PLANT LAYOUT

THE PLANT Refers to the physical components of the manufacturing process of the product Required both in terms of buildings and equipments Accounts for the bulk of the fixed assets of the organization

THE LAYOUT ‘Layout’ refers to the physical disposition of the plant and various parts of the plant. Just on paper,not in true sense. Plant Layout is very important in a production manager’s responsibility since it is very difficult and uneconomical to relocate the plant once it is put in place. Must express policy and not determine it.

THE PLANT LAYOUT Refers to the arrangement of machinery, equipments and other industrial facilities. For the purpose of achieving the quickest and smoothest production at the least cost. According to Knowles and Thomson a plant layout involves “Planning and arranging manufacturing machinery, equipments and services for the first time in completely new plants; “The improvements in layouts already in use in order to introduce new methods and improvements in manufacturing procedure.

How to prepare a layout? Information required Type and quantity of labour. Dimensional plan of the space to be laid out. The volume of work to be produced from the space. The operations to be undertaken, their descriptions, sequence and standard times. The equipments needed to carry out the operations. The number of movements of material from one work centre to another during a representative working period. Any dead, ageing, stabilizing or other process storage time. The volume of main stores and finished part stores required. What lines of consumption and fire exists are required. What special requirements are imposed by the local authority or by the company’s insurer. What special inspection requirement exist. What special geographical requirements must be met. If any spare plant will need to be stored in the space under consideration.

SUGGESTED PROCEDURES Prepare model Study operations sequence Choose ‘key’ operations Locate ‘key’ operations on plant Locate main gangways Locate remaining work areas Locate minor gangways Plan individual areas in detail Locate subsidiary equipment Test completed layout against principles of good layout Verify layout on floor Check against company policy

How to install a layout? Planning the way in which the new installation is to be carried out. Supervising while the plan is carried out.

FEATURES OF A GOOD PLANT LAYOUT  Maximum Flexibility  Maximum Co-ordination  Maximum use of Volume  Maximum Visibility  Maximum Accessibility  Maximum Security

FEATURES OF A GOOD PLANT LAYOUT  Maximum Flexibility  Maximum Co-ordination  Maximum use of Volume  Maximum Visibility  Maximum Accessibility  Maximum Security

FEATURES OF A GOOD PLANT LAYOUT  Maximum Flexibility  Maximum Co-ordination  Maximum use of Volume  Maximum Visibility  Maximum Accessibility  Maximum Security

FEATURES OF A GOOD PLANT LAYOUT  Maximum Flexibility  Maximum Co-ordination  Maximum use of Volume  Maximum Visibility  Maximum Accessibility  Maximum Security

FEATURES OF A GOOD PLANT LAYOUT  Maximum Flexibility  Maximum Co-ordination  Maximum use of Volume  Maximum Visibility  Maximum Accessibility  Maximum Security

FEATURES OF A GOOD PLANT LAYOUT  Maximum Flexibility  Maximum Co-ordination  Maximum use of Volume  Maximum Visibility  Maximum Accessibility  Maximum Security

FEATURES OF A GOOD PLANT LAYOUT  Maximum Flexibility  Maximum Co-ordination  Maximum use of Volume  Maximum Visibility  Maximum Accessibility  Maximum Security

FEATURES OF A GOOD PLANT LAYOUT  Minimum Distance  Minimum Handling  Minimum Discomfort  Inherent Safety  Unidirectional Flow  Visible Routes  Identification

FEATURES OF A GOOD PLANT LAYOUT  Minimum Distance  Minimum Handling  Minimum Discomfort  Inherent Safety  Unidirectional Flow  Visible Routes  Identification

FEATURES OF A GOOD PLANT LAYOUT  Minimum Distance  Minimum Handling  Minimum Discomfort  Inherent Safety  Unidirectional Flow  Visible Routes  Identification

FEATURES OF A GOOD PLANT LAYOUT  Minimum Distance  Minimum Handling  Minimum Discomfort  Inherent Safety  Unidirectional Flow  Visible Routes  Identification

FEATURES OF A GOOD PLANT LAYOUT  Minimum Distance  Minimum Handling  Minimum Discomfort  Inherent Safety  Unidirectional Flow  Visible Routes  Identification

FEATURES OF A GOOD PLANT LAYOUT  Minimum Distance  Minimum Handling  Minimum Discomfort  Inherent Safety  Unidirectional Flow  Visible Routes  Identification

FEATURES OF A GOOD PLANT LAYOUT  Minimum Distance  Minimum Handling  Minimum Discomfort  Inherent Safety  Unidirectional Flow  Visible Routes  Identification

