6-classification of layout and mhs- 160811

7/29/2019 6-Classification of Layout and Mhs- 160811

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CLASSIFICATION OF LAYOUTLayouts can be classified into the following five categories:

1. Process layout

2. Product layout

3. Combination layout4. Fixed position layout

5. Group layout

PROCESS LAYOUT:-

Process layout is recommended for batch production. All machines performing similar type of

operations are grouped at one location in the process layout e.g., all lathes, milling machines,

etc. are grouped in the shop will be clustered in like groups. Thus, in process layout the

arrangement of facilities are grouped together according to their functions. The flow paths vary

from product to product. paths are long and there will be possibility of backtracking.

Advantages

machines are better utilized and fewer machines are required.

Flexibility of equipment , personnel , work distribution

Lower investment (less number of machines and lower cost of general purpose machines)

Higher utilisation of production facilities.

Expert Supervisors

Limitations

Backtracking and long movements

Material handling cannot be mechanised which adds to cost.

Lowered productivity due to number of set-ups.

Throughput (time gap between in and out in the process) time is longer.

Space and capital are tied up by work-in-process.

PRODUCT LAYOUT

machines and auxiliary services are located according to the processing sequence of the

product. Special purpose machines are used which perform the required function quickly and

reliably. The product layout is selected when the volume of production of a product is high such

that a separate production line to manufacture it can be justified.

Advantages

The flow of product will be smooth and logical in flow lines.

In-process inventory, Throughput time is less.


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Minimum material handling cost.

Reduced material handling cost due to mechanised handling systems and straight flow.

Perfect line balancing which eliminates bottlenecks and idle capacity.

Manufacturing cycle is short due to uninterrupted flow of materials.

Small amount of work-in-process inventory.

Unskilled workers can learn and manage the production.Limitations

A breakdown of one machine in a product line may cause stoppages of machines in the

downstream of the line.

A change in product design may require major alterations in the layout.

The line output is decided by the bottleneck machine.

Comparatively high investment in equipments is required.

Lack of flexibility. A change in product may require the facility modification.

COMBINATION LAYOUT

A combination of process and product layouts combines the advantages of both types of

layouts. A combination layout is possible where an item is being made in different types and

sizes. Here machinery is arranged in a process layout but the process grouping is then arranged

in a sequence to manufacture various types and sizes of products.

FIXED POSITION LAYOUT

This is also called the project type of layout. In this type of layout, the material, or major

components remain in a fixed location and tools, machinery, men and other materials are

brought to this location.


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Advantages and disadvantages

Least movement of material

Maximum flexibility

Number of projects can be taken with same layout

Low utilization of labour and equipment

High equipment handling cost

GROUP LAYOUT (OR CELLULAR LAYOUT)

Group technology (GT) is the analysis and comparisons of items to group them into families

with similar characteristics. GT can be used to develop a hybrid between pure process layout

and pure flow line (product) layout. This technique is very useful for companies that produce

variety of parts in small batches . first step is to determine component families or groups,

second step is to arrange the plants equipment used to process a particular family of

components. It reduces production planning time for jobs, reduces the set-up time.

Thus group layout is a combination of the product layout and process layout. It combines the

advantages of both layout systems. The basic aim of a group technology layout is to identify

families of components that require similar of satisfying all the requirements of the machinesare grouped into cells


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Group Technology layout can increase

Component standardization and rationalization.

Reliability of estimates.

Effective machine operation and productivity.

Customer service.

It can decrease thePaper work and overall production time.

Work-in-progress and work movement.

Overall cost.

Limitations of Group Technology Layout

This type of layout may not be feasible for all situations. If the product mix is completely

dissimilar, then we may not have meaningful cell formation.

MATERIAL HANDLING

Definition:-

Material handling embraces the basic operations in connection with the movement of bulk,

packaged and individual products in a semi-solid or solid state by means of gravity manually or

power-actuated equipment and within the limits of individual producing, fabricating, processing

or service establishment

the function dealing with the preparation,placing and positioning of materials to facilitate their

movement or storage.

It does not add any value to the product but adds to the cost of the product

Out of the total time spent for manufacturing a product,20% of the time is utilised for actual

processing on them while the remaining 80% of the time is spent in moving from one place to

another, waiting for the processing.It is the art and science involving the movement, handling and storage of materials during

different stages of manufacturing.

Objectives of material handling

Following are the objectives of material handling:

1. Minimise cost of material handling.

2. Minimise delays and interruptions by making available the materials at the point of use

at right quantity and at right time.

3. Increase the productive capacity of the production facilities by effective utilisation of

capacity and enhancing productivity.

4. Safety in material handling through improvement in working condition.

5. Maximum utilisation of material handling equipment.

6. Prevention of damages to materials.

7. Lower investment in process inventory.

6-classification of layout and mhs- 160811

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