Layouts In Production Industries : A Review

Nagarjuna Reddy Gayam1#, K. Shanmuganandam1, D. Vinodh1

1#
Department Of Mechanical Engineering,
Saveetha School Of Engineering,
Saveetha Institute of Medical and Technical Sciences,
Chennai- 602105
gayamnagarjuna@gmail.com
Abstract

The main objective in this review paper is to conduct a review on various industry layouts,
and to suggest some new modifications to it by proposing modified layout. In the process of
investigation it is important to understand the basic industry structures and establish our own
methods to develop it into a less time bound layout, easy maintenance layout, better coordination
layouts as well. Industry management is a key area we have to focus for the better results in the
fields like manufacturing and production. If the working environment is better known to the
workers they work well and yield good results, easy movable space provided for the materials,
inspection is done in various levels to get better control over quality in the output of the
industries to make good profits.

Keywords

Layouts, production , inspection, industries, management

 1. Introduction

A layout which is which is installed in an industry decides the production levels, efficiency and
even the profits of the company. There are more than four types of layouts already existing in the
present day industries ranging from product, process, combined, fixed layout, group technology
layouts etc.[1] whatever may be the layout pattern they always design for the betterment in the
conditions of work area and impart good output by minimizing losses. Some industries choose,
product layout because they target about the only products and their number which is very
classical mode of production layout[2]. Some select process layout where product work is
divided into various processes, some even choose group technology layouts where similar work
proceedings are grouped together like periodic table elements for better understanding of the
industrial layouts[3].

After understanding the existing industrial layouts and their fallouts, in this paper the modified
layout which is the out come of blend of good patterns of most of these layouts is suggested,
which enhance the production output and reduce the losses incurred during that time.

2. Layouts Investigation

The most well known method to industries are product and process layouts they are very
conventional in nature and allows less worker friendly environment, which are good in
productive but creates some losses in production which are not neglected by these layouts as
well. From this investigation the layout patterns are identified and review their relationship with
every machine in detail that is where the out put error occurs and from where accumulation of
material happens and how to reduce this time by providing auxiliary equipment such as materials
handling basins, quality control equipment, service providing persons and notice boards for
information. These helps in the reduction of cost of production and increase the output to work
ratio.

Orville sutari, Sathish rao U, they reported very first nature of the industrial layouts and their
evolution over the time from beginning [4], the product layout established by one major goods
producing industry have twenty to twenty-five stages of Assembly lines and each one is given
one stage to work on, the legitimisation of the work involves straight line manner and the cnc
machines , oil check stages are not in a position to eliminate the fact that they are the time
consuming stages in small and medium scale industries[5-6]. It provided that the each major
stage is the key area where the lag of production occurs. Workers, working at the heavy
machines are specialized over time to do that work but others are not ,this has to be overcome.
[7], the product layout specific about completing the products, more output oriented and they get
profit by producing more numerous products in given time[8]. Systematic Layout Planning is
key thing we need to understand before establishing new layout models[9], if we use SLP
method we also get increased productivity.[10]

Nurulzulaiha Sa’udah, Mohammad NazriAli explained about process layouts in food

industry[11], they are installed by the industries which requires the process of the production
should complete. It is clear for them as they are segmented into various processes of the products
like, casting process, machining process and assembly work, quality work in cellular
manufacturing using robots[12-13]. The major advantage of this type is better use of the
available resources by minimising the losses of time accumulation at one place. It is a section
wise work and adding to give good results by facilitating the layout simpleness[14-15]. Inspite of
existing benefits one of pump manufacturing industry also experienced more negative factors
which are ranging from lack of information from one batch of technology to other in a way that
one batch consists most skill full persons and they completed the work in good fashion[16].
Flexible manufacturing systems are one or the other way related to process layouts[18]and
algorithms for this dynamic process layout are utilized to check the existing capacity the
same[17]. Process layout is established in electronics manufacturing plant and the better
efficiencies are noted with some safety limitations[19]. Design of shop floor based on process
layout by utilizing facility layout problem is great benefit to the industry in the production[20].

Okpala, Charles Chikwendu and Chukwumuanya, Okechukwu reported that the

combined layout is the one which installed by mixing product and process layouts by taking all
positive outcomes from them, like some work can be like processes and some like product
divided into batch wise(21-22). combined layout is well suited for the large scale industries
where multiple works are going on.[23-24]. The reliability is the key factor one should note that
before going to install the layout and if we develop any model without the said reliability it is of
worthless work[25]. More than profits industries look at the damage of losses, More than
fastness industries strive for worker safety and ease of doing work by utilizing microwork
cells[26]. This layout which uses the special things in both the previous layouts it can be
suggested as best among them all which reduces the risk factor from them[28]. Some layouts in
low capacity manufacturing industries show greater faults in production environment due to lack
of effective management[27]. some of the industries which produce consumer goods,
perpormance is also verified with the worker output ratio which requires modifications to their
layouts[29-30].
Kamal Khanna, Gazal Preet Arneja, Rakesh Kumar, explained about the group
technology, It is the technology which uses all the similar resources at one place to minimize the
individual efforts loss and give better results in production[31-32]. Where heavy machines like
cnc and quality checking machines are to be partially eliminate from the given layout line and
grouped with similar fashion in order to fasten the work and do the proposed work in separate
manner not to include with the prior[33]. Group technology is that instead of completely
eliminating dissimilarities, it tries to include this stages but to separate them major machine
wise[34-35]. This not only improve the output but the space requirement is also less and
improves the efficiency of the work[36]. Production management is the crucial thing done with
carefully by adopting good industrial layouts before establishing new ones[37]. Safety while
operating at heavy machines like CNC lathe machines and time lag between such machines
should be reduced minimum values to obtain good results which benefit all as a whole[38].
However, it is evident that there is a need for considering safety aspects in more detail within
group technology plant layout and design frameworks[39]. Some aspects which require grouping
of individual stages for better coordination is verified by SLP[40].

Buchari , U Tarigan , M B Ambarita, have reported certain things about u shaped layout,
where the operations go in a linear manner and turn like u continue in linear manner to better
coordination [41]. Some new trends like AI can solve the problems of the existing human
failures in manufacturing[42]. Time study and work study of the existing industries gives some
idea about wastages that occur in industrial area, found the cost losses where ever required[43].
U shaped layouts are mentioned here to understand the work in industries like u shaped
production model here one can see the most of the groups in one single point of time and
understand what is going on there[44-45]. If any problem occurs one have to go to back of the
machines and repair. It involves not only time but also money[46]. These existing layouts
utilizes the work of the all similar and dissimilar items for better coordination. The present
crucial industrial demand is to reduce the time losing in production work and to improve safety
of the worker in the industries and to use ergonomics principles for better worker friendly
environment[47-48]. Cellular manufacturing systems and flexible manufacturing layouts should
consider for their relevance before optimization[49]. This CMS utilized in Automotive industrial
sector produces better results if we eliminate the minute errors.[50]

3.Conclusion

This layout study and implementation of industrial layout improves the production in industries
after investigating all existing layouts there is a scope for new layout which suits best to most of
the new industries. The sun layout, in which the management is like sun and sub-sections like
working stages of heavy machines are like planets and auxiliary works like quality checking
areas, materials availability and storage sections are maintained like satellites. Segmented model
is taken from process layout, group technology is used in similarities grouped section wise and
inspection is done in three levels which increases not only quantity, but also quality.

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