36899615 Facility Layout
-
Upload
noopur-bhandari -
Category
Documents
-
view
237 -
download
7
Transcript of 36899615 Facility Layout
-
7/30/2019 36899615 Facility Layout
1/54
Facility Layout
-
7/30/2019 36899615 Facility Layout
2/54
Presented by
Shashank Saxena
Shashi Minchel
Shikha Sinha
Shilpi Kanstiya
Shruti Agnihotri
Shruti Garg
Shuvam kaushik
Simayan Pati
-
7/30/2019 36899615 Facility Layout
3/54
Plant layout
A floor plan for determining and arranging the desired
machinery and equipment of a plant
It permits
The quickest flow of materials in processing the product
From the receipt of the raw materials to the
shipment of the finished product
At the lowest cost, andWith the least amount of handling
-
7/30/2019 36899615 Facility Layout
4/54
Objectives
Provide enough production capacity
Reduce material handling cost
Reduce congestion impeding movement of men andmaterial
Reduce hazards to working personnel
Utilize labour efficiently
Increase employee morale Utilize available floor space efficiently and
effectively
-
7/30/2019 36899615 Facility Layout
5/54
Reduce accidents
Provide for volume and product flexibility
Provide ease of supervision and maintenance
Facilitate co-ordination and face-to-facecommunication
Provide for employee safety and health
Allow high machine utilisation
Improve productivity
Objectives
-
7/30/2019 36899615 Facility Layout
6/54
Principles of layout
Principal of minimum travel
Principle of sequence
Principle of usage
Principle of compactness
Principle of safety and satisfaction
Principle of flexibility
Principle of minimum investment
-
7/30/2019 36899615 Facility Layout
7/54
Basic Types of Layout
Product Layout
Process or Functional Layout
Fixed-position LayoutCell manufacturing/GT
Mixed /Combined Layouts
719/05/2013
-
7/30/2019 36899615 Facility Layout
8/54
Vvolume-variety characteristics
Low VOLUME High
High
VARIETY
Low
Fixedposition layout
Process layout
Cell layout
Product layout
-
7/30/2019 36899615 Facility Layout
9/54
Product layout
Machines arranged in a line depending upon sequence
of operations
Material moves in a line from the first machine to thefinished product on the last machine.
Investment higher as compared to process layout
Better suited for standardised products on a mass scale production. Exchemicals,paper
-
7/30/2019 36899615 Facility Layout
10/54
Product Layout
Plant & machinery layout is designed to cater to
continuous flow of Materials.
The position and order in the sequence for amachine performing particular operation is fixed.
Once a machine is in line, it cannot perform any
operation , which is not designated in the
sequence of operations.
There is a continuous flow of material during the
production process from start to finish.
18-12-2007 10
-
7/30/2019 36899615 Facility Layout
11/54
FINISHED GOODS
MATERIAL FLOW
RAW MATERIALSPRODUCTION SUB-SYSTEM
RECEIVING
STORAGE OPERATION A
OPERATION B
OPERATION C
OPERATION D
SHIPPING
EDP CONTROL
SYSTEMS
INFORMATION
FLOWS
CONTINUOUS FLOW PRODUCTION SYSTEM (FLOW SHOP)
-
7/30/2019 36899615 Facility Layout
12/54
Examples of product layout
Assembly line for air-conditioner
Car manufacturing unit
Car washes and
Canteen facilities
Laundry.
-
7/30/2019 36899615 Facility Layout
13/54
Important Considerations
All machines placed at points demanded by sequence ofoperation
No crossing over of one line with the otherMaterials may be fed where they are required for
assembly but not necessarily all at one point
All operations including assembly, testing and packing
included in the line
-
7/30/2019 36899615 Facility Layout
14/54
Classificationand
marking of
clothes
Washing
MachineDryer
Steam
press
StorageArea for
Pressed
clothes
Delivery
Counter
Product layout of laundry
To produce one standard product in large volumes.
Each unit produced undergoes same sequence of operations and uses same
flow of work.
The work centers and equipments are arranged in a line for continuous
operation.
-
7/30/2019 36899615 Facility Layout
15/54
Advantages
Ensures smooth and regular flow of material and
finished goods.Short processing time.
Reduces material handling.
Low cost labour procurement and lesser training
required.Lesser Inspection & Early detection of mistakes
Layout avoids production bottlenecks
Economy in manufacturing time
Better production control
Requires less floor area per unit of production
Work-in-progress in reduced
-
7/30/2019 36899615 Facility Layout
16/54
Disadvantages:
Inflexible & expensive layout
Difficulty in supervision
Expansion is difficult
Any breakdown along the line can disrupt total
production
Requires heavy capital investment.