FEATURES OF A GOOD PLANT LAYOUT  Minimum Distance  Minimum Handling  Minimum Discomfort  Inherent Safety  Unidirectional Flow  Visible Routes  Identification

PRINCIPLES OF A GOOD PLANT LAYOUT The Principle of Minimum Travel The Principle of Sequence The Principle of Compactness The Principle of Usage The Principle of Safety & Satisfaction The Principle of Flexibility The Principle of Minimum Investment

PRINCIPLES OF A GOOD PLANT LAYOUT The Principle of Minimum Travel The Principle of Sequence The Principle of Compactness The Principle of Usage The Principle of Safety & Satisfaction The Principle of Flexibility The Principle of Minimum Investment

PRINCIPLES OF A GOOD PLANT LAYOUT The Principle of Minimum Travel The Principle of Sequence The Principle of Compactness The Principle of Usage The Principle of Safety & Satisfaction The Principle of Flexibility The Principle of Minimum Investment

PRINCIPLES OF A GOOD PLANT LAYOUT The Principle of Minimum Travel The Principle of Sequence The Principle of Compactness The Principle of Usage The Principle of Safety & Satisfaction The Principle of Flexibility The Principle of Minimum Investment

PRINCIPLES OF A GOOD PLANT LAYOUT The Principle of Minimum Travel The Principle of Sequence The Principle of Compactness The Principle of Usage The Principle of Safety & Satisfaction The Principle of Flexibility The Principle of Minimum Investment

PRINCIPLES OF A GOOD PLANT LAYOUT The Principle of Minimum Travel The Principle of Sequence The Principle of Compactness The Principle of Usage The Principle of Safety & Satisfaction The Principle of Flexibility The Principle of Minimum Investment

PRINCIPLES OF A GOOD PLANT LAYOUT The Principle of Minimum Travel The Principle of Sequence The Principle of Compactness The Principle of Usage The Principle of Safety & Satisfaction The Principle of Flexibility The Principle of Minimum Investment

PRINCIPLES OF A GOOD PLANT LAYOUT The Principle of Minimum Travel The Principle of Sequence The Principle of Compactness The Principle of Usage The Principle of Safety & Satisfaction The Principle of Flexibility The Principle of Minimum Investment

TYPES OF PLANT LAYOUT PLANT LAYOUT FIXED POSITION LAYOUT PROCESS LAYOUT PRODUCT LAYOUT CM LAYOUT

TYPES OF PLANT LAYOUT PLANT LAYOUT FIXED POSITION LAYOUT PROCESS LAYOUT PRODUCT LAYOUT CM LAYOUT

TYPES OF PLANT LAYOUT PLANT LAYOUT FIXED POSITION LAYOUT PROCESS LAYOUT PRODUCT LAYOUT CM LAYOUT

TYPES OF PLANT LAYOUT PLANT LAYOUT FIXED POSITION LAYOUT PROCESS LAYOUT PRODUCT LAYOUT CM LAYOUT

TYPES OF PLANT LAYOUT PLANT LAYOUT FIXED POSITION LAYOUT PROCESS LAYOUT PRODUCT LAYOUT CM LAYOUT

PRODUCT LAYOUT RECEIVING RAW PACKING AND SHIPPING MATERIALS STORAGE FINISHED GOODS STORAGE WC1 WC2 WC3 TEST

PRODUCT LAYOUT RECEIVING RAW PACKING AND SHIPPING MATERIALS STORAGE FINISHED GOODS STORAGE WC1 WC2 WC3 TEST

PRODUCT LAYOUT RECEIVING RAW PACKING AND SHIPPING MATERIALS STORAGE FINISHED GOODS STORAGE WC1 WC2 WC3 TEST

PRODUCT LAYOUT RECEIVING RAW PACKING AND SHIPPING MATERIALS STORAGE FINISHED GOODS STORAGE WC1 WC2 WC3 TEST

PRODUCT LAYOUT RECEIVING RAW PACKING AND SHIPPING MATERIALS STORAGE FINISHED GOODS STORAGE WC1 WC2 WC3 TEST

PRODUCT LAYOUT RECEIVING RAW PACKING AND SHIPPING MATERIALS STORAGE FINISHED GOODS STORAGE WC1 WC2 WC3 TEST

PRODUCT LAYOUT RECEIVING RAW PACKING AND SHIPPING MATERIALS STORAGE FINISHED GOODS STORAGE WC1 WC2 WC3 TEST

PRODUCT LAYOUT RECEIVING RAW PACKING AND SHIPPING MATERIALS STORAGE FINISHED GOODS STORAGE WC1 WC2 WC3 TEST

PRODUCT LAYOUT

SEQUENTIAL

PRODUCT LAYOUT SEQUENTIAL USED ESPECIALLY FOR ASEMBLING OPERATIONS

PRODUCT LAYOUT SEQUENTIAL USED ESPECIALLY FOR ASEMBLING OPERATIONS MORE EQUIPMENTS REQUIRED

PRODUCT LAYOUT SEQUENTIAL USED ESPECIALLY FOR ASEMBLING OPERATIONS MORE EQUIPMENTS REQUIRED ALSO CALLED LINE LAYOUT

PRODUCT LAYOUT SEQUENTIAL USED ESPECIALLY FOR ASEMBLING OPERATIONS MORE EQUIPMENTS REQUIRED ALSO CALLED LINE LAYOUT CATERS ONLY TO ONE PRODUCT

