Plant Layout

Click to edit Master subtitle style

3/31/12

Plant Layout

Plant layout is also known as facilities layout. After the selection of factory site, the factory building is constructed at the selected site.
3/31/12

Distinction between Factory Layout and Plant Layout

Factory Layout is a broader concept and it decides about housing of all the activities inside the factory such as: 1. Office areas in which administrative department is housed. 2. Plant area involves: 3/31/12

b) Personal services like parking areas, time keeper office, canteen and lunch room etc. In relation to factory layout, plant layout is narrow consideration and concentrates on an arrangement of production and services dept. Along with the location and sequence of machines and equiupment .

3/31/12

The objectives of plant layout are:

Minimize overall production time. Utilize existing space most effectively. Provide for employee convenience, safety and comfort. Minimize material-handling cost. To provide adequate safety to 3/31/12 the workers from accidents.

Factors influencing layout choices:

1. Type of Production System 2. Nature of Product Manufactured 3. Availability of total floor area 4. Arrangement of material handling equipment 5. Possibility of future expansion 6. Type of Machines
3/31/12

Types of Layout

3/31/12

Process Layout or Functional Plant Layout

Common for a large variety of products in batch volumes.

L L
Material 1 Material 2

L L

M M

M M

Similar processes are grouped together.

Inefficient: Long material transport routes from dept. to dept. Work in progress is high. Tracking of orders can be difficult.

ASSEMBLY 1 Product 1 Product 2 ASSEMBLY 2

D D

D D

Advantages: Specialist labour and supervision. Flexibility as material can be rerouted in any sequence.

G G

G G

e.g. Machine tools, custom made furniture etc.

3/31/12

Product Plant Layout

Mass production where variety is small and production volumes are very high.

AKA flow or line layout.

More efficient, but less flexible than functional layout.

Work in progress is minimised, and jobs are easily tracked.

Investment in specialised capital equipment is high, so a reliable and steady demand is required.

Very sensitive to machine breakdown or disruption to material supply.

A S S E M B L Y

e.g. Textile, sugar, petroleum, paper and pulp, cement plants etc.

3/31/12

Difference between Product layout and Process Layout

Sr. No. Product Layout Process Layout 1. Duplication or repetition of machines Breakdown of one machine interrupts the entire product flow. Reduced material handling cost due to straight line production flow. No duplication or repetition of machines Breakdown of one machine does not interrupt the entire product flow. Cost of material handling increases due to backtracking between the processes.

2.

3.

4.

No problem of bottlenecks and Problem of bottlenecks i.e. idle-capacity. waiting 3/31/12

Difference between Product layout and Process Laout

Sr. No. 5. Product Layout Process Layout Do not require frequent changes in machine setup. It is relatively easy to control. Duplication of Machines increases investment. No specialization Frequent changes in machine set-up. Not easy to control.

6.

7.

As compared to product layout less investment. Specialization of supervision is possible.

3/31/12

8.

Fully automated Plant layout

WIP Inventory

1212

Assembly Line in a Car Factory

1313

1414

1515

Cellular Plant Layout

AKA Group Technology L D M G

ASSEMBLY CELL 1

Each cell manufactures products belonging to a single family.

Cells are autonomous manufacturing units which can produce finished parts.

Commonly applied to machined parts. M D M G

ASSEMBLY CELL 2

Productivity and quality maximised. Throughput times and work in progress kept to a minimum.

Suited to products in batches and where design changes often occur.

L L

L G

ASSEMBLY CELL 3

3/31/12

Fixed Position Layout Single large, high cost components or products. Product is static. Labour, tools and equipment come to the work rather than vice versa. e.g. ship building , construction of dams and bridges etc.

Fixed Position Layout: (Static Layout or Project Layout)

COMPONENTS MATERIAL LABOUR

PRODUCT

LABOUR COMPONENTS

MATERIAL

3/31/12

Fixed Position Layout

3/31/12

Guess the diagram shows which type of layout?

3/31/12

Importance of plant layout:

Efficient layout makes manufacturing function smooth and efficient an reduces cost of material handling and avoids bottlenecks and minimization of production delays. Economies in handling. Effective use of available area. Minimization of production delays. Better supervision. Improved utilization of labour. Good working conditions.
3/31/12

Characteristics of good layout:

Smooth flow of production.

Maximum utilization of available space. Minimum material handling. Good working condition Facilitates supervision and control
3/31/12

Characteristics of Bad Layout:

Congestion of materials

Poor utilization of available space. Excessive material handling distance. Excessive maintenance time and xost. Long production cycle time.
3/31/12