Download - Facility Layout
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Facility LayoutFacility Layout
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Presented by
• Shashank Saxena • Shashi Minchel• Shikha Sinha• Shilpi Kanstiya• Shruti Agnihotri• Shruti Garg• Shuvam kaushik• Simayan Pati
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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, and – With the least amount of handling
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Objectives
• Provide enough production capacity• Reduce material handling cost• Reduce congestion impeding movement of men and
material• Reduce hazards to working personnel• Utilize labour efficiently• Increase employee morale• Utilize available floor space efficiently and
effectively
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• Reduce accidents• Provide for volume and product flexibility• Provide ease of supervision and maintenance• Facilitate co-ordination and face-to-face
communication• Provide for employee safety and health• Allow high machine utilisation• Improve productivity
Objectives
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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
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Basic Types of Layout
Product LayoutProcess or Functional LayoutFixed-position LayoutCell manufacturing/GTMixed /Combined Layouts
708/04/23
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Vvolume-variety characteristics
Low VOLUME HighH
igh
VA
RIE
TY
Lo
w
Fixedposition layout
Process layout
Cell layout
Product layout
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Product layout
• Machines arranged in a line depending upon sequence of operations
• Material moves in a line from the first machine to the finished product on the last machine.
• Investment higher as compared to process layout
Better suited for standardised products on a mass scale production. Ex chemicals,paper
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Product Layout
• Plant & machinery layout is designed to cater to continuous flow of Materials.
• The position and order in the sequence for a machine 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.
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FINISHED GOODS
MATERIAL FLOW
RAW MATERIALSPRODUCTION SUB-SYSTEM
RECEIVING
STORAGEOPERATION A
OPERATION B
OPERATION C
OPERATION D
SHIPPING
EDP CONTROL SYSTEMS
INFORMATION FLOWS
CONTINUOUS FLOW PRODUCTION SYSTEM (FLOW SHOP)
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Examples of product layout
• Assembly line for air-conditioner
• Car manufacturing unit
• Car washes and
• Canteen facilities
• Laundry.
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Important Considerations
All machines placed at points demanded by sequence of operation
No crossing over of one line with the otherMaterials may be fed where they are required for
assembly but not necessarily all at one pointAll operations including assembly, testing and packing
included in the line
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Classification and
marking of clothes
Washing Machine
DryerSteam press
StorageArea forPressed 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.
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AdvantagesEnsures 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 bottlenecksEconomy in manufacturing timeBetter production controlRequires less floor area per unit of productionWork-in-progress in reduced
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Disadvantages:
Inflexible & expensive layoutDifficulty in supervisionExpansion is difficultAny breakdown along the line can disrupt total
productionRequires heavy capital investment.
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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
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Functional or process layout
• Here machines performing same type of operations are installed at one place .i.e. plant is grouped according to functions e.g. all drilling machines are located at one place known as drilling section.
• This type of layout is most appropriate for intermittent (JOB and BATCH ) type of manufacturing systems where small qty’s of a large range of products are to be manufactured e.g. machine tools etc.
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Process Layout
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Process Layout - work travels to dedicated process centers
Milling
Assembly& Test Grinding
Drilling Plating
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INTERMITTENT FLOW PRODUCTION SYSTEM (JOB SHOP )
PRODUCTION SUB-SYSTEM
RECEIVING
STORAGE
OPERATION A OPERATION B
OPERATION COPERATION DSHIPPING
INFORMATION FLOWS
WIP
WIP WIP
WIP
FINISHED GOODS
EDP CONTROL SYSTEMS
RAW MATERIALS
MATERIAL FLOW
FINISHED GOODS
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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 or amusement centers are planned on this basis.
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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
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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 - 2Paint Shop
Side Entry
Main Entry
Work Shop Office Air
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.
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Advantages
Each production unit of the system works independently 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 doesn’t disrupt production.Lower capital investment. (Less duplication of machines).Better utilization of resourcesFull utilization of machinery
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Disadvantages
More material handling.Longer processing time:- as more time s required for material 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 in labour procurement.Production time increased because of extra travelAccumulation of work-in-process at different machines
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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.
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Fixed Position Layout
• The material remains in a fixed position , but the machinery, tool workmen etc are brought to the material
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AIRCRAFT ASSEMBLYFINISHED PRODUCT (AIRCRAFT)
RAW MATERIALS
MACHINE & EQUIPMENT
LABOUR
FIXED POSITION OR STATIC LAYOUT
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Fixed position layout
• Fixed-position layout is used for products, which are either very big in size (weight/volume) or very critical and 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 the product for execution of the work.
• Building of space shuttle, turbines, aircrafts and ship use fixed-position layout as it is not feasible to move these products due to their size or weight.
