‘Scanned by CamScanner ‘Scanned with CamScanner313. TOOLS AND TECHNIQUES OF PLANT LAYouT \_-7The quality and quantity of the data on various factors is re data is to be collected regarding the various processes, se: frequency of travel, space requirements, techniques are used to analyse the data. . Process charts—(operation process charts, flow Process charts) . Travel Chart . Diagrams—(flow diagrams and string diagrams) . REL—(Relationship chart) . Templates . Scaled models The process charts and diagrams are discussed in chapter on method study. quired to develop a good layout. The us p quence of operations, material, f activities and their relationships. The following 2 i AWLWNE EL CHART : feet flow of material between functional areas of the plant is rec ‘orded on a From— records the distance agd frequency of movements between vatious pairs of wes enart i Scanned with CamScanner| | | | > PLANT LAYOUT ae < genes between partments, It f the degree of closeness be h See nin inimis the total material handling costs, bai ts are: chart is used to deter Iayout design that seek yi "re advantages of trave les js a useful tool for movement : A TEE hetpil to Tocate the activities and backtracking, flows. fut for comparing alternative flows. EB z on te easly computerised as quantitative data is involved. the Travel Chart cde ee centres are listed both rowwise and columnwise, in the same se ach intersecting square (cell) is used to record data from one department to another Tete in the chart are scattered on both sides of the diagonal, tie, ‘Atypical travel chart is shown in Fig. 8.5. ro — Ajale mloja Fig 8.5: Travel chart. MBC represents number of moves from B to C. ‘The entries below the diagonal represent backtracking. Problem 1: A company manufactures three products P, Q, facilities arranged in six departments A, B, C, D, E and F eet ; Sequence of operations of product movement oe i Movement Q Smet ee > OG Cay mand for produet P = Pacity ofthe containers to carry P 12000 per annum =300 lumber of trips (Frequency) of forklift 12000 40 trips Material move Dee anaatlamovement for product Ps Ato & Be B ae "mand for product Q = |: merues cs ewpecly of theconuioesoca poio) s = limber Of trips (requency) of forklift = 12000 30 trips 400 = Scanned with CamScannerINDUSTRIAL &) 120 NGINEERING ANp p, jal movement fe Product D816, 51g Matoal demand for product R = 12000 vo" BC.ctoD, oy Capacity ofthe containers to carry R= 609 ] in. ~ 12000 number fis (Reaueny) of Fri = 120 “600 ~ 20 trips ~ Material movement for product R is Ct ‘These are represented on the From — OE, Eton 0B Bod, Aton p , » Eto D, To chart as shown in vee TO ——. 4 B Gc D . ne 30 is 4 o- Ps 4 20 B | R2 . ' c R20 Py [et | hy a z Be P40 = ay F 20 | % | 7 | 9 | so Fig. 8.6: Travel chart REL (RELATIONSHIP CHART) The relative importance of having one department near another is displayed in sales shart. Robert Muther developed the REL chart. Each diamond-shaped cell in the oe aes ‘lationship if any between two functional plant areas. TWo entries come into the ce meen Sntry is a letter that indicates the degree of closeness of the relationship and the num’ presents the important reason for relationship. ane ae The relationship diagrams recognise the need for exploring Reena pies the “alculating exact flows and costs, The Tequirements of closeness are pales boa ae itese pair-wise interdepartmental “closeness requirement ratings asin ae nay ‘altable layout which satisfies as many pairwise relationship as possible andto The Telationship chart is shown in the Fig. 8.7. Scanned with CamScannerPLANT LAYOUT re Reasons behind closeness value Code | Reason g 2 3 Work Station 4 { 5 Work Station 6 x Closeness Rating 1 Value | Closeness ! : A | Absolutely essential E | Especially important 1 | Important © | Ordinary closeness U | Unimportant X | Not desirable Fig. 8.7: Relationship chan. Problem 2: Given the following Relationship chart, arrange the 23 grid.. work centres into-a suitable This problem can be solved using intuitive approach. In the intuitive approach, prime Department (1) and department (4) requires such relation. Departments (1) and (4) should be as close as possible. Then, ial). another extreme relationship Le,, X (closeness undesirable). This is found between Departments (1) and (6). ‘So, Departments (1) and (6) should be as far as possible from each othér. This is shown in figure below This requirement is to be checked between (4) and (6). Whose relationship is ‘U’ (Unimportant) so the figure is okay. The remaining set of Departments are located to satisfy the | i | importance is given to A relationship (closeness is absolutely essenti requirements of nabours. I as 4 6 Layout step | Scanned with CamScanner122 INDUSTRIAL ENGINEERING AND PRODUCTION MANAGEMENT Department Closeness Type Requirement with E E at there is an undesirable relationship between (3) and (4), The layout is figure below satisty these requirements, Which is the final layout, 1 5 3 Final Layout LOAD DISTANCE MODEL isis mast commonly used quantitative process layout model that minimises flow. Load distance model—an algorithin for laying out work centtes to minisiee product flow, based on the number of loads moved and the distance between each air of work centres. ‘The model can be mathematically expressed as— C= Gr En Lyd) xx tet pat Where Cis the costto be minimised ‘n’ is the number of work centres 10. of loads meved between work centres { and Dy = distance between work centres j und j = costto move one load by one unit distance is constant TEMPLATES ‘This is the most common method of presenting the plant layout. These are two-dimensional eut Guts prepared by cardboard, coloured papers, etc. They are mide to scale and oe placed on the scaled plah of the building drawn on the board. The templates depict the plan of various activities {ike machine tools, work benches, storages, etc. Advantages 1. Cheaper compared to model layout. 2... Congestion, backtracking can be better visualised, 3. Easy for interpretation. 4, They can be convenient feasible arrangements. Limitations 1. Interpretation is difficult for non-technical persons. 