1. OPTIMIZATION OF PLANT LAYOUT
ANJUMAN-I-ISLAM’S KALSEKAR TECHNICAL CAMPUS, NEW PANVEL
OPTIMIZATION OF PLANT LAYOUT
-AT OTOKLIN GLOBAL BUSINESS LIMITED
Partial Fulfilment of Dissertation work by-
MIRZA ANEES 14DME154
SHAIKH ASIF 14DME162
SHAIKH BURHAN 14DME164
SHAIKH FAISAL 14DME166
UNDER THE GUIDANCE OF : PROF. SAAD SHAIKH
DEPARTMENT OF MECHANICAL ENGINEERING

2. OVERVIEW Introduction Problem definition Objective
Review of Literature
Methodology
Predicted Analysing of the work
Expected Outcome
Implementation of SLP
References

3. INTRODUCTION
Plant layout is the most effective physical arrangement, either existing or in plans of industrial facilities.
Optimization of a plant layout is a methodology of making system as fully perfect, functional, or effective as possible.
OTOKLIN GLOBAL BUSINESS LIMITED
Filters making company
Year of establishment : 2003
Products: Air filters, Coolant filters, Sand filters, Strainer, etc.
Major Vendors: L&T, TATA Groups, Reliance.

4. The plant suffers from poor utilization of workspace, poor material handling and safety hazards. Also placement of raw material and in process material hinders manufacturing process.
So, our aim is to optimize the plant layout for efficient production system and select suitable material handling system, which in turn will also increase productivity of plant.

5. GENESIS OF PROBLEM Improper utilization of workspace area.
Poor placement of machining equipment.
Problems in material handling causing unnecessary increase in production time and cost.
Several injuries of labours due to improper precautionary measures.

6. CURRENT SCENARIO

7. OBJECTIVES
To study the current flow pattern and relation of overall plant layout.
To develop a new plant layout.
To select appropriate storage system.

8. REVIEW OF LITERATURE Sr.no Paper name Year Authors Purpose Conclusion1
Efficiency Improvement of a Plant Layout
2014
Vivekanand s Gogi, Rohith Shashi Kiran , Suhail M Shaikh
To study and improve the current plant layout and are analysed & designed by using
string diagram.
Instead of criterion of minimizing total distance
travelled, it is suitable to minimize the total distance of the material travelled. 2
Production Layout Optimization for Small and Medium Scale Food
Industry
2015
Yosra Ojaghia, Alireza Khademia, Noordin Mohd Yusof
To reduce the costs of their product.
Use of SLP and GBT has resulted in six
different layouts involving thirteen departments. (ER) method helped in calculation of efficiency for the different
layouts generated

9. A facility allocation technique of the layout
Sr.no
Paper name
Year
Authors
Purpose
Conclusion 3
Analysis and Optimization of Plant Layout using Relative Allocation of Facilities Technique
2013
Bobby John, Jubin James, R. Mahesh Rengaraj
A facility allocation technique of the layout
The existing layout checked using Computerized Relative Allocation of Facilities Technique (CRAFT) and an improved new layout was proposed. 4
Improvement in Plant Layout Using Material
Handling
2012
Amrita Kirtane, Nagendra Sohani
Produce complete coupling by using the same
Mfg. facilities without major changes.
Existing layouts have been modified by using Travel
Chart Technique analysis and considering material handling
cost as the criterion. 5.
Optimization of Plant Layout Using SLP
Method
2016
Shubham Barnwal,
Prasad Dharmadhikari
To develop a new layout based on the SLP pattern theory
The proposed model based on SLP was found to be effective,
production rate increased, the production time was reduced and total distance travelled by
material also reduced.

10. METHODOLOGY Levels of plant layout design:
The Systematic Layout Planning (SLP) is a tool used to arrange a workplace in a plant by locating areas with high frequency and logical relationships close to each other. The process permits the quickest material flow in processing the product at the lowest cost and least amount of handling.
Levels of plant layout design:
Site layout: shows how the building should be located in a proper way.
Block layout: shows the sizes of departments in the buildings.
Detailed layout: shows the arrangements of equipment and workstations in the departments.
Workstation layout: shows the locations of every part of the workstation.

12. PREDICTED ANALYSING OF THE WORK
After knowing the relationships between flow of raw materials and in process inventories with activities (manufacturing processes and material handling) it becomes necessary to draw plant layout.
In order to select best suitable layout we have to draw different layout with different possibilities.
Some of the software used in drawing plant layout are:
SmartDraw's facility planning software
AutoCAD Plant 3D 
Open Factory 3D.

13. EXPECTED OUTCOME
Proper arrangement of machine tools according to the sequence of operations to be followed.
Less material handling.
Increased production rate.