PROCESS LAYOUT INWARD GOODS STORED PLANNERSAUTOMAT ICS GRINDERS MILLING MACHINES CENTRAL INSPECTI ON AREA HEAT TREATMENT RAW MATERIAL STORED DRILLING SHOPS ELECTRO PLATING SHOPS ASSEMBLY TURNING SHOPSPAINTIINGFINISHED GOODS

PROCESS LAYOUT EQUIPMENTS PERFORMING SIMILAR OPERATIONS GROUPED TOGETHER PREFERRED WHEN VOLUME IS LOW, VARIETY IS HIGH JOB-SHOP TYPE OF PRODUCTION FLEXIBILITY IN SEQUENCE OF OPERATIONS

FIXED POSITION LAYOUT

Material remains in a fixed position

FIXED POSITION LAYOUT Material remains in a fixed position Preferred when equipment, and machinery are small in no. and workers skilled

COMPARISON OF PRODUCT AND PROCESS LAYOUT

Characteristics Product Layout Process Layout 1. Mechanizations of Materials Handling 2. Avoidance of Bottlenecks 3. Economy in Manufacturing Time 4. Minimization of Investment in Work in-process 5. Better Production control 6. Early Detection of bad workmanship 7. Greater incentive to a group of workers

COMPARISON OF PRODUCT AND PROCESS LAYOUT Characteristics Product Layout Process Layout 1. Mechanizations of Materials Handling 2. Avoidance of Bottlenecks 3. Economy in Manufacturing Time 4. Minimization of Investment in Work in-process 5. Better Production control 6. Early Detection of bad workmanship 7. Greater incentive to a group of workers

COMPARISON OF PRODUCT AND PROCESS LAYOUT Characteristics Product Layout Process Layout 1. Mechanizations of Materials Handling 2. Avoidance of Bottlenecks 3. Economy in Manufacturing Time 4. Minimization of Investment in Work in-process 5. Better Production control 6. Early Detection of bad workmanship 7. Greater incentive to a group of workers

COMPARISON OF PRODUCT AND PROCESS LAYOUT Characteristics Product Layout Process Layout 1. Mechanizations of Materials Handling 2. Avoidance of Bottlenecks 3. Economy in Manufacturing Time 4. Minimization of Investment in Work in-process 5. Better Production control 6. Early Detection of bad workmanship 7. Greater incentive to a group of workers

COMPARISON OF PRODUCT AND PROCESS LAYOUT Characteristics Product Layout Process Layout 1. Mechanizations of Materials Handling 2. Avoidance of Bottlenecks 3. Economy in Manufacturing Time 4. Minimization of Investment in Work in-process 5. Better Production control 6. Early Detection of bad workmanship 7. Greater incentive to a group of workers

COMPARISON OF PRODUCT AND PROCESS LAYOUT Characteristics Product Layout Process Layout 1. Mechanizations of Materials Handling 2. Avoidance of Bottlenecks 3. Economy in Manufacturing Time 4. Minimization of Investment in Work in-process 5. Better Production control 6. Early Detection of bad workmanship 7. Greater incentive to a group of workers

COMPARISON OF PRODUCT AND PROCESS LAYOUT Characteristics Product Layout Process Layout 1. Mechanizations of Materials Handling 2. Avoidance of Bottlenecks 3. Economy in Manufacturing Time 4. Minimization of Investment in Work in-process 5. Better Production control 6. Early Detection of bad workmanship 7. Greater incentive to a group of workers

COMPARISON OF PRODUCT AND PROCESS LAYOUT Characteristics Product Layout Process Layout 8. Reduced investment on machines 9. Flexibility in production 10. Scope for expansion 11. Handling of breakdowns is easy 12. Greater incentive to individual workers 13. Better utilization of workers and equipment 14. Specialization in supervision

COMPARISON OF PRODUCT AND PROCESS LAYOUT Characteristics Product Layout Process Layout 8. Reduced investment on machines 9. Flexibility in production 10. Scope for expansion 11. Handling of breakdowns is easy 12. Greater incentive to individual workers 13. Better utilization of workers and equipment 14. Specialization in supervision

