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PLANT LAYOUT & MATERIAL HANDLING

Submitted byK.N.Jakanathan

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Definition Layout is a Fundamental of every organization and enterprise.

“Plant layout involves the development of physical relationships among building equipment and production operations which will enable the manufacturing process to be carried on efficiently”

- Morris

Plant Layout - placement of departments, placement of workgroups within departments,

placement of workstations,

placement of machines,

placement of stock-holding points

All within a facility

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Objectives Proper and efficient utilization of cubic (i.e. length, width and height)

of available floor space. To ensure that work proceeds from one point to another without any

delay. Provide enough production capacity. Reduce material handling costs. Reduce hazards to personnel. Utilize labor efficiently. Increase employee morale. Eliminate conjugation and bottle neck at work. Provide for volume and product flexibility. Provide ease of supervision and control. Provide for employee safety and health. [ Reduce accidents ] Allow ease of maintenance. Allow high machine or equipment utilization. Improve productivity. Reduce Capital Investment.

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Factors Influencing Layout Nature of product. Production process. [Including Waiting Time] Type of machinery. Repairs and maintenance. Human needs. Plant environment. Materials. Material Handling Equipments. Auxiliary Services. Future Changes. Factory building.

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Product Flow

P&Q Analysis - Input data and Activities

Activity relationships

Chart relationship (flow, functional)

Establish space requirements

Space Availability

Space relationships - Diagram

Practical Limitations

Material Handling

Project Project ProjectA B

C Evaluate alternative arrangements

Detail selected layout

INSTALLATION

Definition

Analysis

Synthesis

Evaluation

Selection

Implementation

Adjustment

Systematic Layout Design Process Method - Muther (1973)

MaintenanceQ&C

Mat. Handling

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Types of Layout

Manufacturing units

► Product or line layout

► Process or functional layout

► Fixed position or location layout

► Combined layout

► Fixed Layout

►Cellular (or) Group Technology Layout

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Product oriented Plant Layout (Line Layout) Machinery and Materials are placed following the

product path. This type of plant layout is useful when the production

process is organized in a continuous or repetitive way. Continuous flow: The correct operations flow is

reached through the layout design and the equipment and machinery specifications.

Repetitive flow (assembly line): The correct operations flow will be based in a line balancing exercise, in order to avoid problems generated by bottle necks.

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The plant layout will be based in allocating a machine as close as possible to the next one in line, in the correct sequence to manufacture the product.

Allocating line may be of any form, like straight line L shape

U shaped S shaped

Cont.,

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Factory Product layout

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Product layout Product oriented plant layout

Advantages: Economy material handling activities. Mechanization of material handling equipments. Work In Process almost eliminated. Minimum manufacturing time. Simplification of the production planning and control systems. Tasks simplification. Greater incentive for group.

Disadvantages: No flexibility in the production process Low flexibility in the manufacturing times. High capital investment. Difficulty of supervising, since the person is expert in only one function. Every workstation is critical to the process.- The lack of personnel or shut

down of a machine stops the whole process. Monotonous work. Difficulty in expansion.

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Process oriented plant layout (Functional Layout) This type of plant layout is useful when the production process is

organized in batches. Personnel and equipment to perform the same function are

allocated in the same area. The different items have to move from one area to another one,

according to the sequence of operations previously established. The variety of products to produce will lead to a diversity of flows

through the facility. The variations in the production volumes from one period to the next

one (short periods of time) may lead to modifications in the manufactured quantities as well as the types of products to be produced.

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Factory Process layout

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Process Layout Process oriented plant layout

Advantages: Flexibility in the production process. Better control of manufacturing cost. No Duplication. Easy to handle the problems. Better Supervising. [Experts will be there in each department] Higher Individual incentive.

Disadvantages: Manufacturing time increases. Controlling will be costly and complex. Material handling cost will be higher. More workspace required. Accumulation of work-in process.

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Fixed Layout In Fixed product layout, the products generally circulate

within the production facilities (machines, workers, etc.); in this particular type of layout, the product does not move, the different resources are moved to perform the operations on the product.

This type of layout is commonly found in industries that manufacture large size products, such as ships or aircrafts.

The equipment is brought to the object being processed, and the object does not move. Example: Air craft manufacturing.

Arranging materials and equipment concentrically around the production point in their order of use.

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Factory Fixed Layout

Raw MaterialRaw Material

Machine & Equipment Machine & Equipment

LabourLabour

Finished product

AIRCRAFT

Finished product

AIRCRAFT

AIR CRAFT ASSEMBLY AIR CRAFT ASSEMBLY

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Fixed Layout

Advantages of stationery Layout: Layout is fully flexible and is capable of absorbing any sort of

change in product and process. Lower labor cost [People are drawn from functional departments] Saving in time Less floor space because machines and equipment are in

moving position. Most suitable way of assembling large and heavy products.

Disadvantages Of Stationery Layout: Higher capital investment Unsuitability for manufacturing or assembling small products in

large quantities. It is suitable only in case where the product is big or the assembling process is complex.

