Plant Layout

Objectives of Facility Layout
1. OBJECTIVES FOR MANUFACTURING OPERATIONS LAYOUTS:

Provide enough production capacity.
Reduce materials handling costs.
Plant Layout
Conform to site and building constraints.

Allow space for production machines.
Allow high labour, machine and space utilization and
productivity.
Provide for volume and product flexibility.
Provide for employee safety and health.
Allow ease of supervision.
Allow ease of maintenance.
Achieve objectives with least capital investment.
DR A K SHARMA, IITR
DR A K SHARMA, IITR
2. (Addl.) OBJECTIVES FOR WAREHOUSE OPERATIONS LAYOUTS:
3. (Addl.) OBJECTIVES FOR SERVICE OPERATIONS LAYOUTS:
Promote efficient loading and unloading of shipping vehicles.
Provide for customer comfort and convenience.
Provide for effective stock picking, order filling, and unit

loading.
Provide appealing setting for customers.
Allow ease of inventory counts.

Promote accurate inventory record keeping.
Allow attractive display of merchandise.

Reduce travel of personnel or customers.
Provide for privacy in work areas.
Promote communication between work areas.
Provide for stock rotation for shelf life.
DR A K SHARMA, IITR
DR A K SHARMA, IITR
Principles of Plant Layout
4. (Addl.) OBJECTIVES FOR OFFICE OPERATIONS LAYOUTS:

Reinforce organisation structure.
Reduce travel of personnel or customers.
Provide for privacy in work areas.
Promote communication between work areas.
1. PRICIPLE OF OVERALL INTEGRATION:

That layout is the best which integrates the men, materials,
machinery, supporting activities, and any other considerations
in a way that results in the best compromise.
2. PRICIPLE OF MINIMUM DISTANCE MOVED:
Other things being equal, that layout is the best that permits
the material to move the minimum distance between
operations.
DR A K SHARMA, IITR
3. PRICIPLE OF FLOW:
DR A K SHARMA, IITR
5. PRICIPLE OF SATISFACTION AND SAFETY:
Other things being equal, that layout is the best that arranges
the work area for each operation or process in the same order
or sequence that forms, treats, or assembles the materials.
Other things being equal, that layout is the best which makes
work satisfying and safe for workers.
6. PRICIPLE OF FLEXIBILITY:
4. PRICIPLE OF CUBIC SPACE:

Economy is obtained by using effectively all available space
both vertical and horizontal.
DR A K SHARMA, IITR
Other things being equal, that layout is the best that can be
adjusted and rearranged at minimum cost and inconvenience.
DR A K SHARMA, IITR
Factors Influencing Plant Layout
Factors influencing any layout can be grouped into the following:
1. The Material Factor:
4. The Movement Factor:
Design,
Variety,
Quantity,
The necessary operations and their sequence.
Inter and Intradepartmental transport,

Hand handling at various operations, storages, and
Inspections.
5. The Waiting Factor:

2. The Machinery Factor:
Permanent and temporary storages, and

Delays.
Production equipment and tools,

Their utilisation.
6. The Service Factor:

3. The Man Factor:
Maintenance,
Inspection,
Waste,
Scheduling, and
Despatching.
Supervision,
Service help,
Direct workers.
DR A K SHARMA, IITR
DR A K SHARMA, IITR

Relation of Quality to Type of Layout:

Type of Layout
7. The Building Factor:

Outside and Inside building features,
Utility distribution, and
Equipment.
Hard to pin down quality responsibility.

Bad work will interrupt continuity and starve subsequent operations.
Inspection of tools and gauges before production is far more
important.
Less skilled workers, but fewer errors because of standardized work
and job specialization.
Decentralized inspection with inspectors holding the rate of
production pace.
Process
Interdependental inspection and friction over quality.

Good responsibilities for centralised or semicentralised inspection.
First piece and setup inspection, and floor inspection during runs are
usual.
Fixed position
Quality is fixed responsibility of individual workers.

More skilled workers requiring fewer inspections.
8. The Change Factor:

Versatility,
Flexibility, and
Expansion.
DR A K SHARMA, IITR
Relation to Quality
Product or Line
DR A K SHARMA, IITR
Layout Design
Major Steps in Layout Design
Phases in Layout design:

Facility layout design consists of three major phases:
Phase I:
Arrangement of various departments and offices basically based
on the adjacency of various departments and offices with respect
to each other.
Phase II:
Arrangement of various equipment, machinery, supporting
services, material-handling devices, work centers etc. within a
particular department.
1. Statement of the problem
Objectives,
Scopes.
2. Collection of basic data on
sales forecast,
production volume,
production schedules,
part lists,
operations to be performed etc.
3. Calculation of production rate and equipment requirements

4. Data analysis and its presentation in the form of various charts .
5. Calculations of space requirements and allocation of areas
Phase III:
Implementation of the layout developed in phases one and two.
DR A K SHARMA, IITR

Collection of Data
6. Development of block plan, plot plan, and detailed layout.