-
7/30/2019 36899615 Facility Layout
17/54
Process layout
Grouping together of similar machines in one
department
Material moves from one group of machines to the
other
Movement over longer distance and along criss-
cross paths
May also involve part finished inventory waiting
Best suited for intermittent type of production/light and heavy industries
-
7/30/2019 36899615 Facility Layout
18/54
Functional or process layout
Here machines performing same type ofoperations are installed at one place .i.e. plant isgrouped according to functions e.g. all drilling
machines are located at one place known asdrilling section.
This type of layout is most appropriate forintermittent (JOB and BATCH ) type of
manufacturing systems where small qtys of alarge range of products are to be manufacturede.g. machine tools etc.
-
7/30/2019 36899615 Facility Layout
19/54
Process Layout
11-12-2007 19
Process Layout - work travels
to dedicated process centers
Milling
Assembly
& TestGrinding
Drilling Plating
-
7/30/2019 36899615 Facility Layout
20/54
INTERMITTENT FLOW PRODUCTION SYSTEM (JOB SHOP )
PRODUCTION SUB-
SYSTEM
RECEIVING
STORAGE
OPERATION A OPERATION B
OPERATION COPERATION DSHIPPING
INFORMATION
FLOWS
WIP
WIP WIP
WIP
FINISHE
D
GOODS
EDP
CONTR
OLSYSTEM
S
RAW MATERIALS
MATERIAL FLOW
FINISHED GOODS
-
7/30/2019 36899615 Facility Layout
21/54
Process Layout Examples
Car servicing
Hospital-Patient requiring various tests
Volume low & variety is more
Garment factory producing half sleeve shirts,full sleeve shirts, pants and suits.
Office buildings, schools, universities,hospitals, aerodrome, library, book store oramusement centers are planned on this basis.
21
-
7/30/2019 36899615 Facility Layout
22/54
Important considerations
Distance between departments as small as possible
Departments to be located as per sequence of operation
Convenience for inspection as well as supervision
-
7/30/2019 36899615 Facility Layout
23/54
Process layout
Lathe 1
Lathe 2
Lathe 3
Milling
Machine
Fitting Table 1
Fitting Table 2
Fitting Table 3
Welding M/C - 1
Welding M/C - 2
Paint Shop
Side Entry
Main Entry
Work Shop OfficeAir
Compressor
Product A
Product B
Flow of work is not standardized
Plant produces a variety of products
Some of the processes / operations
might be common.
-
7/30/2019 36899615 Facility Layout
24/54
Advantages
Each production unit of the system worksindependently and is not affected by the happenings in
another section of the plant.
Scope for more skilled labour leads to better quality
in production.
Wide flexibility in production facilities.
Machine breakdown doesnt disrupt production.
Lower capital investment. (Less duplication ofmachines).
Better utilization of resources
Full utilization of machinery
-
7/30/2019 36899615 Facility Layout
25/54
Disadvantages
More material handling.
Longer processing time:- as more time s required formaterial handling, transportation n inspection.
Requires substantial production planning and control.Requires more floor space.
Inspection s more frequent n costlier.
Requires highly skilled labour creating difficulty inlabour procurement.
Production time increased because of extra travel
Accumulation of work-in-process at different machines
-
7/30/2019 36899615 Facility Layout
26/54
Fixed position layout
Movement of men & machinery to the product
Product remains stationary
Cost of moving product is high,bulky
Best suited for bulky & heavy products ex.Ships, aeroplanes etc.
-
7/30/2019 36899615 Facility Layout
27/54
18-12-2007 27
Fixed Position Layout
The material remains in a fixed position , but
the machinery, tool workmen etc are brought to
the material
-
7/30/2019 36899615 Facility Layout
28/54
AIRCRAFT ASSEMBLY
FINISHED PRODUCT
(AIRCRAFT)
RAW MATERIALS
MACHINE &
EQUIPMENT
LABOUR
FIXED POSITION OR STATIC LAYOUT
-
7/30/2019 36899615 Facility Layout
29/54
Fixed position layout
Fixed-position layout is used for products, which areeither very big in size (weight/volume) or very criticaland it is not feasible or desirable to move the product and
product remains in one position only.
Men, materials, equipment and tools are brought to theproduct for execution of the work.
Building of space shuttle, turbines, aircrafts and ship usefixed-position layout as it is not feasible to move these
products due to their size or weight.
