Plant layout and Material

Handling
Introduction Classification
Different Layouts Layout
Design Procedures Overview
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Definitions
Facilities layout describes the
arrangement of equipment, storage areas,
and work areas, usually within the confines
of a physical structure, such as a retail store,
an office, a warehouse, or a manufacturing
facility.
Factors that influence layout

Volume, weight of items to be produced.

Nature of the service to be provided.
Cost of the building to house the operation.
The product mix that must have a facility.
The fragility of the product or component

What is a Layout?
The physical arrangement of
economic activity centers within a
facility.
A center can be anything that
consumes space.

The Layout decisions are:

What centers?
How much space and capacity?
Configuration?
Where to locate them?

Why?
Arrangement of areas within a facility to:
Minimize material-handling
costs
Utilize space efficiently
Utilize labor efficiently
Eliminate bottlenecks
Facilitate communication
and interaction
Reduce manufacturing cycle
time
Reduce customer service
time
Eliminate wasted or
redundant movement
Increase capacity

Facilitate entry, exit, and

placement of material,
products, and people
Incorporate safety and
security measures
Promote product and service
quality
Encourage proper
maintenance activities
Provide a visual control of
activities
Provide flexibility to adapt to
changing conditions

Three Basic Types of Layout

1. Product Layouts
2. Process Layouts
3. Fixed-position Layouts

Types of Layout
Fixed Position
Line-Flow (Product)
Flexible-Flow (Process)
Hybrid
Retail
Warehouse
Office

Directly concerned
with layout of the
transformation
process.

Not directly
concerned with
the transformation
process.

Product Layouts
Product layouts employ standardized
processing operations to achieve
smooth, rapid, and high volume flow.

Process Layout
Process layouts group similar
equipment together according to the
process they perform.
RECEIVING
CUTTING

PRINTING

ASSEMBLY

SHIPPING

PACKING

Process Layout
Grouping together of machines and/or workers
doing similar tasks.
Applicable to both manufacturing and non
manufacturing operations.
Advantages

Flexibility: equipment and personnel can be used

where they are needed.
Smaller investment in equipment: duplication is not
necessary unless volume is large.
Expertise: supervisors for each department become
highly. knowledgeable about their functions
Diversity of tasks: changing work assignments make
work more satisfying for people who prefer variety.

Process Layout
Disadvantages
Lack of process efficiency: backtracking and long
movements may occur in the handling of materials.
Lack of efficiency in timing: workers must wait
between tasks.
Complication of production planning and control.
Cost: workers must have broad skills and must be
paid higher wages than assembly line workers.
Lowered productivity: because each job is different it
requires different setups and operator training.

Fixed-position Layouts
Fixed-position layouts place the
products stationary, and workers,
materials, and equipment are moved
to the products.
MACHINE
GROUP 1

EMPLOYEE
TEAM 1

STORAGE
#1

STORAGE
#2

MACHINE
GROUP 4

EMPLOYEE
TEAM 2

EMPLOYEE
TEAM 4

MACHINE
GROUP 2

STORAGE
#4
STORAGE
#3

EMPLOYEE
TEAM 3

MACHINE
GROUP 3

Fixed Position Layout

Manufacturing and non-manufacturing
operations of bulky or fragile products, e.g.,
ships and planes.
Move machines and/or workers to the site;
products normally remains in one location for its
entire manufacturing period.
Advantages of fixed position layout
Reduces movement of work items; minimizes damage
or cost of moving.
More continuity of the assigned work force (since the
item does not go from one department to another).
This reduces the problems of re-planning and
instructing people each time a new type of activity is
to begin.

Fixed Position Layout

Disadvantages of fixed position layout
Since the same workers are involved in more
operations, skilled and versatile workers are required.
The necessary combination of skills may be difficult to
find and high pay levels may be necessary.
Movement of people and equipment to and from the
work site may be expensive.
Equipment utilization may be low because the
equipment may be left at a location where it will be
needed again in a few days rather than moved to
another location where it would be productive.

Group Technology Layout

Definition of Group Technology
Group technology is the technique
of identifying and bringing together
related or similar parts in a
production process in order to utilize
the inherent economy of flow
production methods.

Group Technology Layout

Group Technology layout is also called
manufacturing cell layout.
Example:
A plant producing 10,000 part numbers may be able
to group the parts into 50 or 60 families. Each family
would possess similar design and manufacturing
characteristics.
Hence, the processing of each member of a given
family would be similar, and this results in
manufacturing efficiencies in the form of:
Reduced set-up,
Lower in-process inventories,
Better scheduling,
Improved tool control,
Standard process plan.

Hybrid Layout
Hybrid layouts modify and/or integrate certain
characteristics of the three basic layout types.
1. Cellular layouts group different machines into cells
that process parts with similar shapes or processing
requirements.
2. Flexible Manufacturing Systems (FMS) integration
of several flexible cells making up a cellular
layout, which is capable of producing a large
variety of products

Flow-Line Layout
Applicable to both manufacturing and non
manufacturing operations.
Arrange machines and/or workers in accordance
with the sequence of operations for a given
product or service.
Advantages of flow-line layout

Reduces materials handling.

