Production Facilities & plant Production Facilities & plant layout with various types of layout with various types of

plant layoutplant layout

CONTENTSCONTENTS Various production facilities.Various production facilities. Meaning of Plant Layout.Meaning of Plant Layout. Features Of plant Layout.Features Of plant Layout. Merits of plant Layout.Merits of plant Layout. Objectives of plant Layout.Objectives of plant Layout. Principles of plant Layout.Principles of plant Layout. Importance of plant Layout..Importance of plant Layout.. Types of plant Layout.Types of plant Layout. Revision of plant Layout.Revision of plant Layout. Tools and techniques of plant Layout.Tools and techniques of plant Layout. Industrial visit of Ayurchem.Industrial visit of Ayurchem. Summary.Summary.

Various Production FacilitiesVarious Production Facilities

1.1. Material Material

2.2. Product Product

3.3. Worker Worker

4.4. MachineryMachinery

5.5. Type of IndustryType of Industry

6.6. LocationLocation

7.7. Managerial PolicyManagerial Policy

Meaning of Plant LayoutMeaning of Plant Layout

A plant layout refers to the arrangement of A plant layout refers to the arrangement of machinery, equipment and other industrial facilitiesmachinery, equipment and other industrial facilities ..

A plant layout involves:A plant layout involves:(1) Planning and arranging manufacturing (1) Planning and arranging manufacturing

machinery, equipment, and services for the first machinery, equipment, and services for the first time in completely new plants.time in completely new plants.

(2) The improvements in layouts already in use in (2) The improvements in layouts already in use in order to introduce new methods and order to introduce new methods and improvements in manufacturing procedures.improvements in manufacturing procedures.

Features of Plant LayoutFeatures of Plant Layout

It ensure smooth and continuous flow of It ensure smooth and continuous flow of production production

adequate safety and security adequate safety and security Sufficient gangway space for materials Sufficient gangway space for materials Stores should be at convenient placeStores should be at convenient placeArrangement of machines and equipments Arrangement of machines and equipments

Merits of Plant Layout Merits of Plant Layout

To the worker To the worker

In manufacturing Costs In manufacturing Costs

In production control and supervision.In production control and supervision.

Objectives of a Good LayoutObjectives of a Good Layout

1.Provide enough production capacity.1.Provide enough production capacity.2. Reduce material handling costs.2. Reduce material handling costs.3. Reduce congestion-that impedes the movement 3. Reduce congestion-that impedes the movement

of people or material.of people or material.4. Reduce hazards to personnel.4. Reduce hazards to personnel.5. Utilize labour efficiently.5. Utilize labour efficiently.6. Increase employee morale.6. Increase employee morale.7. Reduce accidents.7. Reduce accidents.8. Utilize available space efficiently and effectively.8. Utilize available space efficiently and effectively.9. Provide for volume and product flexibility 9. Provide for volume and product flexibility

Principles of LayoutPrinciples of Layout

Minimum Travel Minimum Travel Compactness Compactness Safety and Safety and

SatisfactionSatisfaction Flexibility Flexibility

Sequence Sequence Usage Usage Minimum investment Minimum investment

Importance of LayoutImportance of Layout

Avoidance of Avoidance of Bottlenecks Bottlenecks

Better Production Better Production Control Control

Better Supervision Better Supervision Improved Utilisation Improved Utilisation

of Labour of Labour Improved Employee Improved Employee

Morale Morale

Economies in Economies in Handling Handling

Effective Use of Effective Use of Available AreaAvailable Area

Minimisation of Minimisation of Production Delays Production Delays

Improved Quality Improved Quality Control Control

Minimum Equipment Minimum Equipment Investment Investment

Types of Plant LayoutTypes of Plant Layout

Process LayoutProcess Layout Product LayoutProduct LayoutFixed Position LayoutFixed Position Layout Cellular Manufacturing (Cellular Manufacturing (CMCM) Layout) Layout CombinedCombined Layout LayoutServiceService Facility Layout Facility Layout

Revision of Layout Revision of Layout

(i) Expansion; (i) Expansion; (ii) Technological advancements and (ii) Technological advancements and (iii) Improvement in the layout. (iii) Improvement in the layout.

TOOLS AND TECHNIQUES FOR TOOLS AND TECHNIQUES FOR LAYOUT ANALYSISLAYOUT ANALYSIS

(a) Process Charts (a) Process Charts (b) Diagrams (b) Diagrams (c) Travel Chart (c) Travel Chart (d) REL Chart (d) REL Chart (e) Templates (e) Templates (f)) (f)) Scale Models Scale Models

Ayurchem Industrial VisitAyurchem Industrial Visit

Manufacturing Manufacturing processprocess

Extraction ProcessExtraction Process Separation processSeparation process Chemical LabChemical Lab

Converting the liquid Converting the liquid into solid materialinto solid material

Storage facilitiesStorage facilities Packing departmentPacking department

SUMMARYSUMMARY

When a new plant is erected, the question of the placement of When a new plant is erected, the question of the placement of machinery at different places, the location of stores, machinery at different places, the location of stores, inspection cabins, tool rooms, maintenance wings, plating inspection cabins, tool rooms, maintenance wings, plating shops, heat treatment chambers, toilets canteens, and shops, heat treatment chambers, toilets canteens, and trolleys, cranes and other handling equipments and the like, trolleys, cranes and other handling equipments and the like, receive a priority consideration. This is so because the receive a priority consideration. This is so because the efficiency of the production flow depends, largely on how well efficiency of the production flow depends, largely on how well the various machines, production facilities and employee the various machines, production facilities and employee amenities are located in a plant. In a properly laid out plant, amenities are located in a plant. In a properly laid out plant, the movement of materials, from the raw material stage to the the movement of materials, from the raw material stage to the end product stage, is smooth and rapid; the movement is end product stage, is smooth and rapid; the movement is generally in a forward direction: the materials do not criss-generally in a forward direction: the materials do not criss-cross, or go backward and forward for further operations. cross, or go backward and forward for further operations. Moreover, production bottlenecks delays are few, and Moreover, production bottlenecks delays are few, and materials handling costs are reduced, Such arrangements materials handling costs are reduced, Such arrangements constitute the subject matter of a plant layout.constitute the subject matter of a plant layout.

Cell Manufacturing LayoutCell Manufacturing Layout

Combined LayoutCombined Layout

Service LayoutService Layout