2. FACILITY LAYOUT
Facility layout is a process of arranging all the tangible resources available in the production or a service facility in a manner to maximise productivity.
RESOURCES – men
material
machine

3. PRINCIPLES OF GOOD FACILITY LAYOUT
Maximum safety
Maximum utilisation of space
Minimum distance and travel time
Minimum investment
Maximum coordination
Sequence
Maximum comfort
Ease of access
Maximum flexibility
Minimum handling

4. OBJECTIVES OF FACILITY LAYOUT
AVAILABILITY OF ADEQUATE SPACE FOR WORK
ENSURE SMOOTH FLOW OF WORK
SAFETY OF WORKER
COMFORTABLE WORK ENVIRONMENT
MINIMUM MOVEMENT OF RESOURCES
BETTER SUPERVISION AND MONITORING
DECREASE IN OVERALL PRODUCTION TIME
INCREASED UTILISATION OF MEN AND MACHINE
FLEXIBILITY

5. TYPES OF FACILITY LAYOUT
PROCESS LAYOUT
PRODUCT LAYOUT
COMBINATION LAYOUT
FIXED LAYOUT
CELLULAR LAYOUT

6. 1. PROCESS OR FUNCTIONAL LAYOUT
All the activities or machines are arranged as per functions performed by them
MACHINES HOMOGENEOUS FUNCTION
GROUPED
Suitable where small quantities of large no. Of products are manufactured

7. PROCESS LAYOUT

8. PROCESS LAYOUT DISADVANTAGES ADVANTAGES Manual handling of material
Low pace of processing
Requirement of more space
Delayed detection of defective process
Requires proper scheduling of resources
ADVANTAGES
Flexibility
Less capital intensive
Better utilisation of resources
Better exposure to workers

9. 2. PRODUCT OR LINE LAYOUT
Resources are arranged productwise i.e. Arranged in a line or a sequence to meet production requirement of a specific product.
Suitable where standardised products are manufactured in large quantities.

10. PRODUCT OR LINE LAYOUT

11. PRODUCT LAYOUT ADVANTAGES LIMITATIONS Uninterrupted flow of work
Economies of large scale
Automated handling of material
Proper utilisation of resources
Timely detection of defective good
Less material handling cost
Less space requirement
LIMITATIONS
Less flexible
Heavy investment
Breakdown will cause idle time
Repetitive work
Speed dependence on slowest machine

12. 3. HYBRID OR COMBINATION LAYOUT
PROCESS LAYOUT
PRODUCT LAYOUT
COMBINATION LAYOUT

14. 4. FIXED LAYOUT
Machines are installed at one place but men and material are moving from one place to another to carry on production.

15. FIXED LAYOUT ADVANTAGES LIMITATIONS High flexibility
Less investment in layout
Scope of job enlargement
LIMITATIONS
High equipment handling cost
Non availability of skilled labour
Underutilisation of men and machines
Duplication of tools

16. 5. CELLULAR OR GROUP LAYOUT
Machines that produce homogeneous products are divided into various groups called cells

17. FACTORS AFFECTING LAYOUT
PRODUCT –
Heavy product – fixed layout
Small product – product layout
2. VOLUME –
Large scale production - line layout
On specification of client – process
layout

18. More space – process layout
3. AREA
More space – process layout
4. TYPE OF MACHINERY-
GENERAL
PRODUCTION
PROCESS
SPECIAL PRODUCTION PROCESS
PROCESS LAYOUT
PRODUCT LAYOUT

19. MANUFACTURING PROCESS
CONTINUOUS
ANALYTICAL
SYNTHETIC
INTERMITTENT
IRREGULAR
4. TYPE OF MACHINERY-
PRODUCT LAYOUT
PROCESS LAYOUT

20. Methods of production 6. METHODS OF PRODUCTION 7. WORKING ENVIRONMENT
Project
Job
Batch
FIXED LAYOUT
PROCESS LAYOUT
7. WORKING ENVIRONMENT
PLANT SITE
MATERIAL

21. COMPUTER BASED METHODS
Techniques of Layout Planning
For laying out a plant there is no such universally accepted technique available. Application of one or more techniques depends upon many factors. These techniques can be divided into two main parts.
MANNUAL
METHODS
COMPUTER BASED METHODS

22. 1. Manual methods Process layout: Outline process chart Flow diagram
String diagram
Travel chart
REL chart
Product layout :
Assembly line balancing

