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Unit 4: Plant Layout and MaterialHandling

Classification of layout

Material Handling Principles

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What Is Layout Planning

Layout planning is determining the best physical arrangement

of resources within a facility Facility resource arrangement can significantly affect

productivity

Two broad categories of operations:

Intermittent processing systems low volume of many

different products

Continuous processing systems high volume of a few

standardized products

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Importance of Layout Decisions

Requires substantial investments of money

and effort Involves long-term commitments

Has significant impact on cost and efficiency

of short-term operations

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Objectives of Plant Layout

Minimize the handling and transportation of materials.

To ensure economic utilization of the available space.

To ensure that work processed one point and anotherwithin the factory without any delay.

To ensure efficient control over various process ofproduction.

To provide adequate safety to the worker from accidents.

To obtain more efficient utilization of available resources.

To minimize the over all cost of production.

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The Need for Layout Decisions

Inefficient operations For Example: High Cost

Bottlenecks Changes in the design of products or services

The introduction of new products or services

Accidents- Safety hazards

Changes in environmental or other legal

requirements Changes in volume of output or mix of products

Changes in methods and equipment

Morale problems

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Types of Layouts

Four basic layout types consisting of;

Process layouts - Group similar resourcestogether

Product layouts - Designed to produce aspecific product efficiently

Hybrid layouts - Combine aspects of bothprocess and product layouts

Fixed-Position layouts - Product is two large to

move; e.g. a building

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Process Layouts

Process layout unique characteristics include;

General purpose & flexible resources

Lower capital intensity & automation

Higher labor intensity

Processing rates are slower

Material handling costs are higher Scheduling resources & work flow is more

complex

Space requirements are higher

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Product Layouts

Product layout unique characteristics are

Produce small number of products efficiently Resources are specialized

High capital intensity

Low flexibility relative to the market

Processing rates are faster Material handling costs are lower

Lower space requirements

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Hybrid Layouts

Combine elements of both product & process

layouts Maintain some of the efficiencies of product

layouts

Maintain some of the flexibility of process layouts

Examples: Group technology & manufacturing cells

Grocery stores

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Fixed-Position Layout

Used when product is large

Product is difficult or impossible to move, i.e.very large or fixed

All resources must be brought to the site

Scheduling of crews and resources is a

challenge

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F

acility Layout Across th

eOrganization

Layout planning is organizationally important

for an efficient operations Marketing is affected by layout especially when

clients come to the site

Human resources is affected as layout impacts

people Finance is involved as layout changes can be

costly endeavors

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Material Handling

Material handlingis the function of moving the right

material to the right place in the right time, in theright amount, in sequence, and in the right condition

to minimize production cost.

American materials handling society Defines-

Materials handling as the art and science involving

movement, packing and storing of materials in anyform by means of gravity, manual effort or power-

actuated machinery.

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Overview of Material HandlingEquipment

Material handling equipment includes:

Manual Handling Devices Cranes

Elevators

Conveyors belt

Pipe lines

Trucks

Automatic valves

Robots/Auto transfer devices

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Principles of Material Handling

1. Follow one line direct flow pattern, no U turns, no zig zags or criss crosses.

2. Remove human inconveniences of lifting, bending, going long distances,

climbing up and down by proper material handling systems and theirlocations.

3. Bulk and heavy materials to move minimum distance and help shipping of

finish good.

4. Production sequencing and warehouses or stock points be as per process

flows.

5. Flexibility in layouts be planned to account for unforeseen issues like

electricity stoppages, changes in production, machines breakdowns.

6. Usually equal space is kept along side each plant to allow future expansions.

7. Mobile material handling equipment be used to full capacities.

8. Environment and safety affect be incorporated suitably.

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Thank you