Professional Documents
Culture Documents
and
Engineering Economy
Chapter -3
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Plant layout
Plant layout has been defined as a plan of, or
the act of planning an optimum arrangement
of industrial facilities, including
personnel,
operating equipment,
storage space,
materials handling equipment and
all other supporting services along with the
design of the best structure to contain these
facilities
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Locate All Areas In and Around
Buildings
– Equipment
– Work stations
– Material storage
– Rest/break areas
– Utilities
– Eating areas
– Aisles
– Offices
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Problems of layout develop when needed:
• to start a new product,
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The objectives of a good study of plant
layout are:
• ensure effective space utilization,
• minimize the cost of material handling (internal
transports),
• foresee future developments of the plant according
to a rational master plan,
• improve workers convenience as well as safety and
create job satisfaction, and
• avoid unnecessary capital investment.
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Types of Layout
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Some of the Advantages of Product
Layout are:
• lower total material handling cost,
• lower total production time,
• less work in process,
• greater incentive for groups of workers to raise
level of performance,
• less floor area required per unit of production and
• greater simplicity of production control, fewer
control records needed and lower accounting cost.
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Product Layout is Used When:
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Some of the Advantages of Process
Layout are:
• less duplication of equipment, hence lower
investment cost,
• greater flexibility of production,
• better and more efficient supervision,
• greater incentive for individual workers to raise
level of performance,
• better control of complicated or precision
processes,
• easier to handle breakdowns of equipment by
transferring work to another machine or station.
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Process Layout is Used when
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Fixed-Position Layout
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Developing Simulating Layout Problems
Product Market
Design New Obsolete Poor
Market Cost
Demand Worker
Change product Facility Relocation Reduction
Change Environment
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The SLP procedure leads the
planner through
• Abstraction (Analysis): Gathering
appropriate information and analyzing the
flow of materials and the activity
relationships to form a relationship diagram.
Space considerations when combined with
the relationship diagram develop the space
relationship diagram.
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Search (for possible solution):
• The overall layout is designed by combining space
consideration with the relationship diagram.
• The search phase is the phase in which alternative
layouts are developed by examining the space
relationship diagram under modifying consideration
such as materials handling, storage facilities, site
conditions and surroundings, building types,
personnel convenience, etc., and practical
limitations.
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Selection:
• The most efficient general method of
evaluating layout alternatives is termed
factor analysis. It follows the engineering
concept of breaking down the problem into
its elements and analyzing each one.
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INPUT ACTIVITIES
AND DATA
ABSTRACTION
Flow of Activity
Material Relationship
(ANALYSIS)
Relationship
Diagram
Space Space
Required Available
Space
Computerized
Relationship
Layout Planning
SEARCH
Diagram
Modifying Practical
Consideration limitation
Layout X Layout Z
Layout Y
Layout
EVALUATION
Selected
Detail a
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Detail b
27
Systematic layout Planning Procedure Detail c
Abstraction (Analysis)
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S. Support services
P. Product-Material
With what support will
What is to be produced
production be backed
R. Routing-Process
How will it (they) be produced
T. Time
Q. Quantity-Volume When will it be produced
How much of each
Item will be produced H
W Y
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This phase will require the assembly of
different data. In general, information about
the following is needed:
• the list of items to produce and store, and
the relative quantity;
• successive operations needed for every
product;
• the volume, the weight and the
characteristics of materials to transport
along the production line;
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• the number, type and technical data of
machines and plants necessary;
• the manpower needed;
• the necessary electric energy, steam, water,
compressed air, fuel, oil, etc.
• the necessary general service (offices, labs,
cafeteria etc.);
• the necessary auxiliary services like
maintenance department, tool store, etc;
• the possible variation of the product in the
future.
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• If the study is on an existing plant, it is
necessary to have drawings of the plant
layout and the building with all the technical
data.
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Search for Possible Solution
• The systematic approach of generating possible
alternatives of plant layout is conducted by
taking in to consideration:
1. Type of layout,
2. The possible internal transport systems and
3. The working condition.
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• Type of Layout: It is necessary to determine
which type of layout to select, product (line)
or process (functional) layout.
• In addition to the selection of type of layout it
is also important to fix the arrangement of
machines
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Q
Q A
Product α P= Product
Product β Q=Quantity
B
Product y
P P
P-Q Diagram
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• In region A there are few types of products
but in a great quantity. For these products it
is advisable to have product layout.
• In region C there are very many products in
small quantity. Hence, preferred to have
process layout.