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Combined Layout or Mixed Layout Manufacturing concerns where several products

are produced in repeated numbers with no likelihood of continuous production , combined layout is followed.

Generally, a combination of the product and process layout or other combination are found, in practice, e.g. for industries involving the fabrication of parts and assembly, fabrication tends to employ the process layout, while the assembly areas often employ the product layout.

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Factory Combined Layout

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11

11

22

22

22 44

44

44Combined

Combined

Milling Milling Grinding Grinding

3 3

Painting Painting Packing Packing

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P-Q Analysis

ProductLayouts

FixedPositionLayouts Mixed Layouts Process Layouts

Quantity

Number of different products

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CELLULAR OR GROUP TECHNOLOGY LAYOUT Work cells

Definition: Group of equipment and workers that perform a sequence of

operations over multiple units of an item or family of items. Looks for the advantages of product and process

layouts: Product oriented layout: Efficiency Process oriented layout: Flexibility

Group Technology Grouping outputs with the same characteristics to families, and

assigning groups of machines and workers for the production of each family.

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CELLULAR OR GROUP TECHNOLOGY LAYOUT In a cellular layout the design is not according to

the functional characteristics of equipment, but rather by self-contained groups of equipment (called cells), needed for producing a particular set of goods or services.

Group technology, or cellular manufacturing, classifies parts into families so that efficient mass-production-type layouts can be designed for the families of goods or services.

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Cellular Layout

Process (Functional) Layout

Process (Functional) Layout Group (Cellular) LayoutGroup (Cellular) Layout

Similar resources placed together

Resources to produce similar products placed together

T T T

MM M T

M

SG CG CG

SG

D D D

D

T T T CG CG

T T T SG SG

M M D D D

M M D D D

A cluster or cell

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CL or GT: BENEFITS

Advantages Lower work-in-process Inventories Reduced material handling costs. Shorter flow times in production. Simplified production planning. (MEN, MATERIAL ETC.) Overall performance increased by lowering production

costs & improving on time delivery. Improved Quality.Disadvantages Reduced manufacturing flexibility & potentially increased

machine downtime. Duplicate pieces of machinery may be needed so as to

avoid movement of parts between cells.

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Break Even Analysis

Fixe

d

layo

utFi

xed

layo

ut

Proce

ss

LayoutPro

cess

LayoutCell or GT

layoutCell or GT

layout

Product layoutProduct layout

costs

costs

Volume VolumeUse fixed positionUse fixed position

Use processUse process

Use cell or GT

Use cell or GT

Use productUse product

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EXAMPLE OF SYSTEMATIC LAYOUT PLANNING: REASONS FOR CLOSENESS

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Code

1

2

3

4

5

6

Reason

Type of customer

Ease of supervision

Common personnel

Contact necessary

Share same price

Psychology

Justification Code

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EXAMPLE OF SYSTEMATIC LAYOUT PLANNING: IMPORTANCE OF

CLOSENESS

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Value

A

E

I

O

U

X

ClosenessLinecode

Numericalweights

Absolutely necessary

Especially important

Important

Ordinary closeness OK

Unimportant

Undesirable

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8

4

2

0

80

Priority code

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EXAMPLE OF SYSTEMATIC LAYOUT PLANNING:

RELATING REASONS AND IMPORTANCE

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From

1. Credit department

2. Saree department

3. Wine department

4. Camera department

5. jewelry department

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A

--

U

4

I

6

A

--

U

1

I

1,6

A

--

U

1

X

1

X

To2 3 4 5

Area(sq. ft.)

100

400

300

100

100

Closeness rating

Reason for rating

Note here that the (1) Credit Dept. and (2) Saree Dept. are given a high rating .

Note here that the (1) Credit Dept. and (2) Saree Dept. are given a high rating .Letter

Number

Note here that the (2) Saree Dept. and the (5) Jwellry Dept. are given a high rating of A.

Note here that the (2) Saree Dept. and the (5) Jwellry Dept. are given a high rating of A.

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EXAMPLE OF SYSTEMATIC LAYOUT PLANNING:

INITIAL RELATIONSHIP DIAGRAM

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1

2

4

3

5

U U

E

A

I

The number of lines here represent paths required to be taken in transactions between the departments. The more lines, the more the interaction between departments.

The number of lines here represent paths required to be taken in transactions between the departments. The more lines, the more the interaction between departments.

Note here again, Depts. (1) and (4) are linked together, and Depts. (2) and (5) are linked together by multiple lines or required transactions.

Note here again, Depts. (1) and (4) are linked together, and Depts. (2) and (5) are linked together by multiple lines or required transactions.

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EXAMPLE OF SYSTEMATIC LAYOUT PLANNING:

INITIAL AND FINAL LAYOUTS

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1

2 4

3

5

Initial Layout

Ignoring space andbuilding constraints

2

5 1 43

50 ft

20 ft

Final Layout

Adjusted by squarefootage and buildingsize

Note in the Final Layout that Depts. (1) and (5) are both not placed directly next to Dept. (2).

