Production Technology

PLANT LAYOUT

1. Define Plant layout? What are different types of layout used in industry?
Give suitable example of each?

Ans: - PLANT LAYOUT

Plant layout is defined as techniques of locating different machines
and facilities like person, storage space, material handling equipment and all
other supporting services within in the factory so as to get maximum output
with desired quality at lowest possible cost.

TYPES OF PLANT LAYOUT IN INDUSTRY

The various plant layout are used in the industry are
1. Product layout
Example: Sugar plant, bottling Industry

2. Process layout
Example: Chemical Industry

3. Fixed position layout

Example: Ship Building Industry, Air cra ft production.

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2. Give the main objectives of Plant Layout?

Ans: -
OBJECTIVES OF PLANT LAYOUT
A good layout is one which provides maximum satisfaction to
employees, management and consumers.

The main objectives of good plant layout are

1. Streamline the flow of material through the plant.

2. Effective utilization of men, machines and available space.
3. Easy supervision and better production control.
4. Provide workman safety, convenience and comfort.
5. Minimization of material handling and manufacturing cycle time.

3. State the symptoms of Bad Plant Layout?

Ans: - Symptoms of Bad plant layout
The symptom of bad plant layout are as follows:
1. Long transportation lines
2. Poor utilization of space.
3. Mental or physical stain in the workers.
4. More frequent accident
5. Difficult to supervise and control.
6. Over-crowding of men, material, machine and equipment.
7. Scrap or wastage of material is more.
8. The amount of the work in process is large.

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4. Explain the Muther principle of Good Plant Layout?

Ans: -
Muther principle of Good Plant Layout
According to Muther, there are six basic principles to design best plant layout
These are
1. Principles of overall integration
A good layout is one that integrates men, m aterials, machines, services in
such a way that the best comprise is obtained.

2. Principles of minimum distance or moment

A good layout is one in which the total distance travelled by men and
material is minimum.
Straight line movements are preferred.

3. Principles of flow
A good layout is one that makes the material moves onl y in forward
direction towards the completion stage without backtracking.

4. Principles of cubic space

A good layout is one that make effective utilization of available space in
three dimension i.e. length, breadth and height.

5. Principle of satisfaction and safety

This principle considers workers safety and satisfaction and protecting the
plant and machinery against the fire, theft etc.

6. Principles of flexibility.
The plant must be flexible to absorb necessary changes whenever
required without consuming much cost and time.

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5. What are the techniques used in Plant Layout? Explain any two
OR
State the plant layout techniques used in and explain any one of them?
Ans: -
TOOLS AND TECHNIQUES USED IN PLANT LAYOUT
The various tools and techniques used in plant layout planning are
1. Operational process chart.
2. Flow process chart.
3. Flow diagrams.
4. Machine data cards.
5. Templates
6. Three dimensional models.
7. Relationship chart (REL)

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Relationship chart (REL)

1. The relationship chart is developed by ROBER MUTHER.

2. The relationship and interdependence of one department to another is
shown by REL chart rather than exact flows and related costs.
3. This chart shows how close on workstation is one to another.
This closeness is expressed on a scale.
4. After checking, the degree of closeness suitable placing of department
and machine is possible.
Figure shows REL chart
5. Each block in the chart shoes the relationship between the two
workstations and rating is given in the adjacent tables.

Value Closeness
A Absolute Essential
E Essential
I Important
O Ordinary
U Un-important
X Not desirable

where 1, 2……5 are the depth or workstation

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Three dimensional scaled model.

1. It is modification of the template model. Here in place of templates,3
dimensional scale models of workstation and other facilities are prepared
and are placed on the factory plan at suitable places.
2. These models are made from wood ,plastic and metal.etc
3. This technique gives more realistic view of future plant layout like height
and projection of machine parts, overhead structure,arrnagment for
safety ,ventilation etc.

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6. Short notes on Types of Plant Layout? Explain any two

Ans: - PLANT LAYOUT
Plant layout is defined as techniques of locating different machines
and facilities like person, storage space, material handling equipment and all
other supporting services within in the factory so as to get maximum output
with desired quality at lowes t possible cost.

TYPES OF PLANT LAYOUT IN INDUSTRY

The various plant layout are used in the industry are
1. Product layout
Example: Sugar plant, bottling Industry

2. Process layout
Example: Chemical Industry

3. Fixed position layout

Example: Ship Building Industry, Air craft production.

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1. Product layout

a. It is also known as line layout. It is used in mass production.

b. In this layout, all necessary machinery and equipment are set out in same
are in the sequence of manufacturing process.
c. This layout is used when there is high demand of one or several product.
Example: Sugar plant, bottling Industry , Automobile and TV sets.

Figure: Product Layout

Advantage
a. Low cost per unit
b. Better use of cubic space.
c. Work in a process is high.
d. It needs less skilled workers.
e. Production cycle per unit time is low.