14. STORAGE OF RAW MATERIAL
FLOW OF MATERIAL
STORAGE OF RAW MATERIAL
PROCUREMENT &
MARKING & GAS CUTTING
ROLLING
WELDING
a. Arc Welding
b. spot welding
PAINTING
TESTING
ASSEMBLY & FITTING
DISPATCH

15. ACTIVITY RELATIONSHIP CHART
An Activity relationship Chart is a Tabular means of displaying the closeness rating among all pairs of activities or departments.
Generally, in any manufacturing firm various activities are related to each others either by flow of material, handling possibilities or constraints in layout.
The activity relationship chart of our plant layout is as shown with the possible ratings and reasons for their closeness.

16. Rating
Type of Relationship A
Absolutely Necessary E
Especially Important I
Important O
Ordinary U
Un-important X
Undesired
Rating
Reasons 1
Flow of material 2
Ease of supervision 3
Convenience 4
Production Control 5
Injury Chances/Safety 6
Material Control

17. SPACE AVAILABLE
Perhaps the most difficult step in facilities planning is the determination of the amount of space required in the facility.
Space requirement should be determined:
For individual work stations
For department requirement
The total area available in the plant is 24 x 34 (840) m2 .

18. Types of Products a. Small size Products c. Big size Products
b. Medium size Products

19. PROPOSED STORAGE SYSTEM
Depending upon the weight to be carried by storage device and to decrease the space, we proposed double sided cantilever racking system.
Taking a survey through various websites, we found rack according to our dimensions and load carrying capacity on ‘GLOBAL INDUSTRIAL’ which offers various sub-parts to be assembled.
Such a rack cost Rs. 1,90,000/- approximately.

20. SPACE RELATIONSHIP DIAGRAM
It is derived from activity relationships.
It represents the relation between available space and degree of closeness to be kept between various departments.
Absolutely Necessary
Especially Important
Important

21. PROPOSED LAYOUT - 01 Sr.No. Sections Area (m2) 1. Storage (For pipes)
7 x 2 2.
Machining
(Gas Cutting)
7 x 2+7 x 2 3.
Rolling
4.5 x 9 4.
Fabrication
2.5 x 4.9 5.
Fitting
3 x 3 6.
Temporary Storage
(WIP)
5 x 4 7.
Testing
2 x 2 8.
Painting
3 x 2 9.
Dispatch
5 x 5
10.
Office
4 x 8
11.
Inventory
6 x 9
12.
Scrap
4 x 2

22. Improvements
Proposal of Racks
Previous proposal
New proposal

23. PROPOSED LAYOUT - 02

24. Costing of Rack
Loading and unloading of material is easy as compared to previous rack.
Each individual drawer or shelf can be accessed independently from the others, and offers very safe and secure storage.
Cost when new-$14,000 approx. 9,70,000 INR each.

25. Sizes of VAGs ø3.7m 2.5m 3-Decker Cost-*** 2-Decker Cost-10 Lacs/piece

26. EXPECTED OUTCOME
A. For large size product: (duration - 45 days) Current capacity for large size product : 04 VAGs Total capacity with proposed layout : 05 VAGs Relative increase in productivity: Increase in capacity current capacity =1/4*100 =25%

27. B. For small size products:
Product of size 0.5m x 0.4m x 0.3m
Maximum no. of products: 250 (duration : 60 days)
Currently, no. of products produced simultaneously: 4 in a batch. Thus, requires 63 batches.
With proposed layout, no. of product expected : 5 in a batch. Requires 50 batches.
Total increase in productivity: (63-50)/63
=0.2063
=20.63%

28. Cost of Products

29. Expected profit to be earn:
For large product:
Manufacturing time for a product: 45days
Annual days: 300 working days
Increase in no. of products annually: 6.66= 6 products
Approximate cost of product: 10lacs/product
Profits earned: 6 x 10= 60,00,000 INR
For small products:
Currently, no. of product manufactured: 1,250 per annum
Expected no. of product to be manufactured: 1,560 per annum
Approximate cost of product: 3000rs/product
Profits earned: ( ) x 3000 = 9,30,000 INR
TOTAL PROFIT TO BE EARNED: 69,30,000 INR p.a.

30. References
Subodh B Patil1, S.S.Kuber., “Productivity improvement in plant by using systematic layout planning (SLP) - a case study of medium scale industry”, IJRET: International Journal of Research in Engineering and Technology eISSN:
Amrita Kirtane, Nagendra Sohani, “Improvement in Plant Layout Using Material handling Technique”, International Journal of Science and Research (IJSR) ISSN (Online):
Shubham Barnwal, Prasad Dharmadhikari, “Optimization of Plant Layout Using SLP method”, International Journal of Innovative Research in Science, Engineering and Technology-Vol. 5, Issue 3, March 2016
Chandra Shekhar Tak, Mr.Lalit Yadav, “Improvement in Layout Design using SLP of a small size manufacturing unit: A case study”, IOSR Journal of Engineering (IOSRJEN) - Volume 2, Issue 10 (October 2012), PP 01-07
double-sided-upright-36

31. Thank You!