PLANT REYLAYOUT

SUBMITTED BY
K.N.Jakanathan
 INTRODUCTION
► Burndy Bronx plant is at Norwalk, New York
► It is laid basically as a process layout.
► It is producing variety of small size metal
products.
► Plant building is multi story structure.
► Thousands of square feet space available for
enlarging and modernizing.
► Marvin lee is executive vice-president of
Burndy.
 KEY ISSUES
► Because of multi-story building and
process layout, the material handling
becomes more complicated.
► Process layout leads to increase total
labour cost.
► Increase in production time due to process
layout.
► Sequence of operation get disturbed due
to up and down movement.
 Analysis - l
Main cast lines – Work sheet for ideal flow
► It is prepared to show the relationship of all
operations to all types of product in this line.
► Top of the work sheet are product types.
► Left hand column is various work center for
operations done on these types of product.
After arranging in order
► Type involving the greatest quantity production is
at extreme left.
► It show the ideal flow in arranged order.
► It shows which are universal operations and
occasional operations for the product line.
 Analysis - ll
Material Handling analysis
► It the form used regularly for standard work
► Daily record of trips is kept by each handler.
► Analyzed inter departmental trips.
► In this loaded trips, empty trips, time, trip
number all are noted.
► On analysis the trips made are so high
because of process layout.
 Analysis - lll
Moving time and Boxes moved
► One month’s trip is analyzed.
► Moving time towards each department are
calculated.
► Total Number of boxes moved to and fro to the
departments are calculated.
► All these concentration paths become a factor for
change.
 Qiklug’s process path
1st floor - Press department for flattering
and lettering contact tongue.

3rd floor - Turning department for hollow,

milling and drilling cable hole.

3rd floor - Assembly department for disk

grinding.

Basement - Planting department for tumbling.

3rd floor - Turning department for threading.

Basement - Planting department for Bright dip.

3rd floor - Assembly department for assembly.

1st floor – shipping department for boxing and shipping.

Process layout - Qiklug
5th floor

Threading
grinding

Assembl
Drilling
Hallow

Milling

4th floor
Disc
,

y
,

3rd floor
T B
Flattering

Bo
lettering

u r
i x
m 2nd floor
and
and

b g
h shi
l
t p
i 1st floor
n d
g i
p
Basemen
t
 RE-LAYOUT
► From analysis it is clear that 3rd floor is
predominant.
► Product layout in the 3rd floor will leads
to material handling cost reduction.
► For that punch press, disk grinders,
tumbling barrel and planting facility
should be moved to 3rd floor.
► This will provide qiklug a full
compliment of manufacturing facilities.
 Cont.,
► Actual layout is devised using the analyses
and new re-layout plan.
► Preliminary layout is framed and analyzed.
► Schedule is done for new layout and it is
given to Maintance work department.

► LAYOUT before and after the change.

 Delivered casting
Temporary
storage
Flattering and
Hallow,
letteringMilling,
Drilling
Disc grinding
Tumbling

Threading
Bright dip
Assembl
y
x

p
Bo

shi
and

t
1st floor
4th floor
5th floor

3rd floor

2nd floor

Basemen
Product layout - Qiklug
 Advantages
► It provide direct routes, thereby cutting down
manufacturing delays.
► It reduces the amount of material handling.
► It reduces the likelihood of material loss.
► It reduces the total processing time for an item.
► It reduces the quantity of material tied up in process.
► It reduces the frequency of inspection.
► It simplifies production control.
► It simplifies the breaking-in of new men.
► It speeds production and shipment.
 conclusion
► Not only the qiklug, other production process can
use this arrangement, like mixed layout.
► Other production process is not disturbed by this
3rd floor product layout.
► Now, no complex precision machinery,
consequently breakdown tie-ups are virtually
eliminated.
► Now, brundy equipment requires minimum job-
training and obviates work skill in this product line.
 Cont.,
► Simplicity in equipment furthermore permits
economical production operation, which
offsets the high initial investment cost due
to machinery duplication.
► Simplicity plus similarity in the product itself
eliminates the lack of flexibility flaw.
► volume of burndy orders precludes the low
production unemployment problem found on
other manufacturers.
► Now, the delivery time is reduced to four to
six weeks is hoped to reduce more.