Disadvantage
a. Machines are not used to full capacity.
b. Less flexibility.
c. High capital investment due to SPM.
d. Same kind of work makes the worker feel boredom and montous.
e. For expansion purpose is not possible to add machines

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2. Process Layout.
a. It is also called functional layout. It is suitable for volume production.
b. In process layout, the machines of similar category are grouped together
and one not is arranged according to particular sequence of operation.
c. It is suitable when the product is non standard and there is major variation
in processing time of individual operations.

Figure: Process Layout

Advantage
a. Process layout makes the best use of ma n and machines.
b. Lot of flexibility.
c. Low capital investment due to GPM.
d. Variety of job makes the job challenging and interesting for workers.
e. For expansion purpose, it is possible to add more machines.

Disadvantage
a. High cost per unit.
b. Poor use of available space
c. Work in process is low.
d. It needs specially skilled workers.
e. Production cycle time is per unit is more.

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3. Fixed Position layout

a. It is used for the products which are very massive.
b. It is very inconvenient or it is not desirable to move them
c. In fixed position layout, the works remains in fixed positions.
d. The machines, material, equipment and workers are needed for
productions are brought to the site of the workers.

Figure: Fixed Position Layout

Example: Ship Building Industry, Air craft production, Assembly operation

Industry,

Advantage
a. Capital investment in the plant layout is minimum.
b. Higher flexibility.
c. Effective used of skilled workers.
d. It is easy to measure the progress of work
e. The worker identify themselves with a product in which they took interest
and pride in doing job..

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7. Describe the procedural step involved in making a plant layout?

Ans: - PLANT LAYOUT PRCOEDURE
A step by step procedure for planning or designing a plant layout is
given below.
1. Collect the data regarding the product, process etc and record the data
systematically.
2. Analyze the data using the various techniques of analysis.
3. Determine the machinery a nd equipment recorded.
4. Select the material handling equipment.
5. Draw the plan of site.
6. Design the individual workstation.
7. Fit the individual layout into total layout.
8. Determine the storage space required also make floor diagram.
9. Plan and locate service area s.
10. Check the final layout and prepare master layout.
11. Present the layout to management and get approval.
12. Install the approved layout.
13. Follow up.

8. List the factor to be considered while designing layout?

Ans: - The factors considered while designing layout are
1. Types of Industry
2. Nature of product
3. Production system
4. Production capacity
5. Types of layouts
6. Arrangements of material handling system
7. Types of building
8. Total space available: Machines and equipment should not be fixed very
close each other. Sufficient space should be provided between them to work
conveniently.

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9. Name and describe the various techniques used for layout planning ?
Ans: -The various techniques used in layout planning
1. Operation process chart
It represents the basic activities involves in product.
It gives the information regarding distance moved and time required for
various activities.

2. Flow process chart

It is the graphical representation of all producti on activity occurring on the
floor of the plant.

3. Flow diagram
The flow diagram is the plan of the work area. It is drawn to the scale.
It indicated backtracking, cross traffic, obstacles in the way of the product.

4. Templates
Templates are pieces of cardboard or paper representing the equi pment
of a shop at smaller scale. Templates show the visual picture of desired
layout.
The templates are so arranged so as to give best layout.

5. Machine data cards.

These are cards prepared for each machine showing its capacity, space
and other requirements, handling needs and corresponding activities.

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10. Compare the product layout and Process Layout

Ans:

Nos Product layout Process layout

Product oriented layout Process oriented layout

1
2 Less flexible More flexible

3 Better use of space Poor use of space

4 Work stations are arranged as per Work stations are arranged

sequence of product operations. according to the function.

5 High capital investment is Low capital investment is needed.

needed.

6 Applicable to the mass Applicable to the job or batch

production. production.

7 Work in process is high. Work in process is low

8 Volume of production is high. Volume of production is low

Production cycle time per unit is Production cycle time per unit is
9 less. more.

10 Per unit cost is less. Per unit cost is more

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11. Explain the need for good facilities planning

Ans: - THE NEED FOR GOOD FACILITIES PLANNING
The need for good facilities planning
1. Plant facilities influence the costs of operating and therefore profits.
2. Planning allows facilities to comply with laws ad/or regulations.
3. Facilities involve high capital -cost expenditures.
4. Facilities are fixed investments, not readily convertible to money or resale.
5. Facilities are inflexible (i.e. physically fixed and have limited opportunities
to be changed).
6. Facilities are long term commitments with protracted periods of financial
return.
7. Facilities planning, design and construction require long lead times.
8. Sound plans for implementation can avoid disruptions in production, and
discontinuities for shipping or delivery.
9. Operations often produce detrimental wastes that affect entire
communities.
10. The safety, convenience, appearance, and comfort of industrial facilities
influence the attitudes of and the ability to attract suitable employees.
11. Industrial facilities must be planned to meet anticipated future
requirements yet compete profitably today.
12. Facilities need to be planned for an appropriate degree of flexibility,
expandability, versatility…
13. Good planning buys time for making commitments; it minimizes being
taken by surprise.
14. If plans are made, managements can react faster and take advantage of
business opportunities that arise.
15. Good planning, especially if presented well visually, is an aid to obtain
financing monies.
16. The single most important cause of high materials handling costs is “ad
hoc” expansion of plant facilities “in the absence of a strategic site -
development plan.”

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