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Plant Layout
Plant layout
MeaningPlant layout is the physical arrangement of industrial facilities. It involves the allocation of space & the arrangement of equipment in such a manner that overall operating costs are minimized.
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An efficient layout can be instrumental in the accomplishment of the following objectivesEconomies in materials, facilitate manufacturing process & handling of semi-finished & finished goods. Proper & efficient utilization of available floor space. To avoid congestion & bottlenecks. Provision of better supervision & control of operations.
Principle of integration (of 5Ms) Principle of minimum distance Principle of cubic space utilization( both horizontal & vertical space). Principle of flow( must be forward no backtracking) Principle of maximum flexibility Principle of safety, security & satisfaction Principle of minimum handling.
Layout that uses standardized processing operations to achieve smooth, rapid, highvolume flow Here machines are arranged acc. To the needs of product & in the same sequence as the operations are necessary for manufacture.
Product Layout
Raw materials or customer
Material and/or labor
Station 2
Material and/or labor
Station 3
Material and/or labor
Station 4
Finished item
High rate of output Low unit cost Labor specialization Low material handling cost High utilization of labor and equipment Established routing and scheduling Short processing time
Creates dull, repetitive jobs Poorly skilled workers may not maintain equipment or quality of output Fairly inflexible to changes in volume Highly susceptible to shutdowns Needs preventive maintenance Require large capital investment
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Process layoutLayout that can handle varied processing requirements Here all machines performing similar type of operations are grouped together at one location in the process layout. Thus here facilities are grouped together acc. To their functions. E.g. all drilling machines are located at one place known as drilling section.
Process Layout
Milling
Assembly & Test Grinding
Drilling
Plating
Process Layout
Process Layout (functional)
Dept. A Dept. B Dept. C Dept. D Dept. E Dept. F
Product Layout
Product Layout (sequential)
Work Station 1 Work Station 2 Work Station 3
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Can handle a variety of processing requirements Machines breakdown doesnt result in shutdown. Equipment used is less costly Wide flexibility in production facilities. Each production unit of system works independently. High utilization of facilities Variety makes the job interesting.
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In-process inventory costs can be high Challenging routing and scheduling Equipment utilization rates are low Material handling is slow and inefficient & is more. More space is required Longer processing time Back tracking may occur.
factors
Process layout
Better utilization
5. Material handling
6. inventory 7. breakdown 8. Production centre 9.flexibilty 10. floor space 11. investment
standardized less less High WIP Cant tolerate simple low Requires less high
diversified more more Low WIP Can tolerate complex high more low
Fixed position layout- Layout in which the product or project remains stationary, and workers, materials, and equipment are moved as needed. E.g. Employed in large project type organisation construction of DAMS. ISRO Helicopter Nuclear engg. Division of BHEL
The product, because of its size and/or weight, remains in one location and processes are brought to it.
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Factors affecting plant layout Nature of product- e.g. some products need airconditioned plants. Size of outputFor bulk-product/line layout For small-functional layout Nature of manufacturing systemFor intermittent-functional layout For continuous-product/line layout Localization of plant- e.g. there will be different transportation arrangement if site is located near railway line. Machines or equipment- e.g. heavy machines need stationary layout Climatic conditions, need of light, temperature also affect design of layout.
COMPANY PROFILE
RYDON GROUP,Coimbatore FOUNDED IN THE YEAR 1991 HAS ESTABLISHED BUSINESS IN THE FIELD OF MANUFACTURING AND AS WELL AS AUTOMOBILE DEALERSHIP. THE COMPANY HAS COMPLETE IN-HOUSE FACILITY TO PRODUCE SPROCKETS FOR TWO WHEELER, FOUR WHEELER AND INDUSTRIAL APPLICATIONS.
Types of sprockets
SPROCKETS
OE
RP
FD
OE: Original Equipment (line-2) RP: Retail Product (line-3) FD: Final Drive (line-1)
THE OE AND RP SPROCKETS ARE SIMILAR EXCEPT FOR THE HEAT TREATMENT IS DONE ONLY FOR THE OE SPROCKETS.
Heat treatment
Tooth cutting
Despatch
Heat treatment
Tooth grinding
Despatch
Gear Hobbing
Despatch
Data Collection
Modeling
Simulation
Evaluation