Note in the Final Layout that Depts. (1) and (5) are both not placed directly next to Dept. (2).

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Re-layout

A good plant layout involves not only the designing and installing of the layout for the

first time but also revision of existing layout. The best layout becomes obsolete over a

period of time.

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Reasons for Re-Layout Product Design Change. New Product Production. Changes in volume of demand. Facilities become obsolete. Rearranging the department within the factory. Consideration of safety. Change in location of market. Poor worker environment. Cost reduction. Technology Advancement. Improvement in layout technology.

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Plant location’s influence Plant layout Location may affect make/buy decisions. Location near the source. Location near the transport facilities. Easy Power supply. Cheap labour. Climate. Waste disposal facility.

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Material handling systems

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As the science is getting developed new modern equipments are getting introduced in material handling area.

It is accelerating the activity of loading and unloading. These equipments are used for the movement of material over a short distance.

The bulk handling of the material takes place in shipyards, ports, airports etc.

Role of material handling in logisticsRole of material handling in logistics

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Unloading the incoming material from transport

vehicle. Moving the unloaded material to assigned

storage places in warehouses. Lifting the material from the storage place

during order picking. Moving the material for inspection & packing. Loading the boxes on transport vehicle.

Material handling Operation stepsMaterial handling Operation steps

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Designing the system for continuous flow of material.

No idle time. Going in for the standard equipments – it

reduces the cost. If possible use gravitational force. continuous material movement is most

economical

Material Handling EfficiencyMaterial Handling Efficiency

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Volume of operations. Speed of handling. Productivity. Nature of product. Size, shape, weight of the product. Nature of equipment.

Selecting Material handling EquipmentSelecting Material handling Equipment

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Commonly used equipments in industry – Lift Fixed Path Conveyors Wheeled trolley Variable Path Forklift truck. Overhead cranes

Auxiliary Rigging, Clamps

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Wheeled trolley – two wheeled and four wheeled trolleys are used for transferring boxes from one place to another place within the organization. Trolleys have wide range of sizes and shapes. Organizations decide as per their requirement.

Overhead cranes - these are used for movement of heavy items but for a shorter distances. The movement is controlled by a person having controls in his hand. Many times it is a computerized activity. These cranes are installed on the fixed girders near the ceiling.

Variable pathVariable path

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Wheeled Trolley Wheeled Trolley Overhead Crane inside the factoryOverhead Crane inside the factory

Overhead cranes outside the factoryOverhead cranes outside the factory

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Forklift truck – this is highly useful in material handling activity. It got invented after II world war. The main advantages are,

Movement of larger loads over a longer distance. Moving the load vertically also. Movement of loads vertically and horizontally,

exactly positioning for loading and unloading operations.

It can transfer the load in any direction.

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Fixed Path

Conveyors – these are used where continuous flow of material is essential. It is used in mass production activity on production shop floor also. conveyors are widely used in automated warehouses in big retail shops.

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Wheel conveyors – the small wheels made out of steel or plastic bearing. The load is kept on the bearings and either pushed or gravitational force is utilized for the forward movement of the material.

Roller conveyor – these are mainly used in docks for faster unloading of the goods. They are like wheel conveyors but powered rollers are used.

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Belt conveyor – these are commonly used for material movement. It is used in mass production activity.

Chain conveyor – this is mainly used for movement of heavy material. It is used in mass production activity also. Pallets are kept on the chain and stoppers are provided for carrying out the production related work.

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Wheel ConveyorWheel Conveyor Belt Conveyor Belt Conveyor

Chain ConveyorChain Conveyor Roller ConveyorRoller Conveyor

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• LIFT These are used to lift the heavy materials vertically. It is

useful to lift to upper floor.

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Clamps

These are used for mainly clamping and picking the material in large volumes. It can have more number of trailers.

eg. Clip, metal mesh, Hooks, rings, oblong links.

Riggings

These are used for picking and placing the materials. It is lengthy depends on use.

eg. Chains, ropes, wires.

Auxiliary Auxiliary

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Riggings,Clamps,Chains,oblong links Riggings,Clamps,Chains,oblong links

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Factors influencing material handling equipments Required path of travel (fixed or variable) Nature of the material. Physical characteristics of the building. Space requirement of handling equipment. Required handling capacity. Cost consideration.

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Relation between plant layout and Material Handling

Close relation between plant layout and Material Handling. Material Handling methods influence the layout and factory

building. Material Handling is to be considered as an integral part of plant

layout to design low cost handling system. Good Material Handling is resulted based on the arrangement of

production equipment, location of departments, logical sequence of operations, location of stores, tools.

Material Handling system/equipment can be selected only after the appropriate floor plan.

Plant layout considers the points for material receiving and shipping of products

Careful arrangement of work centers and storage areas Consider horizontal or vertical material transportation

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Thank you… Thank you…