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11/5/2012 Anju Rana

FACILITY LAYOUT



11/5/2012 Anju Rana

CONTENTS

Concepts1) Introduction2)Factors afecting Layout

3)Scope o Facility Layout4)Types o Facility Layout Scope o the TopicCasesReerences



11/5/2012 Anju Rana

What is Facility Layout?

The layout acility is the physical location o the ariousdepart!ents"units o the acility #ithin the pre!ises o theacility$

The depart!ents !ay %e located %ased on theconsiderations such as&Less #al'ing distanceLogical se(uence o the processing re(uire!ents o theproduct

!ergency serices* etc



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Factors a!ctin" Layout

o+aterialo,roducto+achineryoLa%ouroLocationo+anagerial ,olicieso

Type o Industry



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Sco#! o Facility Layout

R!lat!$ to %at!rial

L!ss %at!rial han$lin" an$ %ini%u% trans#ortation cost L!ss &aitin" ti%! or in'#roc!ss in(!ntory )

R!lat!$ to &or* #lac!

Sa! &or*in" con$itions ro% th! #oint o (!ntilation+ li"htin"+ !tc) ,ini%u% %o(!%!nt o &or*!rs

L!ast chanc!s o acci$!nts+ ir!+ !tc) -ro#!r s#ac! or %achin!s+ &or*!r+ tools+ !tc)



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-!ror%anc! r!lat!$ o.j!cti(!s

Si%#l!r #lant %aint!nanc! ncr!as!$ #ro$ucti(ity+ .!tt!r #ro$uct uality+ an$ r!$uc!$ cost

L!ast s!t'u# cost an$ %ini%al chan"!'o(!r

O.j!cti(! r!lat!$ to l!i.ility

Sco#! or utur! !#ansion



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Ty#!s o Layouts

1 -roc!ss Layout

• suita.l! &h!n #ro$uct ha(in" stan$ar$ !atur!s is to .!#ro$uc!$ in lar"! (olu%!s)• th! s#!ciali3!$ %achin!s an$ !ui#%!nts ar! arran"!$ on! at!ranoth!r in th! or$!r o s!u!nc! r!uir!$ in th! #ro$uction#roc!ss)

CAR1

CAR 2

CAR 4Con(!y!r



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Advantages of Process Layout:•-reater Fle.i%ility

•/etter and !ore e0cient superision possi%lethrough specialiation•Capacity o diferent product line can %ee.panded easily$

•/etter utiliation o !en and !achine$

Disadvantages:•+ore oor space

•+ore #or' in progress•+ore distance traelled %y the product$



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2 -ro$uct Layout

•It is appropriate or producing one standardied

product* usually in large olu!e$ It is also called aso#shop layout or straight line layouts$ The!achines are arranged according to the progressiesteps %y #hich the product is !ade$•Example: che!ical* paper* ru%%er* reneries*

ce!ent industry$



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Advantages:•+echaniation o !aterials is possi%le and

!aterial handling cost can %e reduced$•It re(uires less oor area$•It acilitates %etter production control$•,roduction %ottlenec's are aoided$

Disadvantages:•.pansion o product line is di0cult$• There is di0culty is superising$•/rea'do#n o e(uip!ent disrupts the

production$



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Example of Product layout



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-rouping technology layout o cellular !anuacturing layoutis !ade or a single part a!ily i$e parts #ith co!!oncharacteristics$ In this layout dissi!ilar !achines aregrouped into cells and each cell unctions li'e productlayout$

Advantage and Disadvantages:

4 Grouping TechnologyLayout

It reduces !aterial handlingcost and si!plies !achinechangeoers$ It reduces in

process inentory andauto!ate the production %utreduces the e.i%ility$



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5hen due to sie* shape and other characteristics

constraints* the products cannot %e !oed* the!achine and operators !oe around the product$.a!ple& construction o a %uilding* asse!%le o anaircrat or ship$

Advantage:Less inest!ent is re(uired in thislayout and less transport cost as

%ul'y !achines are not !oed$

Fi!$ -osition Layout



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Example of Fixed PositionLayout



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CASE STUDY 1

Henry Ford The !nventor of the

Assem"ly LineIn 1673* 8enry Ford e!ployed up to 1*999 people si!ply to !oe!aterial in his auto!o%ile actory* an occupation that #as to %eirtually eli!inated In a ne# %uilding #ith an i!proed layout and#ith !echanied and graity%ased !aterialhandling syste!s$

Ford discovered that great economies could be made bymoving stocks to the assembly staf rather than havingthem leave their workplace to get materials. He alsonoted that costs could be greatly reduced by providingthat workers with all the necessary tooling and therebyeliminating tool rooms. The great emphasis placed on

eciency in transporting materials in ord actoriesseems to have been the motivating actor that led to thedevelopment o an assemble line.



