MANAGEMENT OF MACHINES AND MATERIALS (MS-5)

UNIT 5 FACILITY LAYOUT AND MATERIAL HANDLING

Roshan Gnyawali

Facilities Layout
Layout: The configuration of departments, work centers, and equipment, with particular emphasis on movement of work (customers or materials) through the system.
Planning a new facility

Expanding or relocating an existing facility

Rearrangement of existing facility Minor modifications in present layout
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Objective of Layout Design

1. Effective utilization of space 2. Attainment of product or service quality 3. Worker satisfaction/ Improved environment 4. Avoid bottlenecks 5. Minimize material handling costs 6. Eliminate unnecessary movement 7. Minimize production time/ service time 8. Design for safety 9. Reduce Inventory 10. Better supervision and control
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Basic Layout Types

Product (Line) Layout
Process (Functional) Layout Cellular (Group) Layout Fixed-Position Layout Job Shop Layout Combination Layout
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Product Layout
Work Centers are organized in the sequence of appearance. Raw Material enters at one end and finished product comes out at the other end with different operations in between.
Raw materials or customer

Station 1

Station 2

Station 3

Station 4

Finished item

Material and/or labor

Used for Repetitive or Continuous Processing

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Condition for Product Layout

High Volume of Production
Standardization of Product Stable Product Demand Uninterrupted Supply of Material

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Advantages of Product Layout

High rate of output Low unit cost Labor specialization Low material handling cost High utilization of labor and equipment Established routing and scheduling Reduced congestion and Work-in-Process Effective Supervision and Control
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Disadvantages of Product Layout

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 Individual incentive plans are impractical
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Process Layout
Processing units are organized by function into departments. Similar equipments and operations are grouped together. Suitable for low-volumes (batch) production. When flexibility is the basic requirement.
Dept. A Dept. B Dept. C Dept. D Dept. E Dept. F

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Advantages of Process Layout

Better Machine Utilization Higher flexibility/ variety of Products Not vulnerable to equipment failures Equipment used is less costly Possible to use individual incentive plans

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Disadvantages of Process Layout

In-process inventory costs can be high Challenging routing and scheduling Equipment utilization rates are low Material handling slow and inefficient Complexities in supervision Special attention for each product

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Cellular Layout
Machines are grouped into a cell that can process items that have similar processing requirements.
Cell A Cell B 5 2

3 4

MACHINE

FAMILY (GROUP) A

CELL

FAMILY (GROUP) B

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Cellular Layout
Offers advantages of Mass Production with high degree of flexibility. High degree of Automation can be employed. Similar Functions are performed for a group of products in a single cell. Uses concepts of Group Technology

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Functional vs. Cellular Layout

Dimension
Number of moves between departments
Travel distances Travel paths Job waiting times Throughput time Amount of work in process Supervision difficulty Scheduling complexity Equipment utilization

Functional
many
longer variable greater higher higher higher higher lower

Cellular
few
shorter fixed shorter lower lower lower lower higher

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Fixed Position Layout

Layout in which the product or project remains stationary, and workers, materials, and equipment are moved as needed. Nature of the product (Weight, Size) dictates this type of layout Large construction projects

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Features of Fixed Position Layout

Product Handling is minimized. Flexibility in design changes. High variety of products. Quality responsibility is high. Capital Investment in minimum. Multi-skilled labor are required.

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Plant Layout Factors

Material Man Machinery Movement Waiting Service Building Change
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Systematic Layout Planning

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Tools and Techniques

Process Charts
Operation Process Chart Flow Process Chart

Flow Diagram Travel Chart REL Chart

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Operation Process Chart

Graphic representation of different operations (O) and inspection (c) including information regarding time, location etc.

Cutting 2 min Station 1

Milling 14 min Station 2

Inspection 1 min Station 2

Grinding 12 min Station 3

Final Check 2 min Station A1

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Flow Process Chart

Summary of different flow and activity of a component/ people
Operation Transportation Inspection Delay Storage

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Flow Process Chart

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Flow Diagram

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Travel Chart

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REL Chart

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Layout Implementation
Plot Plan Block Plan Detailed Layout Checking the Layout Evaluation of Layout Installation of Layout

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Material Handling
It is the art and science involving the movement, packaging and storing of substances in any form.
Reduce inventory Smoothing work flow Minimize Waste during handling Improve Routing Increase equipment and space utilization Improve working condition
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Material Handling Systems

Equipment Oriented System
Overhead, Conveyer, Tractor-trailer, Fork-lift truck and pallet, Industrial Truck, Underground

Material Oriented System

Unit handling, Bulk handling, Liquid handling system

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Material Handling Systems

Method Oriented System
Manual, Mechanized (automated) Job-shop handling, Mass-production handling systems

Function Oriented System

Transportation, Conveying, Transferring, Elevating Systems

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Discussion Questions
Compare process and product layouts. Give some suitable examples. Explain the meaning and importance of plant layout decision. How does it improve productivity? Explain various factors that govern the design of any layout of a plant. Give suitable examples. What layout design procedure would you adopt to develop a layout for a small toy unit manufacturing plastic toys at the rate of 5000/day? Discuss. Draw flow process chart of changing tire of your motor cycle or car. Assume all necessary data.
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End of Unit 5

UNIT 6: Capacity Planning