• For products in region B (medium types of
products and medium quantity) the case has
to be studied closely so as to be able which
layout to select.
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• There are different types of machine
arrangements. The form of an industrial
building is mainly dependent on machine
arrangements and the advancement of a
workpiece. The usual forms are shown
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a) IN PARALLEL
a) IN SERIES
a) COMBINED
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Cont’d…
• The type of material handling equipment
influences directly the plant layout and also
the building. The working position, the form
of the layout, the height, width and length of
the building, the loading and unloading of
materials, the positions and dimensions of
accessibility depends in general, on the type
of internal transport system adopted.
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• A good study of internal transport system may boil
down to the following major benefits:
Reduce costs by
- utilizing space to better advantage,
- increasing productivity and
- making few number of effective movements.
Reduce waste by
- eliminating damage to material during the
handling process and
- maintaining proper control over in-and-out of
stock handling process.
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Improve working conditions by
• providing safer working conditions and
• reducing worker fatigue.
Improve the efficiency of the plant by
• improving location of storage facilities,
• improving routing and
• increasing productivity.
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Raw Material
Finished Good
Store
Working Dep’t
Future Expansion
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Typical One Floor Industrial Building
• In some plants, the cost of repeated handling
constitutes a very high proportion of the total
cost of the end product, and in some others, the
distance, materials have to move is not the sole
criterion, and often is not even the primary
concern for locating an area or an operation.
Hence, more realistic value assessment of the
factors that truly affect total cost in different
kinds of layout planning situations is needed.
• The available computer aided layout algorithms
fall into, either improvement, or construction
routine categories.
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IMPROVEMENT ROUTINE:
4
...
i
...
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• A relationship chart is a triangular matrix
whose elements represent the relationships
among plant layout departments. Letter
codes are also used to represent desirable
or undesirable levels of closeness between
departments.
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• Six standard letter codes are used to show
closeness relationships.
• "A" indicates an absolutely necessary closeness
relationship;
• "E" indicates especially important;
• "I" important;
• "O" ordinary;
• "U" unimportant;
• "X" indicates a not desirable closeness relationship.
Although the letter codes are standard, the ratings
reflect the user's own reasons for assigning the
letter codes.
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CONSTRUCTION ROUTINE:
• This routine constructs layouts without the
need for an existing (preliminary) layout.
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n
TCRi =
j=1
V( r ij ); i = 1 ... m
where
• TCRj =Total Closeness Rating for department;
• V(rij)=Numerical value assigned to the closeness value for
department i and j.
• n = Total number of departments.
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DEPT.
2
...
k
...
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• The first department to be placed in the layout is
assigned by taking the department with the greatest
TCR. Next, the relationship chart is scanned to see
if there is any department that has an A value with
the department already placed. If no A value exists,
a check is made for E value, and if no E value
appears, a check is made for I value, followed by O
value. If ties develop, the department having the
greatest TCR is chosen. This process is continually
used until finally all departments are placed in the
layout.
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Working Condition
• Proper working conditions are considered
important by management because they
increase production effectiveness.
Employee working conditions are influenced
by many factors, over which the employee
has very little or no control.
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• In most European countries, the law
requires for a minimum level of illumination.
The following ranges are accepted
internationally
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TYPE OF WORK ILLUMINATION VALUE IN FLUX
• Store and rarely accessible
working places 100 - 200
• Rough work (Brewery) 200 - 500
• Medium work (automobile assembly) 500 - 1000
• Precise work (wool work) 500 – 1000
• Fine work (Radio and TV assembly) 1000 - 2000
• Very fine work (controlling wool work) 1000 - 2000
• Working on a very small pieces
(watch assembly) 2000 - 7500
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AIR CONDITIONING
• Air conditioning is used for many plants to
control contamination by dust, bacteria and
toxic gases in addition to air temperature
and humidity.
• Air conditioning is a system which provides
an atmosphere comfortable to the human
being and maintain an atmospheric
environment demanded by a manufacturing
process or storage of products.
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NOISE
• A wide variety of sound exists in industry.
Continuous exposure to high noise levels
frequently results in temporary or even
permanent loss of hearing.
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The reduction of noise may be brought about
by a variety of methods. Some of these
methods are:
Control of the noise at the source.
Isolation of the noise.
Use of baffles and sound absorbers.
Acoustical treatment.
Use of ear protection devices.
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USE OF COLOR
• The objective of utilizing scientifically selected
colors is to bring about a clear three dimensional
vision.
