PLANT LAYOUT

Plant Layout
Plant Layout refers to the physical arrangement of machinery, equipment & other industrial facilities- such as receiving & shipping departments, tool rooms, maintenance rooms & employee amenities for the purpose of achieving the quickest and smoothest production at the least cost.

PLANT LAYOUT
According to Knowles & Thomson, Plant Layout Involves Planning & arranging manufacturing machinery, equipment & services for the first time in completely new plants. The improvement in layouts already in use in order to introduce new methods & improvements in manufacturing procedures.

WHY LAYOUT PROBLEMS EXISTS?

Enlargement or contraction of existing departments Movement of a department due to change in the design of product. Addition of some new department e.g. computerization Replacement or addition of some new facility/machinery e.g. lift system, material handling innovations etc.

OBJECTIVES OF LAYOUT

To facilitate the manufacturing process. To provide operational flexibility. To ensure economics in materials. To ensure proper utilization of available floor space. To reduce the material handling costs. To reduce the congestion of personnel & material. To promote effective utilization of human resources.

OBJECTIVES OF LAYOUT

To meet the quality and capacity requirement in the most economical manner. Provision of medical facilities & cafeteria at suitable & convenient places. To provide efficient material handling system. To suggest improvements in production process and work methods. To improve safety of human resources. To improve morale & Labour efficiency.

ADVANTAGE OF A GOOD LAYOUT

TO THE WORKER:
1.

2. 3.

4.

Lesser number of operations & material handling. More labour productivity. More safety & Security to workers from accidents. Better Working Conditions resulting in improved efficiency.

ADVANTAGE OF A GOOD LAYOUT

IN MANUFACTURING COSTS:
1.

2. 3.

4.

Maintenance & Replacement costs are reduced. Loss due to waste & Spoilage is minimized Improved quality of product with reduction in handling w.r.t. movement, time and cost. Better Cost control

ADVANTAGE OF A GOOD LAYOUT

IN PRODUCTION CONTROL & SUPERVISION:
1. 2.

3.
4.

5. 6.

Provides more space for production operations. Control & Supervision operations are provided at appropriate points. Better & Convenient storage facilities. Efficient arrangement for receipt, transportation & delivery of raw material & finished goods. Result in less inspection activity Costs & efforts in the supervision of production process are minimized.

LAYOUT PROCESS

PRODUCT ANALYSIS MANUFACTURING PRACTICES SELECTION EQUIPMENT SELECTION MATERIAL FLOW ANALYSIS RELATIONSHIP ANALYSIS LAYOUT OPTIMIZATION

TECHNIQUES OF PLANT LAYOUT

Process Charts Operations Process Charts Flow Process Charts Process Flow Diagram Machine data cards Visualization of Layout Two-dimensional plan or templates Three-dimensional Plan or machine models

FACTORS RELEVANT IN THE CHOICE OF THE LAYOUT

Nature of the Product Size of Output Nature of manufacturing system Localization of plant Machines or equipments

FACTORS RESPONSIBLE FOR INEFFICIENT LAYOUT CAN BE

Layout planning is entrusted to unqualified/incompetent persons. Various department heads are given the responsibility of planning the layout. This leads to unhealthy competition for location & floor space & irrational emphasis on some plant activities. The site selected for plant may impose restrictions on the choice of good layout. The choice of unsuitable building may result in high production costs. Existing layout may not have the future plant expansion.

BUILDING FOR THE PLANT

Adoptability Fire Protection Proper Lighting & Ventilation Service Areas & Employees Facilities

Single Storey Plant Building

1.

2. 3. 4. 5.

6.

Advantages: There is greater scope for expansion & Modification Cost per sqm. is likely to be less. Provides more floor space Routing & Scheduling is comparatively easy Natural light can be more utilized from the rooftops & ventilators Better & Effective fire-protection appliances can be used

Multi Storey Plant Building

1.
2.

3.

4.

Advantages: Economy in Land Concept of gravity can be used in flow of material thus reducing the handling costs Vertical arrangements may provide more compact layout Upper floor are likely to impose less problem with regard to dust, dirt & Bad Smell.

PRINCIPLES OF LAYOUT

Principle of minimum travel Principle of sequence Principle of usage Principle of compactness Principle of safety & satisfaction Principle of flexibility Principle of minimum investment

Layout of Retail Outlet

Cafetera

Cafetera

TYPES OF LAYOUT

PROCESS LAYOUT/FUNCTIONAL LAYOUT/JOB-SHOP LAYOUT PRODUCT LAYOUT/LINE PROCESSING LAYOUT/FLOW-LINE LAYOUT FIXED POSITION/STATIC LAYOUT COMBINATION LAYOUT/HYBRID LAYOUT