UNIT 02: PLANT LAYOUT

Definition Plant Layout involves the allocation of space and the arrangement of equipment in such a manner that overall operating costs are minimized. It includes the arrangement and location of work centres and various service centres like inspection, storage and shipping within the factory building. Characteristics of an Efficient Layout 1. Smooth flow of production Raw materials and workers have access to each machine without any difficulty and delay. 2. Maximum utilization of available space 3. Minimum handling Product of one operation may pass on to the next operation with minimum handling, thus reducing wastage of raw materials and labour hours. 4. Provides better working conditions Facilities such as water, ventilation, retiring rooms etc., to safeguard the health of workers. 5. Flexibility capable of incorporating new equipment to meet technological progress or increased production or to eliminate waste. 6. Facilitates supervision and control 7. Provision of safety Reorganization of existing Layout 1. Variation in the level of demand 2. Change in the location of the product markets 3. Change in style and obsolescence or failure of existing equipment Objectives of Plant Layout 1. Economy in material handling raw materials, work-in-progress and finished stock 2. Optimum utilization of resources men, materials, equipment and space 3. Better inventory control Minimizing work-in-progress and maximizing inventory turnover 4. Good work flow Minimizing delays and eliminating bottlenecks in the production system, thus avoiding accumulation of work at vital points 5. Efficient control Efficient supervision and production control 6. Avoidance of changes Frequent changes cause rise in cost of production 7. Safety Elimination or atleast minimizing the chances of accidents 8. Flexibility Meeting future changes and requirements Advantages of Good Layout 1. Extension of the process of specialization 2. Better working conditions and reducing the accidents 3. Minimum lost motions between operations 4. Improved quality through reduced material handling 5. Better conditions for receipt, shipment and delivery 6. Provision of adequate and convenient storage facilities 7. Achievement of production targets consistently 8. Helps in easing the burden of supervision 9. Floor space and shop areas required for manufacturing are reduced 10. Investment in machinery and equipment is reduced because of a) increase in production per machine, b) Minimization of idle time and c) reduction in the number of operations per machine Symptoms of Bad Layout Page 1 of 3

1. Congestion of machines, materials and workers 5. Increase in maintenance time 2. Excessive work-in progress inventory 3. Poor utilization of space 4. Long material flow lines Principles and criteria of Plant Layout 1. Maximum flexibility 2. Maximum co-ordination 3. Maximum use of volume 4. Maximum visibility 5. Maximum accessibility 6. Minimum distance movement 7. Minimum discomfort 8. Minimum handling 9. Safety aspects 10. Efficient process flow 6. Delay in delivery schedules 7. Increase in handling costs

Procedure involved in Plant Layout 1. Fixing of objectives Capacity, production, flexibility, future expansion 2. Collection and compilation of data Operations listing, space dimensions, machinery and processes, sequence of operations 3. Formulation of an Overall Plan including flow of production, arrangement of services activities, type of building 4. Service activities development of material handling system, location of shipping and receiving areas, maintenance shop, office and facilities 5. Building specification Floor space required, load capacity of the floor, ceiling heights, location of partitions, size and location of doors and windows 6. Layout for individual machine Access to the machine, work-in progress area, repair and maintenance, services connections such as electricity, gas, high pressure air, etc. 7. Preparation of layout drawings and test run preparation of layout drawings and necessary supporting charts for management approval Tools and techniques of Plant Layout Process Charts: It is a classification and graphical representation of production activities in a plant. It is a systematic analysis of the whole process by sub-dividing the various operations and material movements and study their effectiveness. The study will reveal the operations that can be eliminated, rearranged or simplified to achieve optimality and economy in production. Operation Process Chart: This chart divides the whole manufacturing process into operations and inspection. It indicates the point at which materials are introduced into the process and exhibits the sequence of all operations and inspection excepting material handling activities. Flow Process Chart: It is a graphical representation of of all production activities occurring on the floor of the plant. It accumulates and classifies the complete information necessary for the analysis and improvement of plant operations as a whole or any one phase. The study of this chart can reveal the operations that can be eliminated, rearranged or simplified to achieve economy in production viz., relocating work stations, storage areas, inspection cribs to reduce travel distance and labour time. The data is collected from the receipt of materials to the completion of product, in order to ascertain the inflexibility of the layout. Process Flow Diagrams: It is both a supplement and a substitute of flow charts. It is an aid to visualize the movement of materials on the existing floor layout, to bring out back-tracking and excessive movement of materials and helps in relocation of part activities to reduce travel distance. Factors influencing Plant Layout 1. Nature of the product Heavy, medium and light products 2. Volume of production Standardized products, customer order product Page 2 of 3

3. Basic managerial policies and decisions Size of plant, type and quantity of the product, scope for expansion, stock quantities to be carried, facilities to employees, etc. 4. Nature of plant location size, shape and topography of the site 5. Type of industry process Intermittent or continuous 6. Types or method of production Job order production, Batch production, Mass production 7. Nature of machines Heavy or light machines 8. Climate Temperature, illumination and air 9. Nature of materials Design and specification, physical and chemical properties, quantity and quality, leads to decision on material storage and handling 10. Human factors and working conditions Obstruction free floor, not exposing workmen to hazards, emergency exit points rest rooms, drinking water and other services 11. Service centres Provision for repair and replacement of equipment, electricity wires, steam, water and gas pipelines and water disposal 12. Characteristics of he building Shape of a building, covered and open areas, number of stores, facilities of elevators, storing place, parking area

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