36899615 Facility Layout

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Facility Layout


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Presented by

Shashank Saxena

Shashi Minchel

Shikha Sinha

Shilpi Kanstiya

Shruti Agnihotri

Shruti Garg

Shuvam kaushik

Simayan Pati


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Plant layout

A floor plan for determining and arranging the desired

machinery and equipment of a plant

It permits

The quickest flow of materials in processing the product

From the receipt of the raw materials to the

shipment of the finished product

At the lowest cost, andWith the least amount of handling


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Objectives

Provide enough production capacity

Reduce material handling cost

Reduce congestion impeding movement of men andmaterial

Reduce hazards to working personnel

Utilize labour efficiently

Increase employee morale Utilize available floor space efficiently and

effectively


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Reduce accidents

Provide for volume and product flexibility

Provide ease of supervision and maintenance

Facilitate co-ordination and face-to-facecommunication

Provide for employee safety and health

Allow high machine utilisation

Improve productivity

Objectives


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Principles of layout

Principal of minimum travel

Principle of sequence

Principle of usage

Principle of compactness

Principle of safety and satisfaction

Principle of flexibility

Principle of minimum investment


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Basic Types of Layout

Product Layout

Process or Functional Layout

Fixed-position LayoutCell manufacturing/GT

Mixed /Combined Layouts

719/05/2013


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Vvolume-variety characteristics

Low VOLUME High

High

VARIETY

Low

Fixedposition layout

Process layout

Cell layout

Product layout


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Product layout

Machines arranged in a line depending upon sequence

of operations

Material moves in a line from the first machine to thefinished product on the last machine.

Investment higher as compared to process layout

Better suited for standardised products on a mass scale production. Exchemicals,paper


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Product Layout

Plant & machinery layout is designed to cater to

continuous flow of Materials.

The position and order in the sequence for amachine performing particular operation is fixed.

Once a machine is in line, it cannot perform any

operation , which is not designated in the

sequence of operations.

There is a continuous flow of material during the

production process from start to finish.

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FINISHED GOODS

MATERIAL FLOW

RAW MATERIALSPRODUCTION SUB-SYSTEM

RECEIVING

STORAGE OPERATION A

OPERATION B

OPERATION C

OPERATION D

SHIPPING

EDP CONTROL

SYSTEMS

INFORMATION

FLOWS

CONTINUOUS FLOW PRODUCTION SYSTEM (FLOW SHOP)


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Examples of product layout

Assembly line for air-conditioner

Car manufacturing unit

Car washes and

Canteen facilities

Laundry.


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Important Considerations

All machines placed at points demanded by sequence ofoperation

No crossing over of one line with the otherMaterials may be fed where they are required for

assembly but not necessarily all at one point

All operations including assembly, testing and packing

included in the line


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Classificationand

marking of

clothes

Washing

MachineDryer

Steam

press

StorageArea for

Pressed

clothes

Delivery

Counter

Product layout of laundry

To produce one standard product in large volumes.

Each unit produced undergoes same sequence of operations and uses same

flow of work.

The work centers and equipments are arranged in a line for continuous

operation.


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Advantages

Ensures smooth and regular flow of material and

finished goods.Short processing time.

Reduces material handling.

Low cost labour procurement and lesser training

required.Lesser Inspection & Early detection of mistakes

Layout avoids production bottlenecks

Economy in manufacturing time

Better production control

Requires less floor area per unit of production

Work-in-progress in reduced


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Disadvantages:

Inflexible & expensive layout

Difficulty in supervision

Expansion is difficult

Any breakdown along the line can disrupt total

production

Requires heavy capital investment.


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Process layout

Grouping together of similar machines in one

department

Material moves from one group of machines to the

other

Movement over longer distance and along criss-

cross paths

May also involve part finished inventory waiting

Best suited for intermittent type of production/light and heavy industries


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Functional or process layout

Here machines performing same type ofoperations are installed at one place .i.e. plant isgrouped according to functions e.g. all drilling

machines are located at one place known asdrilling section.

This type of layout is most appropriate forintermittent (JOB and BATCH ) type of

manufacturing systems where small qtys of alarge range of products are to be manufacturede.g. machine tools etc.


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Process Layout

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Process Layout - work travels

to dedicated process centers

Milling

Assembly

& TestGrinding

Drilling Plating


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INTERMITTENT FLOW PRODUCTION SYSTEM (JOB SHOP )

PRODUCTION SUB-

SYSTEM

RECEIVING

STORAGE

OPERATION A OPERATION B

OPERATION COPERATION DSHIPPING

INFORMATION

FLOWS

WIP

WIP WIP

WIP

FINISHE

D

GOODS

EDP

CONTR

OLSYSTEM

S

RAW MATERIALS

MATERIAL FLOW

FINISHED GOODS


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Process Layout Examples

Car servicing

Hospital-Patient requiring various tests

Volume low & variety is more

Garment factory producing half sleeve shirts,full sleeve shirts, pants and suits.