• Color codes have been developed for particular
uses. The red, yellow and green of traffic lights is a
well known example of color coding.
Red - danger; stop
Yellow - caution
Green - safety equipment
• It is advisable to paint the roof of the industrial
building with a minimum reflection index of 0.7, the
walls
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Different colors have different psychological effects.
• Red - Hot and heavy, exciting, stimulating.
• Orange - Hot, exciting and stimulating less than red.
• Yellow - Hot, exciting lovely.
• Green - Fresh and light, pacific.
• Blue - Light, pacific.
• Violet - Light, loneliness.
• White - Cold, brilliant (seems to increase volume).
• Black - Hot (seems to decrease volume) depressing.
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SPACE REQUIREMENTS
• The layout man often finds himself involved in work space
arrangement; at any rate, he must determine the floor space
that will be required by an operator. The study of floor space
needed considers the following points:
• While at work, the operator's arms and hands should move as
easily as possible and he ought to reduce, to the minimum the
movement of his shoulders, his body and his person from one
position to another.
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• Fixed posts for utensils and materials should be assured.
• The disposition of utensils, materials and organs of maneuver
near and infront of the operator.
• Avoidance of the standing operator wherever possible. The
study of the working area should consider a proper and
comfortable position for the legs of the operator in an
armchair or on a stool.
• When the operator is transporting material, or when he is in a
position to push, or pull he should do it in such a way that:
• he is in an equilibrium position and
• he applies the possible minimum force to produce the effect.
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PASSAGE IN AN INDUSTRIAL
BUILDING
• From the very beginning of the study one has to determine the
corridors within the building. Their width is determined
according to the internal transport system selected and
according to the clearance needed for passages.
• Principal corridors which normally start from one end of the
building and end at the other end are 3 to 5 meters wide.
• Corridors within the department:
1. passage for one person 60 cm,
2. passage for two persons 120 cm,
3. passage for three persons 170 cm.
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SAFETY
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• The layout man should give due
consideration to the problem of safety.
Overlooking the problem will lead to
lower morale of the workers,
lower productivity and
heavy accident liability costs.
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Selection
• Every layout plan has intangible costs which
to all intents and purposes cannot be
measured in terms of birr and cents.
• Moreover, a comparative cost analysis of
alternative layouts is sometimes a standoff,
no one plan has a clear-cut financial
advantage over the other. Essentially,
however, there are three:
1. balancing advantages against disadvantages;
2. cost comparison and justification; and
3. factor analysis rating.
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Advantages versus Disadvantages
• Probably the easiest of the three evaluation
methods mentioned above is the listing of
advantages and disadvantages.
• It is also the least accurate; therefore, it is used
more for preliminary screening out of rough
alternatives.
• This pros and cons system involves merely listing in
columns or on sheets placed adjacent to each other
all the advantages of each alternative, below them
are listed the disadvantages.
• This simple comparison is surprisingly effective and
certainly is not a time consuming procedure
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Cost Comparisons
• A more economical approach to the
evaluation problem is cost comparison, by
establishing the total factory cost of a
product and added investment for machine
tools, a comparison between alternatives is
possible.
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• In preparing a cost analysis, there are
basically two approaches we can
follow.
– We may either consider total cost involved
or
– We may consider only those costs that will
be affected by the project under
considerations.
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• A systematic way of classifying cost
elements and accumulating cost figures are
required. For this the following procedures
are recommended.
– prepare a worksheet(s) that picks up investment
requirements for each alternatives;
– prepare a worksheet that establishes operating
cost estimates, and
– make calculations to compare and justify
expenditures for alternative layout plans.
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Factor Analysis
• The overall desires of what is wanted in
layout being planned are broken down into
so-called factors or considerations. They
may also be termed criteria or objectives.
Follows a list of the most commonly involved
factors or considerations; not in order of
importance.
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• ease of future expansion,
• adaptability and versatility,
• flexibility of layout,
• flow of materials effectiveness,
• materials handling effectiveness,
• storage effectiveness,
• space utilization,
• effectiveness of supporting service integration,
• safety and housekeeping,
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• working conditions and employee satisfaction,
• ease of supervision and control,
• appearance, promotions value, public or community relations,
• quality of products,
• maintenance problems,
• fit with company organization structure,
• equipment utilization,
• utilization of natural conditions or surroundings ,
• ability to meet capacity or requirements,
• investment or capital required and
• savings, payout, returns, profitability.
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PROCEDURE FOR EVALUATING
ALTERNATIVES BY FACTOR ANALYSIS ?
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