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Fixed Position Layout
• Employed in large project type organisation• Example• ISRO• Helicopter• Nuclear engg. Division of BHEL
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Advantages
• Men/machinery can be moved for a wide variety of 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
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Mixed layouts
Mixed layouts – pure basic layouts can be used in different departments in one organisation.
Example: A hospital would be arranged on process-layout principles. 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.
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Combined layout
• Combination of product & process layout with an emphasis on either
• Generally adopted in industry• In fabrication plants including assembly,
fabrication tends to employ process layout while assembly 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 on functional basis.
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F.P.
F.P.
G.C.
G.C.
G.C.
H.T.
H.T.
G.G.
G.G.
RAW MATERIAL
RAW MATERIAL
PR
OC
ES
S L
AY
OU
T
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
PRODUCT LAYOUT
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Combination layout
• In an industrial plant, it is difficult to confine to one type of layout only i.e. process or product layout.
• It becomes necessary to use process layout for some of the 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, grinding and mixing of the various raw-materials such as lime-stone, clay, bauxite and iron-ore.
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Combination layout
• Once the raw materials are prepared and converted into raw-meal by mixing different raw materials in predetermined proportion, production processes such as pre-heating, pre-calcining, calcinations for conversion of raw-meal into clinker and cooling of clinker would use product layout.
• Within the plant, workshop activities are arranged by using process layout, whereas the packing and dispatch operations of the cement through trucks need product layout.
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Combination layout
• If different modes of dispatches are adopted such as dispatch by rail (both by bags and bulk containers), sea (bags and bulk loading) or by road in trucks (bags) or in bulk containers, the dispatch operations would need process layout.
• In cases of repairs of kiln in a cement plant, which cannot be moved, a fixed layout is to be used.
• It is clear from the example of cement plant that a big plant needs application of all the three types of layouts for different applications or a combination of all the layouts for meeting the requirements of its total operations.
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ClayYard
BauxiteYard
Iron oreYard
Lime StoneYard
Raw Mill
ESP
Cyclone
Chimney
BlendingStorage cyclone
Inlet chamberOf kiln
Rotary kiln
Clinker cooler
Cement Mill
Combination layout – case of a cement plant
Process layout for a portion of Cement plant
Product layout for a portion of Cement plant
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Cellular manufacturing (cm) layout
• Grouping of machines into cells • Cells function somewhat like product layout
within a larger shop or process layout• Each cell in the cm formed to produce a single
part / a few parts– All with common characteristics which usually requires
similar machines and settings
• Flow of parts within the cell can take many forms
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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)
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CARAVAN, BATON and MIXED CELLS
Operator and product
move from station to
station
Operators are fixed but
products move from
station to station
Products move from station to station and
operators movebetween stations
CARAVAN CELLSBATON CELLS
MIXED CELLS
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1 2
3
45
1 2 3
1 2
34
21
CELL # 3
CELL # 4
CELL # 1 CELL # 2
PRODUCTION OPERATION PRODUCT OR MATERIAL FLOW
CELLULAR MANUFACTURING LAYOUT
PART D
PART Y
PART X
PART A
PART B
3
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-1111 -1111
2222 - 2222
Ass
emb
ly
3333 - 3333
4444 - 4444
Lathe
Lathe
Mill
Mill
Mill
Mill
Drill
Drill
Drill
Heat treat
Heat treat
Heat treat
Gear cut
Gear cut
Grind
Grind
Cellular Manufacturing Layout
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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
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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
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Cellular Layout- Examples
• Reliance industries- HDPE & LDPE
• Titan Industry
• ABB( Industrial fans & blowers)
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CM layout limitations
• 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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Service facility layout
• Main difference between service and manufacturing facility is to bring together customers & services in many 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
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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 LOUNGE
CAFETERIA
CASUALTY DEPT / INPATIENT DEPT
ENTRANCE EXIT
CASUALTY DEPT / INPATIENT DEPT
ENTRANCEEXIT
AIS
LE
S /
GA
NG
WA
YS
PA
RK
ING
AR
EA
PA
RK
ING
AR
EA
SERVICE FACILITY LAYOUT ( HOSPITAL LAYOUT )
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• 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 AS REDUCE 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
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• 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
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SERVICE WAITING LINE MODULES
SINGLE CHANNEL, SINGLE PHASE MODULE
WAITING LINE SERVICE FACILITY
MULTIPLE CHANNEL, SINGLE PHASE MODULE
SERVICE FACILITY
WAITING LINE
SINGLE CHANNEL, MULTIPLE PHASE MODULE
WAITING LINE SERVICE FACILITY
SERVICE FACILITY
WAITING LINE
MULTIPLE CHANNEL, MULTIPLE PHASE MODULE
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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 facilities
technique)
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Thank YouThank You