C0NP0TERIZEB

PLANT LAY00T
(uioup - 8)
FUPESH SATSH NAPHA0E (09mIb0J4)
F SAN0EEP FE00Y (09|8046)
SANKAFANAFAYANAN 8 (09|8047)
A.|.SAFANYA (09|8048)
SH7A| SETH (09|805J)
W The basIc objectIve of a plant layout Is to
ensure a smooth flow of work, materIal, and
InformatIon through the system
W Mlnlmlze maLerlal handllng cosLs
W uLlllze space efflclenLly
W uLlllze labor efflclenLly
W LllmlnaLe boLLlenecks
W laclllLaLe communlcaLlon and lnLeracLlon beLween workers and Lhelr
supervlsors or beLween workers and cusLomers
W 8educe manufacLurlng cycle Llme and cusLomer servlce Llme
W LllmlnaLe wasLed or redundanL movemenL
W laclllLaLe Lhe enLry exlL and placemenL of maLerlal producLs and people
W Lncourage proper malnLenance acLlvlLles
W rovlde a vlsual conLrol of operaLlons or acLlvlLles
W rovlde flexlblllLy Lo adapL Lo changlng condlLlons
@here are 4 baslc Lypes of layouLs
W rocess LayouL
W roducL LayouL
W llxed poslLlon LayouL
W Croup @echnology LayouL (ComblnaLlon LayouL)
W eflnlLlon of Croup @echnology
Croup Lechnology ls Lhe Lechnlque of ldenLlfylng and brlnglng
LogeLher relaLed or slmllar parLs ln a producLlon process ln order
Lo uLlllze Lhe lnherenL economy of flow producLlon meLhods"
v 8 Sola[alnsLlLuLe of Machlne @ools 8elgrade ?ugoslavla
Cntu..
W Croup @echnology layouL ls also called manufacLurlng cell
layouL
W Lxample
W A planL produclng 10000 parL numbers may be able Lo group Lhe
parLs lnLo 30 or 60 famllles Lach famlly would possess slmllar
deslgn and manufacLurlng characLerlsLlcs
W Pence Lhe processlng of each member of a glven famlly would be
slmllar and Lhls resulLs ln manufacLurlng efflclencles ln Lhe form of
W 8educed seLup
W Lower lnprocess lnvenLorles
W 8eLLer schedullng
W lmproved Lool conLrol
W SLandard process plan
Concept
W Many problems are slmllar by grouplng slmllar problems a slngle
soluLlon can be found Lo a seL of problems Lhus savlng Llme and
efforL
W A manufacLurlng phllosophy ln whlch slmllar parLs are ldenLlfled
and grouped LogeLher Lo Lake advanLage of Lhelr slmllarlLles ln
deslgn and manufacLurlng
W A Lechnlque for ldenLlfylng and brlnglng LogeLher relaLed or slmllar
componenLs ln order Lo Lake advanLage of Lhelr slmllarlLles ln Lhe
producLlon process
Co vc e t De .i g v Mavvf ac tvri vg
Mav, ro b t e v . are
.i v i t ar
Similar Shapes Similar
Manuacturing
Processes
Cro v i v i t ar
Pro b t e v .
Design lamilies Production lamily
i vg t e o t vti o v o f
Pro b t e v .
One standard design
plus minor
modiication
One standard
process plan to a
amily and
modiication and
extension
W Appllcable Lo boLh manufacLurlng and non manufacLurlng
operaLlons
W Arrange machlnes and/or workers ln accordance wlLh Lhe
sequence of operaLlons for a glven producL or servlce
W AdvanLages of flowllne layouL
W 8educes maLerlals handllng
W AccommodaLes small amounLs of work ln process
W 8educes LranslL Llmes
W Slmpllfles producLlon plannlng and conLrol sysLems
W Slmpllfles Lasks enabllng unskllled workers Lo learn Lask qulckly
Cntu.
