouty Layout refers to the arrangement of facilities. y According to SHUBIN, Plant layout is the arrangement and location of production machinery, work centres and auxiliary facilities and activities for the purpose of achieving efficiency in manufacturing products or supplying consumer services.

IMPORTANCE OF LAYOUTy

Improved utilization of labor:labor is paid for every hour it spends in the factory. The efficiency of a management lies in utilizing the time for productive purpose. Avoidance of unnecessary and costly changes:a planned layout avoids frequent changes which are difficult and costly. Better production control:production control is concerned with the production of a product of a right type at the right time and at reasonable cost.

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y Improved quality control:-

timely execution of orders will be meaningful when the quality of the output is not below expectations. To ensure quality, inspection should be conducted at different stages of manufacture.y Minimum equipment investment:-

investment on equipment can be minimized by planned machine balance and location, minimum handling distances, by the installation of general purpose machines and by planned machine loading.

TYPES OF LAYOUTy A layout essentially refers to the arranging and grouping of machines which are meant to produce goods. Grouping is done on different lines.

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PRODUCT LAYOUTy Also called the straight line or layout for serialized manufacture, product layout involves the arrangement of machines in one line, depending upon the sequence of operations. y Materials are fed into the first machine and finished products come out of the last machine. y In between , partly finished goods travel automatically, from machine to machine, the output on one machine becoming the input for the next.

EXAMPLE:y It is a feast for the eyes to watch the way sugarcane, fed at one end of the mill, comes out as a sugar at the other end. y Similarly, in paper mill, bamboos are fed into the machine at one end and paper comes out at the another end.

y The grouping of machines should be done, on product line, keeping in mind the following principles:-

all the machine tools or other items of equipment must be placed at the point demanded by the sequence of operations. there should be no points where one line crosses another line. Materials may be fed where there are required for assembly but not necessarily all at one point All the operations, including assembly , testing and packaging should be included in the line.

START PR DUCTI N

LATHE

DRILL PRESS #2 PACKAGING MACHINE

DRILL PRESS #1

PAINTING MACINE INISH PR DUCTI N

PRODUCT LAYOUT IN MANUFACTURING PRODUCT

ADVANTAGESy Low work in progress:-

since production is carried on in a pre arranged continuous sequence, the stock of work in progress of materials in transitory process is reduced to the minimum. lesser need for inspection or supervision is another merit of this type of layout.

y Lesser supervision:-

y Greater possibility of space utilization:-

there will be a greater productive utilization for the floor area under this type of layout.

y Regulation of production:-

since production is planned according to an orderly sequence, manufacturing time from the initial operation to the finished product is economically and effectively regulated.y No bottleneck in production:-

the well balanced and adjusted plant line will eliminate almost all the possible bottlenecks in the production process.y production promptly:-

since intermediate activities between operations are minimum due to absence of dilatory internal transportation of materials, production will be completed promptly through the shortened built in sequence of the plant complex.

DISADVANTAGESy Inflexibility:-

inflexibility is a drawback of this type of layout. The equipment laid out is designed to perform specific operations.y Demerits of breakdown:-

the production line is vulnerable to interruptions and shutdowns. A breakdown of a machine will render the entire line ineffective.y Additional output not possible:-

expansion of output on substantial scale is impossible on product lines out to specific capacity.

COMPARISON BETWEEN PRODUCT AND PROCESS LAYOUTPRODUCT LAYOUT One or few standard products Material and products require continuous handling of mechanical means Little or no occasion to use same machine PROCESS LAYOUT Many types or styles of production or emphasis on special order Materials or products too large to too heavy to permit bulk or continuous handling by mechanical means Frequent necessity to use same machine

Possibility of good labor and equipment Difficult to achieve good labor and balance. equipment balance.

LOADING PROCESS

QUALITY TESTING

FI ING CA ERA

TESTING PROCESS

ASSE LY & CONFIGURING PROCESS

SOFTWARE INSTALLATION

PROTECTION COVER

ADDING FUNCTIONALITY

UNIQUE SERIAL NO. PROCESS

DIAGNOSTIC TEST

PACKING

FINAL INSPECTION TEST

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FINI H D GOOD ORAG

y Raw Material Supply from suppliers: y Most electronic components, from resisters and capacitors to highly integrated y circuits, are delivered by suppliers on reels of tape, protected in y circular plastic cases.

y The Foundation: A Printed Circuit Board (Soldering Process): y At the heart of every Nokia phone is a slender strip of plastic covered with a latticework of basic circuits and settings for the installation of chips and other electronic components. y Here, printed circuit boards enter the paste printing machine, which lays down a patterned layer of solder paste, made from a tin copper-silver alloy. The paste is later melted in an oven to bind electronic components to the board.

y Providing the Parts (Loading Process): y Reels of components are loaded onto spindles. From there, they feed into automated "pick-and-place machines" that grab individual parts off the tape and lay them precisely onto the printed circuit boards. y Nokia uses mostly "surface mount" components that lie flat on the board.

y Laying Down the Basics (Laying Process): y Circuit boards travel down a belt from one pick-andplace machine to the next, and by the time they reach the end of the line, all the basic components have been installed. After the parts are in place, the boards go to an oven for seven minutes, where the solder paste is melted and the parts become firmly attached.

y Quality Testing: y The first quality test takes place after the basic components have been installed.

y Configuring (Software Installation Process): y The boards are advanced automatically on tracks into the "flash and alignment" stage, where basic software is first installed into programmable components.

y Assembly and configuring Process: y A robotic arm lifts the board off the track and puts it into a bay. There, the chips on the board are configured with low-level settings, such as what power level the phone will operate on.

y Testing Process: y Then, a series of electronic tests are administered to ensure that the circuit board is perfect, all the parts work, and that they have been correctly installed

y Fixing camera and LCD displays: y At this stage, the hand work begins. Here, a worker plucks digital camera modules from a reel and installs them with tweezers onto assembled, tested, printed circuit boards. The expensive and fragile liquid-crystal display screens are also added by hand.

y Protection covers Fixing:

A nearby worker performs another essential task by hand: sandwiching the completed printed circuit board between front and back structural frames, later adding the outside covers.y Adding Functionality:

The last step in the production turns a generic phone into one customized to the exacting specifications of mobile-phone users around the world.

y Unique Serial numbering process: y Each handset is put into a cradle, where it is given a unique serial number, known as its IMEI code. y Then, depending on who the customer is, a unique batch of software code is pumped into the phone.

y Diagnostic Test: y Finally, the phone and installed software undergo a battery of diagnostic tests. From this point forward, the IMEI code links each individual phone to its intended customer.

y Final Inspection Test (by human eye): y It seems quaint after all the high-tech assembly and testing, but before every Nokia phone goes into a box, it's inspected one last time by an unmatched resource: the human eye. Only a tiny fraction of phones fail this final test. y Then, before being packed, the phone is de-ionized to remove dust and electrical charge from the surface.

y Packing y Phones are packed into retail boxes by hand, with appropriate documentation and accessories, and then logged into a tracking system using a bar-code reader.

y Finished Goods Storage: y Phones packed into retail boxes are grouped territory wise and order wise in ware house. From there it is dispatched to specific places based on the orders