2. Its dificultto visualise the impact of overhead cilities on the plant and proces, SCALE MODELS ‘Three-dimensional models are the scaled models ‘equipment with their appropriate scale are used in “sade up of wood or plastic. These are costly, Advantages 1. Basy to visualise and explain, ly moved on the board providing flexibility to evaluate various Of the facilities, The models of the plant and Preparing the model layout, They att usually Scanned with CamScannererapavaese sees eeaspuieetweiwaere tes wwe pone ee en wnt en nnn neon - 8.3. OBJECTIVES OF PLANT LAYOUT “The primary goal of the plant layout is to maximise the profit by arrangement of al! the plane facilities to the best advantage of total manufacturing of the product. Thus the objective of plant planning is the best relationship between output, space and manufacturing cost. The objectives of plant layout are: 1, Stremline the flow of materials through the plant. 2. Facilitate the manufacturing process. 110 Scanned with CamScannerPLANT LAYOUT . Maintain hi . Flexibility of manufacturing operations and arrangement ae |. Provide for employee convenience, safety and comfort. CrNaAnAw igh turnover of in process inventory - Minimise materials handling. Effective utilisation of men. Equipment and space. Make effective utilisation of cubic space. Wy Scanned with CamScanner8.10. SYMPTOMS OF BAD LAYOUT 1. Long material flow lines and backtracking (rehandling). 2. Poor utilisation of space. 3. Congestion for movement of materials and men, 4, Lasge amount of work-in-process. 5. Long production cycles. 6. Excessive handling of materials, 7. More frequent accidents. 8. Difficult to supervise and control. Scanned with CamScannerNOUNES, WAILITZ BU EE prewrreeens ve memo Ne ae 4. OBJECTIVES OF MATERIAL HANDLING i 2, DAWvD Minimise cost of material handling. Minimise delays and interruptions by making available the materials at the point of use at right quantity and at right time. _ Increase the productive capacity of the production facilities by effective utilisation of ca pacity and enhancing productivity. . Safety in material handling through improvement in working condition. . Maximum utilisation of material handling-equipment. . Prevention of damages to materials. . Lower investment in inprocess inventory. Scanned with CamScannererent, “5:7. ALLOWANCES € Normal tim, © for an Operati c n allowance (2) Interference Contingency allowance. Relaxation Allowance 3 Relaxation allowances are calculated so as to allow the worker to recover from fatigue. Relaxation allowance is a addition to the bas ic time intended to provide the Worker with the Opportunity to recover from the physiological an 'd psychological effects of carrying out specified work under specified conditions and to allow attention to perscnal needs. The amount of allowance will depend’on’ nature of the job. “ Relaxation allowances are of two types—fixed allowances and Variable allowances, Fixed allowacces constitute: (a) Personal needs allowance. It is intended to compensate the operator for the time necessary ta leave, the workpjace to attend to personal nee ds like drinking water, smoking, washing Scanned with CamScannerEMENT i INDUSTRIAL ENGINEERING AND PRODUCTION MANAG! 10.3. OBJECTIVES OF JOB EVALUATION i in the |. To establish a sound wage and salary system by determining’ the worth of each job i ility involved factory in relation to various factors like skill required, effort and responsibility invol ‘To eliminate the wage inequal To establish a general wage level for a given factory. To clearly define the line of authority and responsibility. ‘To formulate an appropriate and ‘uniform wage structure. To provide a lea bee es recruitment, wilesions promotion and transfer of ea To identify the training needs of the employees so as to prepare them for future positions. | A sound base for individual performance measurement. ‘To promote a good employec-cmployer relations. eer avawnr 10.4. PROCEDURE FOR JOB EVALUATION ‘The steps involved in job evaluation are shown in Fig. 10.1. pe a as JOB ANALYSIS Determine detailed facts about the jobs JOB DESCRIPTION Describe clearly the requirement of jobs JOB SPECIFICATION Specify the atributes possessed by employee to complete the job satisfactorily JOB CLASSIFICATION Determine the relative worth of jobs WAGE DETERMINATION ‘Compare jobs with predetermined job and ‘arrive at suitable wage structure i EVALUATE PERFORMANCE Based on job description and specification g Fig. 10.4: Stapsin job evaluation. ‘Scanned with CamScannerFactors Affecting the Selection of Material Handling equipment e PROPERTIES OF THE MATERIAL. ... e LAYOUT AND CHARACTERISTICS OF THE BUILDING. ... e« PRODUCTION FLOW. ... e COST CONSIDERATIONS. ... e NATURE OF OPERATIONS. ... e ENGINEERING FACTORS. ... e EQUIPMENT RELIABILITY. Scanned with CamScannerPrinciples of Value Analysis Do not use a part thatdoes not contribute to the value of the product, Do not use @ part whose cost is not proportional to itt: functions usefulness. Do not provide any features to the component or finished product that are not @bsoluteh) required, Accept change if part of required qualityis made by a process costing lessthan the alternative process. Use standardized parts wherever poxsible, Use proper manufacturing methods taking into account the quanti ties, Lise the material best.sulted for the purpose. Purchase the part instead of im house manufacturing if suiteble supplier can provide the partof good quality ata reasonable price. Scanned with CamScannerDifference between Value Analysis and Value Engineering Mote es SUE a tert tala Itindicates application on the product thatis It indicates application on the product at its into manufacturing design stage In value analysis all factors come together Value engineerin is ahways done by a specific including workers,subcontractors,engineers to product design(engineers) team make a team with total experience and knowledge It may change the present stage of the ‘The changes are executed at the initial stages product or operation only Itis worked out mostly with the help of Itrequires specific technical knowledge knowledge and experience Scanned with CamScanner