-
7/30/2019 36899615 Facility Layout
30/54
18-12-2007 30
Fixed Position Layout
Employed in large project type organisation
Example
ISRO
Helicopter
Nuclear engg. Division of BHEL
-
7/30/2019 36899615 Facility Layout
31/54
Advantages
Men/machinery can be moved for a wide varietyof operations producing different products
Worker identifies himself with the product &
takes pride when the work is completed
Investment on layout is small
High cost & difficulty in transporting a bulky job
avoided
-
7/30/2019 36899615 Facility Layout
32/54
Mixed layouts
Mixed layoutspure basic layouts can be used in different
departments in one organisation.
Example: A hospital would be arranged on process-layoutprinciples. Within individual departments different
layouts are used e.g. x-ray department probably process,
surgical theatres fixed-position and the blood-processing
lab a product layout.
-
7/30/2019 36899615 Facility Layout
33/54
Combined layout
Combination of product & process layout with anemphasis on either
Generally adopted in industry
In fabrication plants including assembly,fabrication tends to employ process layout whileassembly areas employ product layout Soap manufacturing industry employs product line for
manufacturing of soap, but ancillaries such as heating,manufacturing of gleycerine, power house etc. Are arranged onfunctional basis.
-
7/30/2019 36899615 Facility Layout
34/54
F.P.
F.P.
G.C.
G.C.
G.C.
H.T.
H.T.
G.G.
G.G.
RAW MATERIAL
RAW MATERIAL
FINISHED
PRODUCTS
(GEARS)
F.P. = FORGING PRESS G.C. = GEAR CUTTING
H.T. = HEAT TREATMENT FURNACE G.G. = GEAR GRINDING MACHINE
COMBINATION LAYOUT OR HYBRID LAYOUT FOR GEAR MANUFACTURING
-
7/30/2019 36899615 Facility Layout
35/54
Combination layout
In an industrial plant, it is difficult to confine to one typeof layout only i.e. process or product layout.
It becomes necessary to use process layout for some ofthe activities and to use product layout for certain other
activities in the same plant.
Cement manufacturing may need process layout for raw-material preparation, which require crushing, grindingand mixing of the various raw-materials such as lime-
stone, clay, bauxite and iron-ore.
-
7/30/2019 36899615 Facility Layout
36/54
Combination layout
Once the raw materials are prepared and converted intoraw-meal by mixing different raw materials in
predetermined proportion, production processes such aspre-heating, pre-calcining, calcinations for conversion of
raw-meal into clinker and cooling of clinker would useproduct layout.
Within the plant, workshop activities are arranged byusing process layout, whereas the packing and dispatch
operations of the cement through trucks need productlayout.
-
7/30/2019 36899615 Facility Layout
37/54
-
7/30/2019 36899615 Facility Layout
38/54
Clay
Yard
BauxiteYard
Iron ore
Yard
Lime StoneYard
Raw
Mill
ESP
Cyclone
Chimney
BlendingSt
oragecyclone
Inlet chamber
Of kiln
Rotary kiln
Clinker cooler
Cement
Mill
Combination layoutcase of a cement plant
Process layout for a portion of
Cement plant
Product layout for a portion of
Cement plant
-
7/30/2019 36899615 Facility Layout
39/54
Cellular manufacturing (cm) layout
Grouping of machines into cells
Cells function somewhat like product layoutwithin a larger shop or process layout
Each cell in the cm formed to produce a singlepart / a few parts
All with common characteristics which usually requiressimilar machines and settings
Flow of parts within the cell can take many forms
-
7/30/2019 36899615 Facility Layout
40/54
18-12-2007 40
Group Technology
This is philosophy that seeks to exploit the
commonality in manufacturing and uses this as a
basis for grouping components and resources. This is
also known as cellular manufacturing.