W lsadvanLages of flowllne layouL
W Lack of process flexlblllLy
W uependence of Lhe whole on each parL a breakdown of one
machlne or absence of enough operaLors Lo sLaff all work sLaLlons
may sLop Lhe enLlre llne
W Worker faLlgue workers may become bored by Lhe endless
repeLlLlon of slmple Lasks
W Lack of flexlblllLy ln Llmlng Lhe producL cannoL flow Lhrough Lhe
llne fasLer Lhan Lhe slowesL Lask can be accompllshed unless LhaL
Lask ls performed aL several sLaLlons
W Large lnvesLmenLs speclalpurpose equlpmenL and dupllcaLlon ls
requlred Lo offseL lack of flexlblllLy ln Llmlng
W locus on how compuLers can ald Lhe faclllLy layouL n
W ueslgner musL lnLeracL wlLh mulLlple deslgn daLabases and
provlde Lhe lnLegraLlon beLween Lhem Lo LranslaLe lnformaLlon
and ensure conslsLency
W under Lhls meLhod Lhe layouL deslgn procedures can be
classlfled lnLo consLrucLlve Lype and algorlLhms and
lmprovemenL Lype algorlLhms
CompeLlLlve Lype algorlLhms
AuLomaLed LayouL ueslgn rogram (ALuL)
CompuLerlzed 8elaLlonshlp LayouL lannlng (CC8LLA)
lmprovemenL Lype AlgorlLhms
CompuLerlzed 8elaLlve AllocaLlon of laclllLles @echnlque (C8Al@)
W ey elemenL of compuLerlzed layouL plannlng ls Lhe
represenLaLlon and manlpulaLlon of Lhese Lhree Lypes of
lnformaLlon
W lnformaLlon ln layouL plannlng
W numerlc lnformaLlon
W Space requlred for an acLlvlLy
W @oLal flow beLween Lwo acLlvlLles
W Loglc lnformaLlon
W references of Lhe deslgner le acLlvlLy relaLlonshlp charL
W Craphlcal lnformaLlon
W urawlng of Lhe block plan
CRAFT
W Computerized Relative Allocation oI Facilities Technique
W Developed by Armour and BuIIa
W Most widely used than ALDEP and CORELAP
W The result given is not optimum in terms oI minimum cost ,but
close to optimum in majority oI applications
CRAFT pioceuuie
nitial layout
2 Flow data
3 Cost per unit distance
4 Fixed depatrments
5 Area oI department
Example
Present layout oI the departments
TEP
Cost matiix -Cij
The values in above matrix represents cost per unit distance Irom
department to department
Flow Natiix - Fij
The values in above matrix Ilow oI items in terms oI number oI trips
in given time
Aiea of uepaitment - Aij
TEP
Centoiiu
WFind The centroid oI each department in the initial layout
WConsider leIt side oI layout as Y axis and bottom as X axis
(x1?1) 26
(x2?2) 22
(x3?3) 72
(x4y4) 86
(x3?3) 36
TEP
Bistance -uij
WFind Distance between the two departments by Iormula
dij ,Xi-Xj,,Yi-Yj,
We get the distances as shown below
TEP
Total Cost - TCij
Total cost __Iij*dij*cij
TEP
Bepaitmental inteichanges
Consider various departmental interchanges Ior improvement
nterchanges possible are given below
WDepartments having common border
WDepartments having equal area
For each interchnage the associated total cost matrix is
calculated
Consiuei inteichange between
anu
ew centorid aIter interchange will be
(x1?1) 22
(x2?2) 26
(x3?3) 72
(x4y4) 86
(x3?3) 36
new ulsLance maLrlx ls as shown below
@oLal CosL 203
ummaiy of total cost uue to
inteichange
$tep 6 nterchange which gives lowest handling cost is
selected Ior actual interchange in layout
$tep 7 The cost is compared with the cost oI present layout
Here the handling cost is 63 which is less than present cost oI
205
Hence it is accepted
tep 8
Final layout
(Automated Layout
Design Program)
t is a construction type algorithm This algorithm uses
the basic data on Iacilities and build a design by successively
placing the departments in the layout and scores is computed
This algorithm is repeated Ior a prespeciIied number oI times
and the best is selected out oI it
Basic data required for algorithm
W umber oI departments in the layout
W Area oI each department
W Length and width oI layout
W Rel-chart
W Minimum department preIerence value(MDP)
W $weep width
W umber oI iterations to be carried
PROBLEM$
) umber oI departments in the layout7