Accommodates small amounts of work in process.
Reduces transit times.
Simplifies production planning and control systems.
Simplifies tasks, enabling unskilled workers to learn
task quickly.

Flow-Line Layout
Disadvantages of flow-line layout
Lack of process flexibility.
Lack of flexibility in timing: the product can not flow
through the line faster than the slowest task can be
accomplished unless that task is performed at several
stations.
Large investments: special-purpose equipment and
duplication is required to offset lack of flexibility in
timing.
Dependence of the whole on each part: a breakdown
of one machine or absence of enough operators to
staff all work stations may stop the entire line.
Worker fatigue: workers may become bored by the
endless repetition of simple tasks.

Classification

Process Layout
Lathe Department

Milling
Department

Drilling Department

Grinding
Department
Receiving and
Shipping

Painting Department

A
Assembly

Product Layout
In

Out

Factors To Be Considered For

Selection Of Region
Primary Factors
Market nearness
Raw-material
availability
Labor availability
Transport
availability
Power and fuel
supply
Existence of similar
firms

Secondary Factors
Climate suitability
Character of the
inhabiting
community
State and local
taxation-rates
Expansion facility
Decentralization
suitability

Facility Location Study

Category
Process Input
Process Output
Process Characteristics
Personal Preference
Government Policy
Local Conditions
Cost Factors
Competition
Intangible Factors

Factors

Raw Material, Personnel, Transportation of Raw Material,

work force availability, Availability of water and power, Road
Transport, Railways etc.
Market nearness
Environmental factors such as pollution, noise etc., weather
(e.g. knitting industry), level of humidity and season, rainfall.
Preference of executives and entrepreneur
Tax exemptions, legal requirements, Incentives, Availability of
Loan/Land etc.
Community culture and attitude. Past history of industry
located in the area, incidents of labour unrest in the area,
Political Interference etc.
Cost of land, cost of transportation, Wages of unskilled labour
Location of other industries in the area, Market forces for
competition etc.
International considerations, Possibility for expansion and
growth, School, Churches, Medical, Recreation Facilities etc.

Comparative study of Rural and

Urban Sites
Factors

Urban/Cit Sub- Rural/Cou

y site
Urban ntry site

Availability of land

Less

Moderate Plenty

Cost of land

High

Moderate Low

Connected by rail/road etc.

Well

Moderate Poor

Availability of labour

Less

Moderate More

Wages of labour

More

Moderate Less

Comparative study of Rural and

Urban Sites
Factors

Urban/City Subsite
Urban

Rural/Cou
ntry site

Communication network like internet, Very good

facsimile, telephone, e-mail etc.

Moderate

Poor

Power and water availability

Moderate

Poor

Supporting industries and ancillaries units Near by

Moderate

Far

Quality of life, such as recreation, school, Very good

hospital etc.

Moderate

Poor

Market and consumer

Near by

Moderate

To be built

Building for site

May be rented or Rented

build

Good

Poor

Comparative study of Rural and

Urban Sites
Factors

Urban/Cit Sub- Rural/Cou

y site
Urban ntry site

Availability and retaining potential for Better

professional like manger and engineers

Not
available
outside

Training of workers and foreman

In
local May or may Less
institutions
not

Security

Better

Moderate

Less

Expansion of site

Difficult

Moderate

Easy

Taxes

More

Moderate

Less

Government support

Less

More

Union problem and industrial relation

Poor

Better

Comparative study of Rural and

Urban Sites

Factors
Pollution
constraints
Waste disposal

and

Urban/City
site

environmental More
Difficult

SubUrban

Rural/Coun
try site
Less
Easy

Location of sub contractors, retailers, Nearby

etc.

Far

Incentives from financial institutions Less

like banks, IDBI, IFCI etc.

More

A Good Layout ...

Reduces bottlenecks in moving people or
material.
Minimizes materials-handling costs.
Reduces hazards to personnel.
Utilizes labor efficiently.
Increases morale.
Utilizes available space effectively and efficiently.
Provides flexibility.
Provides ease of supervision.
Facilitates coordination and face-to-face
communication where appropriate.

Computer Packages (Unit 2)

Heuristic, improvement algorithms.
CRAFT (Computerized Relative Allocation of Facilities Techniques)
is the best known of the heuristics approaches; attempts to minimize
materials-handling cost by calculating cost, pair-wise interchanging
departments, calculating more costs until a good solution is obtained.
ALDEP (Automated Layout Design Program) and CORELAP
(Computerized Relationship Layout Planning) attempt to maximize a
nearness rating within the facility dimension constraints.
PREP (Plant Re-layout and Evaluation Package) analyzes multilevel
structures and is based on actual footage traveled by materialshandling equipment.