2 Facility Layout

8/9/2019 2 Facility Layout

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Facility/Plant Layout

Plant Layout is most effective arrangement ofmachines, processing equipment and servicedepartments to have the best co-ordination &

efficiency of man, machine and material in a plant .

For a factory which is already in operation what is

Facility layout ?


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Factors affecting Layout

Types of industries

Types of Production system

Job shop production

Type of product

Volume of production


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Types of industries

Synthetic process based

Eg: Limestone + clay Cement

Analytic process basedEg : Crude oil petroleum products

Conditioning process based

Eg :Jute products, milk products

Extractive process based

Eg : Bauxite Al ,

Sugarcane juice Jaggery, sugar


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Types of production system

Continuous production

Std., high volume, capital intensive Pdts.

Pdts made to store in inventory

Continuous product flow

Leaf springs

Job shop production

Made to order, low volume, labor-intense Pdts. Interrupted pdt flow

Space aircrafts, space vehicles.


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Types of production system

Batch Production

medium volume of same type of item or pdt

May be produced once or on regular interval

Generally Plant capacity > demand

General purpose machine but having productionrate

Industrial equipt, furniture , plastic molding.

Type of pdt.

Product is heavy or light, large or small, liquid orsolid


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Types of Layout

Fixed position Layout

Major part of pdt remains in fixed space

Limited space

Different material at different stages

Volume required is huge

Ship building industry


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Types of Layout

Process or Function Layout

Low volume , high variety prodn

All machines/eqpts of same type are grouped inone section or area

All drilling machines, etc.

Different sequence of operations

Eg : patients Radiology, nursing beds, etc.

Product Layout Flow of material unidirectionally

Backtracking avoided

Automobiles, refrigerators, sugar , steel, cementetc.


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Types of Layout

Retail Layout

Many products are exposed to customer

Dairy pdts on oneside of supermkt &backery pdts on another.

Objective profitability maximization

Slotting manufactures have to pay fees for positioning Services -> Ambient conditions like lightning, sound, smell,

temperature.

Spatial layout & functionality

Warehousing &Storage layout

Optimise handling cost & cost of warehouse space

.


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Combination Layout

Process + Product Layout

Office Layout

Information more important

Technology cellular phones, space utilisation,Internet, laptop computers

Virtual companies require few employee


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Cross docking

Avoid placing of materials, supplies in storage byprocessing them as received

SLP

Collect Data abt Current & forecasted prodn units

PQRST

Product,Supporting activities, Route,

Supporting activites, Timing


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A Travel Chartis a simple table that is useful where thereare multiple (and possibly irregular) movement betweenplaces. It is a variation on the Check Sheet, indicatingmovements from and to any combination of a given setof locations.


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Gant Charts (Sequencing

Technique)

How each machine /work centre is planned for different joborders

Scheduled start & finish times

Word document


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LOB (Sequencing Technique)


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LOB

Compare scheduled v/s Actual Units

with period (Units Y, Time X)

Find deviation , take corrective action

If possible take preventive measures Forecast future performance


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Johnsons Rule

Maiden Charm(Un) ltd beauty Pdts, go through twooperations: Preparation & Finishing at the respectivetwo places& in that order. The operation times atthese work- centres are given below:

How should the above items be sequenced so thatthe total completion time is minimized ?

BeautyPdts\hrs

Preparationhrs

Finishing Hrs

Baby Blue 1 3

Virgin White 4 2

Shy Pink 5 4

Daring Purple 2 5


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Use of computers for Scheduling

Computers /software are requiredfor Production Analysis

PPC software, SAP/ERP

Documents

2 Facility Layout