Office buildings, schools, universities,hospitals, aerodrome, library, book store oramusement centers are planned on this basis.

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Important considerations

Distance between departments as small as possible

Departments to be located as per sequence of operation

Convenience for inspection as well as supervision


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Process layout

Lathe 1

Lathe 2

Lathe 3

Milling

Machine

Fitting Table 1

Fitting Table 2

Fitting Table 3

Welding M/C - 1

Welding M/C - 2

Paint Shop

Side Entry

Main Entry

Work Shop OfficeAir

Compressor

Product A

Product B

Flow of work is not standardized

Plant produces a variety of products

Some of the processes / operations

might be common.


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Advantages

Each production unit of the system worksindependently and is not affected by the happenings in

another section of the plant.

Scope for more skilled labour leads to better quality

in production.

Wide flexibility in production facilities.

Machine breakdown doesnt disrupt production.

Lower capital investment. (Less duplication ofmachines).

Better utilization of resources

Full utilization of machinery


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Disadvantages

More material handling.

Longer processing time:- as more time s required formaterial handling, transportation n inspection.

Requires substantial production planning and control.Requires more floor space.

Inspection s more frequent n costlier.

Requires highly skilled labour creating difficulty inlabour procurement.

Production time increased because of extra travel

Accumulation of work-in-process at different machines


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Fixed position layout

Movement of men & machinery to the product

Product remains stationary

Cost of moving product is high,bulky

Best suited for bulky & heavy products ex.Ships, aeroplanes etc.


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Fixed Position Layout

The material remains in a fixed position , but

the machinery, tool workmen etc are brought to

the material


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AIRCRAFT ASSEMBLY

FINISHED PRODUCT

(AIRCRAFT)

RAW MATERIALS

MACHINE &

EQUIPMENT

LABOUR

FIXED POSITION OR STATIC LAYOUT


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Fixed position layout

Fixed-position layout is used for products, which areeither very big in size (weight/volume) or very criticaland it is not feasible or desirable to move the product and

product remains in one position only.

Men, materials, equipment and tools are brought to theproduct for execution of the work.

Building of space shuttle, turbines, aircrafts and ship usefixed-position layout as it is not feasible to move these

products due to their size or weight.


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18-12-2007 30

Fixed Position Layout

Employed in large project type organisation

Example

ISRO

Helicopter

Nuclear engg. Division of BHEL


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Advantages

Men/machinery can be moved for a wide varietyof operations producing different products

Worker identifies himself with the product &

takes pride when the work is completed

Investment on layout is small

High cost & difficulty in transporting a bulky job

avoided


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Mixed layouts

Mixed layoutspure basic layouts can be used in different

departments in one organisation.

Example: A hospital would be arranged on process-layoutprinciples. Within individual departments different

layouts are used e.g. x-ray department probably process,

surgical theatres fixed-position and the blood-processing

lab a product layout.


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Combined layout

Combination of product & process layout with anemphasis on either

Generally adopted in industry

In fabrication plants including assembly,fabrication tends to employ process layout whileassembly areas employ product layout Soap manufacturing industry employs product line for

manufacturing of soap, but ancillaries such as heating,manufacturing of gleycerine, power house etc. Are arranged onfunctional basis.


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F.P.

F.P.

G.C.

G.C.

G.C.

H.T.

H.T.

G.G.

G.G.

RAW MATERIAL

RAW MATERIAL

FINISHED

PRODUCTS

(GEARS)

F.P. = FORGING PRESS G.C. = GEAR CUTTING

H.T. = HEAT TREATMENT FURNACE G.G. = GEAR GRINDING MACHINE

COMBINATION LAYOUT OR HYBRID LAYOUT FOR GEAR MANUFACTURING


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Combination layout

In an industrial plant, it is difficult to confine to one typeof layout only i.e. process or product layout.

It becomes necessary to use process layout for some ofthe activities and to use product layout for certain other

activities in the same plant.

Cement manufacturing may need process layout for raw-material preparation, which require crushing, grindingand mixing of the various raw-materials such as lime-

stone, clay, bauxite and iron-ore.


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Combination layout

Once the raw materials are prepared and converted intoraw-meal by mixing different raw materials in

predetermined proportion, production processes such aspre-heating, pre-calcining, calcinations for conversion of

raw-meal into clinker and cooling of clinker would useproduct layout.

Within the plant, workshop activities are arranged byusing process layout, whereas the packing and dispatch

operations of the cement through trucks need productlayout.