23. TIME OF EACH ACTIVITY ACTIVITIES
Outline Process Chart: Outline Process Chart (OPC) is also known as Operation Process Chart. It is a graphical representation of all the ‘Operations’ and ‘Inspections’ of the whole process It presents the raw material used, activity to be performed and the time taken by the operator for the different parts of the work.
The Standard Practices followed while making OPC is given below:
Write name at the top of the chart.
Use vertical lines in the downward direction
to indicate the operations and inspections.
Describe the activity on the right side and
time of each activity on left side of the
standard symbols.
Label all operations in one serial order and
inspections in another serial order.
TIME OF EACH ACTIVITY
ACTIVITIES

24. Activity: Repair of punctured scooter type
Jack up scooter 1
Activity: Repair of punctured scooter type
Chart begins: Scooter ready for jacking up
Chart ends: Tube ready after repair to mount on tyre
Method
Charted by:
Remove hub-cap of wheel 2
Loosen nut and place properly 3
Remove a wheel 4
Remove outer cover 5
Remove rim 6
Locate the puncture in tube 1
ACTIVITY
SYMBOL
METHOD (PRESENT)
Operations 8
Inspection 2
Mark the puncture 7
Repair the puncture and remove nails, if any 8
Recheck 2

25. Flow diagrams: They presents movement or flow of workers, material and equipments during the execution of a work or operation and indicates the direction of travel with the help of arrows, drawn on the diagram.
According to Robert, L. Harris,
“flow diagram is a graphic representation of the physical route or flow of peoples, materials, paperwork’s, vehicles, or communication associated with a process, procedure plan, or investigation.”

26. FLOW DIAGRAM FOR MANUFACTURE OF BI-CYCLE PEDAL AXLE
Raw material store
Forge shop
Raw material
Cutting shed
Heat treatment section
Assemble section
Part
storage
Machine shop
(Turning
Section)
Inspection
Milling section
FLOW DIAGRAM FOR MANUFACTURE OF BI-CYCLE PEDAL AXLE

27. 3. String Diagram: The diagram records heavy movement and distance travelled of worker, material or equipment at the job.
Thee string diagram is a scale plan or model on which a thread is used to measure and trace the path of workers, material or equipment during a specified sequence of events.
The layout plan of working area is fixed on a soft board.
The pins are put on the layout on stops and turning points of the worker.
A thread is woven on the pins as per movements of workers.
The thread is then measured to find the actual distance covered by the workers.
The diagram is useful in following circumstances:
One worker working on several machines.
Several workers working on a single machine.

28. Symbol Meaning Symbol Meaning
STACK
FOLD
RIVERT
DRILL
DRILL
RIVERT
CUT
CUT
CHECK
MARK
CHECK
FOLD
SHEET METAL
STACK
SHEET METAL
MARK
Symbol
Meaning
“O”
Operations
Transportation
Inspection
Symbol
Meaning
Storage
“D”
Delay

29. Travel Chart: The chart records heavy and regular movements in a working area.
“A travel chart is a tabular record for presenting quantitative data about the workers materials or equipment between any numbers of places over any given period of time.”
Application
Several worker working on one machine.
One worker working on several machines.
Several workers working on several machines.

30. TO Store Punching Trimming Shining Packaging Total FROM Store Punching
500 pieces
400 pieces
200 pieces
Store
1100
Punching
50 pieces
50 pieces
100
Trimming
100 pieces
100
Shining
20 pieces 20
Packaging
Each bigger square represents work station.
Along the top, squares towards right denotes the stations to which travel happens and down the left hand denotes from where movement is made.
Construction of Travel chart
Firstly, a big square (divided in small squares) is drawn.
A diagonal line is drawn from top left to bottom right square.

31. REL Chart: REL chart stands for relationship charts
REL Chart: REL chart stands for relationship charts. These relationship charts records heavy movement between two work centres. It combines qualitative and quantitative aspect to decide about the layout.
Construction :
Name all the departments on the relationship chart.
Outline the basis of determining closeness of relationship between departments.
Give rating or code for the relationship.

32. Rating Meaning A Absolutely necessary E Especially important I
Ordinary closeness U
Unimportant X
Undesirable
Rating
Reason 1
High use 2
Medium use 3
Low use 4
High flow 5
Medium flow 6
Low flow
As in the example it is most important that The Store and The Punching operation are Close to one Another since the greatest number of journeys are made between these two stations.
Store
Punching
Trimming
Shining
Packaging 5 4 O A U 1

33. Assembly line balancing
Product layout :
Assembly line balancing
Under product layout all the production resources such as men, material and machine are arranged in a line or a sequence. The raw materials move from one work station to another till it is converted into finished goods.
Designing a product layout requires sequence of operations to be determined, assessment of speed to analyse volume of work done so that all work stations get equal work load. This whole process is called assembly line balancing.