COMPARISON OF PRODUCT AND PROCESS LAYOUT Characteristics Product Layout Process Layout 8. Reduced investment on machines 9. Flexibility in production 10. Scope for expansion 11. Handling of breakdowns is easy 12. Greater incentive to individual workers 13. Better utilization of workers and equipment 14. Specialization in supervision

COMPARISON OF PRODUCT AND PROCESS LAYOUT Characteristics Product Layout Process Layout 8. Reduced investment on machines 9. Flexibility in production 10. Scope for expansion 11. Handling of breakdowns is easy 12. Greater incentive to individual workers 13. Better utilization of workers and equipment 14. Specialization in supervision

COMPARISON OF PRODUCT AND PROCESS LAYOUT Characteristics Product Layout Process Layout 8. Reduced investment on machines 9. Flexibility in production 10. Scope for expansion 11. Handling of breakdowns is easy 12. Greater incentive to individual workers 13. Better utilization of workers and equipment 14. Specialization in supervision

COMPARISON OF PRODUCT AND PROCESS LAYOUT Characteristics Product Layout Process Layout 8. Reduced investment on machines 9. Flexibility in production 10. Scope for expansion 11. Handling of breakdowns is easy 12. Greater incentive to individual workers 13. Better utilization of workers and equipment 14. Specialization in supervision

COMPARISON OF PRODUCT AND PROCESS LAYOUT Characteristics Product Layout Process Layout 8. Reduced investment on machines 9. Flexibility in production 10. Scope for expansion 11. Handling of breakdowns is easy 12. Greater incentive to individual workers 13. Better utilization of workers and equipment 14. Specialization in supervision

CIRCUMSTANCES WHEN PRODUCT AND PROCESS LAYOUT CAN BE USED Product LayoutProcess Layout 1. One or few standard products 2. Large volume of production 3. Minimum inspection required 1. Many types of products or emphasis on special orders 2. Relatively low volume of production 3. Many inspection required during an operation

CIRCUMSTANCES WHEN PRODUCT AND PROCESS LAYOUT CAN BE USED Product LayoutProcess Layout 4. Materials and products permit bulk or continuous handling by mechanical means 5. Little or no occasion to use the same machine or work station for more than one operation 4. Materials and products too bulky to permit bulk or continuous handling by mechanical means 5. Frequent need for using the same machine or work machine for two or more different operations

ADVANTAGES OF A PROCESS LAYOUT Reduced investment on machines Greater production facility Specialization Greater scope for expansion Better utilization of mean and machines Easy handling breakdown of equipment Full utilization of equipment Low investment Greater incentives to workers

DISADVANTAGES OF PROCESS LAYOUT Difficulty in movement of materials Requires more floor space Difficulty in production control More production time Accumulation of work-in-progress

ADVANTAGES OF PRODUCT LAYOUT Mechanization of materials handling Avoids production bottlenecks Economy in manufacturing time Facilitation of better production control Less floor per unit area of production Reduction in materials handling cost Reduced work-in-progress and investment Early detection of mistakes or badly produced items Greater incentive to workers

DISADVANTAGES OF PRODUCT LAYOUT Known for it’s inflexibility Expensive Difficulty in supervision Expansion difficult Breakdown of equipment can disrupt the system

APPLICATION IN SERVISE SECTOR INDUSTRIES CRAFT,CORELAP,ALDEP and other computerized process layout techniques are useful in service facilities. There should be economy of movement of materials, reduced confusion,greater safety,greater adaptability to changing conditions. Hospitals,petrol pumps,schools and colleges’ layouts needs much improvement.

OBJECTIVES OF PLANT LAYOUT Economies of handling Effective use of available area Minimization of production delays Improved quality control Minimum equipment investment Avoidance of bottlenecks Better supervision Improved utilization of labour Improved employee morale Avoidance of unnecessary and costly changes

REVISION OF PLANT LAYOUT REASONS FOR REVISION EXPANSION TECHNOLOGICAL ADVANCEMENT IMPROVEMENT IN LAYOUT

EXPANSION Increase in the output of existing product Introduction of a new product in the same line Diversification of the line of activity

TECHNOLOGICAL ADVANCEMENT Replacement of labour by machines Developments in process Development in product design Advancement in I.T

IMPROVING LAYOUT Hidden costs Built in adjustability to any circumstances Materials and work-in-process move at a lower rate than expected High material handling costs Aisles and individual work places are conjested

IMPROVING LAYOUT Service debts given adequate space and are inconveniently located Materials in process frequently damaged Frequent accident to workers Delays in production schedule No plans for future expansion Increased production costs Reduced operational inefficiency