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Clay

Yard

BauxiteYard

Iron ore

Yard

Lime StoneYard

Raw

Mill

ESP

Cyclone

Chimney

BlendingSt

oragecyclone

Inlet chamber

Of kiln

Rotary kiln

Clinker cooler

Cement

Mill

Combination layoutcase of a cement plant

Process layout for a portion of

Cement plant

Product layout for a portion of

Cement plant


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Cellular manufacturing (cm) layout

Grouping of machines into cells

Cells function somewhat like product layoutwithin a larger shop or process layout

Each cell in the cm formed to produce a singlepart / a few parts

All with common characteristics which usually requiressimilar machines and settings

Flow of parts within the cell can take many forms


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Group Technology

This is philosophy that seeks to exploit the

commonality in manufacturing and uses this as a

basis for grouping components and resources. This is

also known as cellular manufacturing.

Pioneered by Russians

Mid volume & mid variety scenario

70% of mfg. industry may fall under this category)


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CARAVAN, BATON and MIXED CELLS

Operator andproduct

move from station

to

station

Operators arefixed but

products move

from

station to station

Products move fromstation

to station and

operators move

between stations

CARAVAN CELLS

BATON CELLS

MIXED CELLS

CELLULAR MANUFACTURING


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1 2

3

45

1 2 3

1 2

34

21

CELL # 3

CELL # 4

CELL # 1CELL # 2

PRODUCTION OPERATION PRODUCT OR MATERIAL FLOW

CELLULAR MANUFACTURING

LAYOUT

PART D

PART Y

PART X

PART A

PART B

3


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-1111 -1111

2222 - 2222

Assemb

ly

3333 - 3333

4444 - 4444

Lathe

Lathe

Mill

Mill

Mill

Mill

Drill

Drill

Drill

Heattreat

Heat

treat

Heat

treat

Gearcut

Gear

cut

Grind

Grind

Cellular Manufacturing Layout

CM LAYOUT


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CM LAYOUTADVANTAGES

LOWER WORK-IN-PROCESS INVENTORIES

REDUCED MATERIAL HANDLING COSTS

SHORTER FLOW TIMES IN PRODUCTION

SIMPLIFIED PRODUCTION PLANNING (MEN,

MATERIAL ETC.)

OVERALL PERFORMANCE OFTEN INCREASES

BY LOWERING PRODUCTION COSTS &

IMPROVING ON-TIME DELIVERY

IMPROVED QUALITY

Ad f C ll l L


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Advantages of Cellular Layout

PPC becomes simpler

Material handling becomes easier

Traceability improves Employees are able to relate better.

Helps in implementing SGA, Kaizen an

JIT

C ll l L E l


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Cellular Layout- Examples

Reliance industries- HDPE & LDPE

Titan Industry

ABB( Industrial fans & blowers)

CM l t li i i


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CM layout limitations

Reduced manufacturing flexibility & potentially

increased machine downtime

Duplicate pieces of machinery may be needed so asto avoid movement of parts between cells


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Service facility layout

Main difference between service and manufacturingfacility is to bring together customers & services inmany service facilities

Facilities to provide for Easy entrance from the freeways and busy thoroughfares

Large well organised and amply illuminated parking areas etc.

Hotels, cinema halls etc have different areas to cater to

the comfort & convenience of customers

ENTRANCEEXIT


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PARKING AREAPARKING AREA

PARKING AREA PARKING AREA

HOSPITAL WARDS

HOSPITAL WARDS

HOSPITAL WARDS

SURGERY, RADIOLOGY,

I.C.U., TECH SERVICES

DOCTORS

LOUNGE /

OFFICES

ADMIN. OFFICE

NURSES

LOUNGECAFETERIA

CASUALTY DEPT / INPATIENT DEPT

ENTRANCE EXIT

CASUALTY DEPT / INPATIENT DEPT

ENTRANCEEXIT

SERVICE FACILITY LAYOUT ( HOSPITAL LAYOUT )


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Layout important to achieve client-customer goal of fast service FAST SERVICE SUPPORTED BY POINT OF SALE SYSTEM,

SCANNERS, SELF SERVICE TO PROVIDE SPEED AS WELL ASREDUCE COST, atms BY BANKS ETC.

Flow line approach followed in fast food service

Process line layout occurs in many services like medical clinics,offices etc.



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Generally, as in manufacturing

Line layout preferred in high volume,

standardised products Fast food service

Process layout preferred in service operations

also

General offices, banks, general hospitals, municipal

offices etc.



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SERVICE WAITING LINE MODULES

SINGLE CHANNEL,

SINGLE PHASE MODULE

WAITING LINE SERVICE

FACILITY

MULTIPLE CHANNEL,

SINGLE PHASE MODULE

SERVICE

FACILITYWAITING LINE

SINGLE CHANNEL,

MULTIPLE PHASE MODULE

WAITING LINE SERVICE

FACILITY

SERVICEFACILITY

WAITING LINE

MULTIPLE CHANNEL,

MULTIPLE PHASE MODULE

L l i


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Layout planning methodology

Travel chart method

Load-distance analysis method

Systematic layout planning method

Analysing layouts with computers

Aldep (automated layout designing programme)

Corelap (computerised relationship layout planning)

Craft (computerised relative allocation of facilitiestechnique)


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Documents

36899615 Facility Layout