34. Important Terms Activity - Specific task or job.
Event - Instant of time when an activity starts or ends.
Network - Graphical representation of activity.
Tail and Head Event - When an activity starts and; when an activity ends.
NODE
HEAD EVENT A 3
TAIL EVENT

35. Successor activity Predecessor activity activity
5) Activities:
Predecessor activity – Activities that must be accomplished before other activities.
Successor activity - One which starts immediately after completion of other activity.
Concurrent activity - Activities which can be performed simultaneously.
Successor
activity D A B
Predecessor
activity C
Concurrent
activity

36. A B C E G H I D F Task Predecessor TIME(minutes) A _ .3 B .6 C .4 D
1.2
Task
Predecessor
TIME (minutes) E C .2 F D .6 G .1 H
F,G .5 I .3 A B C E G H I D F

37. A F C G D I H B E Cycle time = Operating time Output required = 440.6 C .4 G .1 D
1.2 I .3 H .5 A B E .2
Output : 275 units/day
Operating time :
440 min/day
IDLE TIIME = 0.6 minutes
W/S # 1
1.6min.
W/S # 2
1.6min.
W/S # 3
1.6min.
Minimum number =
of workstations
Total time
Cycle time
Cycle time = Operating time
Output required
Idle time B D F H A
= min/unit
1.6 min/unit
= 2.6 workstations
0.4
= 440
275
= 1.6 min/unit I C
= 3 workstations
0.2 E G

38. Improvement softwares
2. Computer based methods
Computer based layout planning methods are used in modern world to solve various process layout issues. These methods are divided into two categories i.e. Construction programs and improvement programs.
Improvement softwares
CRAFT
Construction
softwares
ALDEP
CORELAP

39. 1. Construction softwares : The softwares helps in designing a layout from the very beginning is called construction programs.
ALDEP: ALDEP is developed by IBM to solve issues created while constructing relationship charts. ALDEP stands for automated layout design program.
STEPS:
It randomly selects first department.
If more than one department has similar relationship, it can choose any
It positions departments on upper left corner and start laying out departments downwards and then left to right continue laying bottom up and left and right

40. CORELAP : It means computerised relationship layout planning and is one step forward to ALDEP Software. The software creates best layout on the basis of total closeness rating
Improvement Softwares : These softwares begin with an initial layout and make improvement through additional changes. More the number of departments, layout design may be in millions and trillions. Programs like ALDEP and CORELAP are used in these circumstances. The most popular software to improve layout design is CRAFT.
CRAFT: It stands for Computerised Relative Allocation Of Facilities Techniques. The software requires basic travel chart and load distance score to start its operations.
Features :
It compares two adjacent departments and exchange them in layout pair wise.
It tries to reduce the overall cost.
Generally it can handle up to 40 departments.

41. Calculate centre point and rectilinear distance of all departments.
Steps
Calculate centre point and rectilinear distance of all departments.
Find the cost of initial layout by multiplying the material flow, unit cost and distance i.e. F×C×D= TOTAL COST
Improve the layout by interchanging
adjacent departments till
a least total cost layout is found. A B C D
A B C D --
FLOW DATA
Rectilinear
Distance
Centroid A
(5,15) D
(35,5) C
(15,5) B
(25,15) 20 10
INITIAL LAYOUT
Distance:
A to B 20 units = |25-5|+|15-15|
A to D 40 units =|35-5|+|5-15|
B to D 20 units =|35-25|+|5-15|
C to D 20 units =|35-15|+|5-5|
Total movement cost = (20x15)+(20x10)+(40x50)+(20x20)+(20X5)+(20x10)
= 3200

42. Reduction in movement cost= 3200-1650=1550A B C D
A B C D --
FLOW DATA A
(35,15) D
(35,5) C
(15,5) B
(15,15) 20 10
Total movement cost
=(20x15)+(30x10)+(10x50)+(10x20)
+(30X5)+(20x10)
= 1650 A
(5,15) D
(35,5) C
(15,5) B
(25,15) 20 10
INITIAL LAYOUT
Distance:
A to B 20 units = |35-15|+|15-15|
A to D 10 units =|35-35|+|5-15|
B to D 30 units =|15-35|+|15-5|
C to D 20 units =|35-15|+|5-5|
Reduction in movement cost= =1550