Facility layout

Delivered By: Tanuj kumar sharma B - 42

Facility LayoutMeaning :Arrangement of – Machinery Equipment Other industrial facilities Achieving Quick production at least cost

• Facility layout and design is an important component of a business's overall operations, both in terms of maximizing the effectiveness of the production process and meeting the needs of employees. • The basic objective of layout is to ensure a smooth flow of work, material, and information through a system. • The basic meaning of facility is the space in which a business's activities take place. The layout and design of that space impact greatly how the work is done—the flow of work, materials, and information through the system.

Objective of Facility layout - Material handling costs.- Production capacity- labour efficiency- Employee morale- Space utilization- Ease of Supervision and Maintenance

There are 3 basic types of layouts:-processproductfixed - position

Process layout

also known as functional layoutsdefinition: a layout that groups similar

activities together in departments of work centers according to the process or function that they perform characteristic of operations that serve different customers different needs.

Advantages of process layouts include:-Flexibility:- The firm has the ability to handle a variety of processing requirements.

Cost:-_ Sometimes, the general-purpose equipment utilized may be less costly to purchase and less costly and easier to maintain than specialized equipment.

Motivation:- Employees in this type of layout will probably be able to perform a variety of tasks on multiple machines, as opposed to the boredom of performing a repetitive task on an assembly line. A process layout also allows the employer to use some type of individual incentive system.

System protection:- Since there are multiple machines available, process layouts are not particularly vulnerable to equipment failures.

Product layouts

also known as assembly linedefinition: Product layouts arrange

activities in a line according to the sequence of operations that need to be performed to assemble a particular product.

Advantages of product layouts include:

Output:- Product layouts can generate a large volume of products in a short time.

Cost:- Unit cost is low as a result of the high volume. Labor specialization results in reduced training time and cost. Accounting, purchasing, and inventory control are routine. Because routing is fixed, less attention is required.

Utilization:- There is a high degree of labor and equipment utilization.

Process vs. Product Layouts Here are the characteristic differences

between a process and product layout.

Fixed-Position Layout

definition: Fixed-Position layouts are layouts are used in projects in which the product is too fragile, bulky, or heavy to move.

examples: ships, houses, aircraftThe workers on such job sites are highly

skilled at performing the special tasks that they are requested to do.

In such a process the fixed costs would be low and variable costs would be high.

Requirements for effective layout

Minimize material handling costs.Utilize space efficiently.Utilize labor efficiently.Facilitate communication and interaction between

workers, between workers and their supervisors, or between workers and customers.

Reduce manufacturing cycle time and customer service time.

Eliminate wasted or redundant movement.Provide a visual control of operations or activities.Provide flexibility to adapt to changing conditions.

CASE STUDY PepsiCo Since the creation of its iconic Pepsi-Cola soft drink in

1898, PepsiCo has grown into a global consumer products leader offering a vast portfolio of food and beverage brands. One of its divisions, Pepsi Beverages Company (PBC), manufactures, sells, and distributes some of the company’s most recognized beverages – including Pepsi, SoBe, Gatorade, and Mountain Dew – in the United States, Canada, and Mexico.

As part of consolidation strategies, the company decided to relocate a beverage filling line from an Oklahoma facility to an existing 50,000 square foot facility in Dallas where it was currently operating three other filling lines for the Gatorade and SoBe beverage brands.

Challenge Configure Existing Facility Layout to Include

New Bottling LinePepsi did not want to relocate any of the original

platforms that were around the existing line. “We wanted to put this new line in a completely different configuration,” said Ken Graham, project lead and senior principal engineer for PBC.

Because safety is first in everything they do, PepsiCo needed to make sure the platform design would meet OSHA’s safe work standards. The platforms would be supporting conveyor and other equipment over an open product zone, so they also had to make sure the platforms met – and exceeded – all of the company’s strict food grade standards.

SolutionTo aid in this effort, Graham and his team chose

Cubic Designs to design, manufacture and install these new 18 foot tall food grade platforms that would span a total of about 4,000 square feet between two separate areas of the filling line.

The platform’s structures had to be made of galvanized steel to keep them corrosion resistant. “The hot-fill process involves pasteurizing the product, resulting in a very humid atmosphere, “ explains Graham. Along the edges of the platform, a 4-inch and 6-inch kick plate prevents particles from falling down onto the open bottle area on the bottom level.

ResultsFabrication of the structure took about 6 to 8

weeks to complete. Installation was even quicker than regular, non-food grade platforms. “Cubic Designs uses a pre-built structure, which they design in their plant, and then just bolt together at the customer’s site,” says Graham. “This greatly reduces the amount of metal fabrication, metal shavings, etc. on the production floor. This also allows for quicker assembly and less down time needed for installation.” A few months later, Pepsi hired an independent auditor to inspect the new line (including the new platforms). They received very favorable comments and a passing grade.

REFERNCES:- http://www.connstep.org/continuous-improve

ment/http://www.inc.com/encyclopedia/facility-layo

ut-and-design_pagen_2.htmlhttp://nptel.ac.in/courses/112107142/part2/fa

cility%20designhttp://mdcegypt.com/pages/operation%20ma

nagement/production%20and%20operation%20management/facility%20layout.asp

http://www.cubicdesigns.com/case-studies/pepsi