Pioneered by Russians
Mid volume & mid variety scenario
70% of mfg. industry may fall under this category)
-
7/30/2019 36899615 Facility Layout
41/54
CARAVAN, BATON and MIXED CELLS
Operator andproduct
move from station
to
station
Operators arefixed but
products move
from
station to station
Products move fromstation
to station and
operators move
between stations
CARAVAN CELLS
BATON CELLS
MIXED CELLS
CELLULAR MANUFACTURING
-
7/30/2019 36899615 Facility Layout
42/54
1 2
3
45
1 2 3
1 2
34
21
CELL # 3
CELL # 4
CELL # 1CELL # 2
PRODUCTION OPERATION PRODUCT OR MATERIAL FLOW
CELLULAR MANUFACTURING
LAYOUT
PART D
PART Y
PART X
PART A
PART B
3
-
7/30/2019 36899615 Facility Layout
43/54
-1111 -1111
2222 - 2222
Assemb
ly
3333 - 3333
4444 - 4444
Lathe
Lathe
Mill
Mill
Mill
Mill
Drill
Drill
Drill
Heattreat
Heat
treat
Heat
treat
Gearcut
Gear
cut
Grind
Grind
Cellular Manufacturing Layout
CM LAYOUT
-
7/30/2019 36899615 Facility Layout
44/54
CM LAYOUTADVANTAGES
LOWER WORK-IN-PROCESS INVENTORIES
REDUCED MATERIAL HANDLING COSTS
SHORTER FLOW TIMES IN PRODUCTION
SIMPLIFIED PRODUCTION PLANNING (MEN,
MATERIAL ETC.)
OVERALL PERFORMANCE OFTEN INCREASES
BY LOWERING PRODUCTION COSTS &
IMPROVING ON-TIME DELIVERY
IMPROVED QUALITY
Ad f C ll l L
-
7/30/2019 36899615 Facility Layout
45/54
Advantages of Cellular Layout
PPC becomes simpler
Material handling becomes easier
Traceability improves Employees are able to relate better.
Helps in implementing SGA, Kaizen an
JIT
C ll l L E l
-
7/30/2019 36899615 Facility Layout
46/54
Cellular Layout- Examples
Reliance industries- HDPE & LDPE
Titan Industry
ABB( Industrial fans & blowers)
CM l t li i i
-
7/30/2019 36899615 Facility Layout
47/54
CM layout limitations
Reduced manufacturing flexibility & potentially
increased machine downtime
Duplicate pieces of machinery may be needed so asto avoid movement of parts between cells
-
7/30/2019 36899615 Facility Layout
48/54
Service facility layout
Main difference between service and manufacturingfacility is to bring together customers & services inmany service facilities
Facilities to provide for Easy entrance from the freeways and busy thoroughfares
Large well organised and amply illuminated parking areas etc.
Hotels, cinema halls etc have different areas to cater to
the comfort & convenience of customers
ENTRANCEEXIT
-
7/30/2019 36899615 Facility Layout
49/54
PARKING AREAPARKING AREA
PARKING AREA PARKING AREA
HOSPITAL WARDS
HOSPITAL WARDS
HOSPITAL WARDS
SURGERY, RADIOLOGY,
I.C.U., TECH SERVICES
DOCTORS
LOUNGE /
OFFICES
ADMIN. OFFICE
NURSES
LOUNGECAFETERIA
CASUALTY DEPT / INPATIENT DEPT
ENTRANCE EXIT
CASUALTY DEPT / INPATIENT DEPT
ENTRANCEEXIT
SERVICE FACILITY LAYOUT ( HOSPITAL LAYOUT )
-
7/30/2019 36899615 Facility Layout
50/54
Layout important to achieve client-customer goal of fast service FAST SERVICE SUPPORTED BY POINT OF SALE SYSTEM,
SCANNERS, SELF SERVICE TO PROVIDE SPEED AS WELL ASREDUCE COST, atms BY BANKS ETC.
Flow line approach followed in fast food service
Process line layout occurs in many services like medical clinics,offices etc.
Service facility layout
-
7/30/2019 36899615 Facility Layout
51/54
Generally, as in manufacturing
Line layout preferred in high volume,
standardised products Fast food service
Process layout preferred in service operations
also
General offices, banks, general hospitals, municipal
offices etc.
Service facility layout
-
7/30/2019 36899615 Facility Layout
52/54
SERVICE WAITING LINE MODULES
SINGLE CHANNEL,
SINGLE PHASE MODULE
WAITING LINE SERVICE
FACILITY
MULTIPLE CHANNEL,
SINGLE PHASE MODULE
SERVICE
FACILITYWAITING LINE
SINGLE CHANNEL,
MULTIPLE PHASE MODULE
WAITING LINE SERVICE
FACILITY
SERVICEFACILITY
WAITING LINE
MULTIPLE CHANNEL,
MULTIPLE PHASE MODULE
L l i
-
7/30/2019 36899615 Facility Layout
53/54
Layout planning methodology
Travel chart method
Load-distance analysis method
Systematic layout planning method
Analysing layouts with computers
Aldep (automated layout designing programme)
Corelap (computerised relationship layout planning)
Craft (computerised relative allocation of facilitiestechnique)
-
7/30/2019 36899615 Facility Layout
54/54