11/5/2012 Anju Rana

Ford engineers consered space %y using ery detailed oorplans and positioned e(uip!ent such that #hen a !achineco!es into the actory* it is placed so that the !aterial co!ing

ro! an operation #ill %e as e.actly as possi%le in position orsucceeding one.

Ford himsel said, “they machines! are scienti"callyarranged, not only in the se#uence o operations, but

to give every man and every machine every s#uare incho space that he$it re#uires and% not% more&. Ford #ase.tre!ely conscious that space in his actory #as alua%le andsought to e.ploit it as co!pletely as possi%le #ithout giingany !ore to #or' in progress than #as necessary$ Forde!phasies :diiding and su%diiding operations* 'eeping the

#or' in !otion those are the 'eynotes o production;* in aperspectie that leaes no roo! or e.cessie or idleinentories <5ilson 166=)$



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CASE STUDY 2

#aruti $dyog

challenge %&Shinichi Ta'euchi* or!er head o Suu'i;s >osai acility in ?apan* #assent to one o Suu'i;s !ost prota%le su%sidiaries* +aruti @dyog* asdirector<,roduction) in Acto%er 2991$

Thus trying to ll in the #ide peror!ance gap %et#een +aruti andSuu'i;s >osai acility* #hich produces B99*999 cars in a year$The low production cost will give 'aruti not (ust more pro"ts,but an advantage over competition$t +aruti;s -urgaon plant* Ta'euchi has pulled ro! under the carpet all 'inds o +uda<?apaneseor #astage) starting #ith the asse!%le line$ )t some o the

workstations o the assemble line, the number o steps aworker has to walk to etch parts and tools rom their rackshas been brought down to * rom the earlier +-+*.5ith al!ost299 #or'ers !anning one asse!%le line* the saing hae led not Dustto increase in productiity* %ut also saety$

n may //, Takeuchi launched the challenge * programme at 'aruti. 0hallenge * aims at increasing the productivity at 'aruti1s 2urgaon acility by *3 andreducing the costs by 43.



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nother pro%le! successully handled %y Ta'euchi at theasse!%le line is the proper installation o ru%%er %eadingsor doors %y the line operators$ arlier staggering 14E o

the cars #ould ail the sho#er test<to chec' the lea'age)as a result o the i!proper installation o these %eadings$

Today* the gure stands at less than 1E$ Ta'euchi is stillnot happy %ecause that !eans nine cars ail the test ineery shit$ There is a specic se(uence to %e ollo#ed or

!a'ing the t!ent$ I that is not done* it !ay result in#arranty clai!s at the custo!er;s end$ en i it isdetected in the sho#er test* costly re#or' is re(uired$ Thecar needs to %e ta'en of the asse!%ly line to a re#or'station* #here e.tra !anhours hae to %e spent .ing the

pro%le!$ Takeuchi ensured that the workers ollowthe installation se#uence e5actly, so that there isno scope or rework.



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+aruti udyog ltd$ is raising (uality and e0ciencyleels across the %oard in order to achiee its%ench!ar' o Suu'i;s acility at >osai* ?apan*

through the challenge =9 progra!!e$0ompared to the +3 benchmark o 6osai, 'aruti

presently has comparative assemble hours pervehicle o 78.+/3 and a direct pass rate o 8.9:3.Takeuchi has introduced a #uicker set-up techni#ue

called the single-minute e5change o dies.;imultaneously to tackle the non-availability ocomponents, about +9 vendors who do not meetstrict parameters o #uality, cost, productivity, anddelivery will be dropped.

To increase the speed and #uality, 'aruti has +/robots now compared to only hal a do<en o robots"ve years ago. t is striving to reach its benchmarkon every parameter by the year /:-/*.



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REFERENCES

htt#6//!n)&i*i#!$ia)or"/&i*i/-lant7layout7stu$y

htt#6//#ino)uni(all!)!$u)co/8juan#99/ARTC:LOS;20-LANTAS/ARTC:LOS/<R:-O;200=;20',ONTA;>1O;20NE

T;20<ENERATON;20FACTOR@;20LA@O:TS)#$

htt#6//&&&)c.#a)!&u)!$u/8#n!%!t3%ills/O,ch5/O,Fac)ht%l

http://en.wikipedia.org/wiki/Plant_layout_study

http://pino.univalle.edu.co/~juanp77/ARTICULOS%20PLANTAS/ARTICULOS/GRUPO%2009%20-MONTA%D1O%20NEXT%20GENERATION%20FACTORY%20LAYOUTS.pdf



http://www.cbpa.ewu.edu/~pnemetzmills/OMch5/OMFac.html

http://www.cbpa.ewu.edu/~pnemetzmills/OMch5/OMFac.html




http://en.wikipedia.org/wiki/Plant_layout_study

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