2) Area oI departments
DLAk1MLN1 IUNC1ICNS AkLA(sqm)
1 rece|v|ng 12000
2 m||||ng 8000
3 press 6000
4 screw mc 12000
S assemb|y 8000
6 pa|nt|ng 12000
7 sh|pp|ng 12000
1C1AL 70000
3) Relationship chart
IkCM
1 NIL
2 L NIL
3 C U
NIL
4 I L
U
NIL
S C I
U
I NIL
6 U I
C
U A NIL
7 U U
U
U I L NIL
1C 1 2 3 4 S 6 7
4) Minimum department preIerence value4
5) $weep width2
6) umber oI iterations to be perIormed2
SOLUTION
Area oI the department
DLAk1MLN1 AkLA(sqm)
NC CI SUAkLS
1 12000
30
2 8000
20
3 6000
1S
4 12000
30
S 8000
20
6 12000
30
7 12000
30
1C1AL 70000
17S
Assume one square oI department 400sqm
The total scaled area is 75squnits
Length and width oI proposed layout are exactly
a) 0m*75m75sqm
Or we can choose approximately 0sqm
2m*5m0sqm
) Randomly select a department to entre in to layout Iirst Here let us consider 4
th
dep which is 30 squnits
4 4
4 4
4 4
4 4
4 4
4 4
4 4
4 4
4 4
4 4 4 4
4 4 4 4
4 4 4 4
2) now classlfy Lhe unselecLed depL base on Lhe 8elcharL ln Lo LlsL A LlsL 8 where A
conLalns depL whlch have relaLlon value less Lhan l ln relaLlon Lo Lhe lasL selecLed depL
and 8 conLalns depL whlch have value greaLer Lhan l wlLh comparlson wlLh Lhe lasL
selecLed depL unselecLed depL are 123367
LlsL A (3 67)
LlsL 8 (123)
3) SelecL Lhe depL from Lhe llsL 8 wlLh Lhe max 8LL value ln relaLlon Lo 4
Lh
depL so
depL 2 ls seleced
Area of depL 2 ls 20 squnlLs
4 4 2 2 2 2
4 4 2 2
4 4 2 2
4 4 2 2
4 4 2 2
4 4 2 2
4 4 2 2
4 4 2 2
4 4 2 2
4 4 4 4
4 4 4 4
4 4 4 4
4) now Lhe lasL selecLed depL ls 2
nd
flnd Lhe 8LL value for unselecLed depL wlLh Lhe
2
nd
depL now Lhe unselecLed depL are 13367
LlsL A (37)
LlsL 8 (136)
Pere 1
sL
depL has Lhe max 8LL value wlLh 2
nd
depL so we selecL 1
sL
depL whlch has Lhe
area of 30 sq unlLs
4 4
2 2 2 2
4 4
2 2 1 1
4 4
2 2 1 1
4 4
2 2 1 1
4 4
2 2 1 1
4 4
2 2 1 1
4 4
2 2 1 1
4 4
2 2 1 1
4 4
2 2 1 1 1 1
4
4 4 4 1 1 1 1
4
4 4 4 1 1 1 1
4
4 4 4 1 1 1 1
3) Slmllllarly for all Lhe oLher depL lL needs Lo be fllled ln relaLlon wlLh Lhe lasL
selecLed depL afLer selecLlng all Lhe oLher depL Lhe layouL wlll be
4 4
2 2 2 2 6 6 6 6 7 7 7 7 0
4 4
2 2 1 1 6 6 6 6 7 7 7 7 0
4 4
2 2 1 1 6 6 6 6 7 7 7 7 0
4 4
2 2 1 1 6 6 6 6 7 7 7 7 0
4 4
2 2 1 1 6 6 6 6 7 7 7 7 0
4 4
2 2 1 1 6 6 6 6 7 7 7 7 3
4 4
2 2 1 1 6 6 6 6 7 7 7 7 3
4 4
2 2 1 1 6 6 5 5 5 5 7 7 3
4 4
2 2 1 1 1 1 5 5 5 5 3 3 3
4
4 4 4 1 1 1 1 5 5 5 5 3 3 3
4
4 4 4 1 1 1 1 5 5 5 5 3 3 3
4
4 4 4 1 1 1 1 5 5 5 5 3 3 3
Where ln Lhe above layouL 0" denoLes Lhe empLy space for furLher use
6) llnally Lhe score of Lhe layouL ls compuLed Lhe score ls Lhe sum of Lhe 8el
values of varlous nelghborlng palrs of depL ln Lhe layouL
NEIGHBOURING PAIRS
OF DEPT
REL GRADE REL VALUE
4-2 E 16
4-1 I 4
2-1 E 16
2-6 I 4
1-6 U 0
1-5 O 1
6-7 E 16
5-6 A 64
5-7 I 4
5-3 U O
7-3 U O
TOTAL 125
@he score based on 2 way relaLlonshlp ls 230 le(2*123)
Slnce Lhls ls Lhe flrsL layouL LreaL Lhls as Lhe besL layouL and sLore Lhe correspondlng
score
lncremenL Lhe lLeraLlon number ll+12 lf ln repeaL Lhe same process agaln
AfLer dolng lL check wheLher Lhe second lLeraLlon layouL ls lesser Lhan Lhe 230 Lhen
Lhe 1
sL
layouL wlll be prlnLed as Lhe besL one
Computerized Relationsbip
Layout Planning{C0RELAP]
W ueveloped by 8CLee based upon MuLher's algorlLhm
W INU1 kLUIkLMLN1S
1 number of deparLmenLs and Lhelr area
2 Closeness relaLlonshlp as glven by 8LL charL
3 WelghLed raLlngs for 8LL charL enLrles
C0RELAP(contu..)
W @he mosL crlLlcal deparLmenL ls placed flrsL aL Lhe cenLer of
Lhe layouL
W @he hlghesL closeness relaLlonshlp wlLh Lhe deparLmenL
already placed are consecuLlvely placed
W @he flnal layouL may noL be ln recLangular ln shape and llLLle
modlflcaLlon ls requlred Lo sulL Lhe slLuaLlon
C0RELAP(contu.)
CCkLLA A|gor|thm
1 ueflnlng baslc daLa
2 ueLermlnaLlon of placemenL order
3 lacemenL of deparLmenLs ln Lhe layouL
4 flndlng Lhe LoLal score of Lhe layouL