7. Evaluation, selection, and installation of layout.
DR A K SHARMA, IITR

Equipment Requirements
SQ
F = -------------EHR
where,
F = Pieces of equipment required per shift
S = Standard time (minutes) per unit produced
Q = Number of units to be produced per shift
E = Actual performance expressed as % of standard time
H = Amount of time (minutes) available per machine
R = Reliability of machine in %.
DR A K SHARMA, IITR
DR A K SHARMA, IITR

Data Presentation Techniques
Manpower Requirements
Five Major Flow Patterns:
SQ
M = -----------H
where,
M = Number of persons required per shift
S = Standard time (minutes) per unit produced
Q = Number of units to be produced per shift
H = Amount of time (minutes) available per shift
DR A K SHARMA, IITR
Flow Process Chart
This chart summarizes the flow and activity of a component

through a procedure in terms of sequence of operation,
transportation, inspection, delay and storage.
It includes information about time required and distance

moved.
Information are obtained from the process design department

in the form of a route sheet.
A separate route sheet is required for each part. Flow process

charts are used for high volume products.
Various symbols are used as an aid in developing a flow

process chart.
DR A K SHARMA, IITR
DR A K SHARMA, IITR
Route Sheet
DR A K SHARMA, IITR

Data Presentation Techniques
Multi-product Process Chart
Multi-product process chart is used when a large variety of

items are produced (normally between 6 to 10) and the
volume of production is medium.
A multi-product process chart is used to combine the

operation process charts for more than one product.
In a multi-product process chart only two symbols are

used, circle for operation and rectangle or square for
inspection.
Flow Charts:
DR A K SHARMA, IITR
DR A K SHARMA, IITR
From-To Chart
Multi-product Process Chart
DR A K SHARMA, IITR
From-to chart (or Travel chart) is used to represent the

amount of flow between various departments.
It indicates the distances and number of moves between

different pairs of departments.
The pair of departments that has the largest value of

either the distance between them or the moves between
them must be placed closest to each other.
Thus, the material handling between the departments can

be reduced.
The from-to chart is helpful in the process type of layout

design; but is not applicable to a product layout.
DR A K SHARMA, IITR
Activity Relationship Chart
An activity relationship chart shows the relationship of

every department, office, or service area with every other
department and area.
The REL chart represents the importance of adjacency

between departments using codes.
These codes are called closeness codes and must be

associated with pre-specified reason codes. Reason
codes are not standard codes.
The facility planner, to aid in justifying the selection of

closeness codes, establishes such codes.
Activity Relationship Chart
DR A K SHARMA, IITR
Estimation of Space
Space requirement involves space required by
DR A K SHARMA, IITR
Development and Presentation of Layout

Plot Plan:
offices,
equipment,
workstations,
warehouse,
maintenance,
power generation and/or distribution,
material handling,
sewage treatment, if any
recreation etc.
DR A K SHARMA, IITR
DR A K SHARMA, IITR
Development and Presentation of Layout

Block Plan:
Construction of Detailed Layout

Any one of the three methods is used:
1. Drafting or sketching
2. Templates
3. Models.
DR A K SHARMA, IITR
Checking the Layout
DR A K SHARMA, IITR
Installation of Layout
To check the proposal against the objectives of plant layout.
A layout installation usually takes place over a period of time.
The layout should be checked against the following

objectives:
The layout may occur in the following phases:
1. Overall integration
2. Minimum distance moved
3. Flow of the product
4. Space utilization
5. Employee satisfaction and safety
1. Plan (sequence of moves, making up inventory of everything

to be relocated, set up time tables with specific date and time
etc.)
2. Provide (outsourcing, good communication, get moving

equipment etc.)
3. Prepare (new location, foundations, partitions, paintings etc.)

4. Move (move as close to installation as possible)
5. Install (install and flag equipment ready for installation
6. Flexibility.
inspection)
6. Start up (be sure for placement, hook-up etc.) and

7. Clean up (set deadline for clean up to avoid temporary feel).
DR A K SHARMA, IITR
DR A K SHARMA, IITR
Installation of Layout
Evaluation of Layouts
A typical scheduling of layout installation:
Evaluation means the assessment of each alternative in terms of

the criteria decided earlier.
Evaluation provides the basis for analyzing the various

and helps in selecting the best layout among them.
The best layout, in fact, is the BEST COMPROMISE.
No standard evaluation procedure does exits.
DR A K SHARMA, IITR
The following systematic approaches are in practice:
layouts
DR A K SHARMA, IITR
Productivity Evaluation
1. Pilot plant,
2. Cost comparison,
3. Productivity evaluation,
4. Space evaluation,
5. Sequence demand straight line,
6. Sequence demand non directional,
7. Factor analysis,
8. Ranking, and
9. Analysis of pros and cons.
DR A K SHARMA, IITR
DR A K SHARMA, IITR
Space Evaluation
Sequence Demand straight line
DR A K SHARMA, IITR
DR A K SHARMA, IITR
Floor plan of the area assigned
DR A K SHARMA, IITR
DR A K SHARMA, IITR
10

DemPosMean
Pos Dem
Dem
i
For example, DemandPosition Mean for Centre C:

DemPosMean
1 60 2 300 4 160
60 300
DR A K SHARMA,
IITR 160
Demand
graph
DR Aposition
K SHARMA,
IITR for Press C
Sequence Demand Non-directional
PPROBLEM : A drill press, a turret lathe, a turret lathe, and an inspection
station are to be located in an established layout. There are four areas
available within this layout for locating the new machines. Figure shows the
location of these areas and indicates the distances between each.
The final layout developed by sequence demand method
DR A K SHARMA, IITR
DR A K SHARMA, IITR
11
The number of trips between the various combinations of machines taken

two at a time is shown schematically in the Figure below.
SOLUTION: A load-path matrix as given by Wimmert can be developed as

given below:
DR A K SHARMA, IITR
DR A K SHARMA, IITR
SOLUTION:
SOLUTION: The resulting layout can be presented schematically as below:
Here, all combinations of the possible locations, taken two at a time, are
plotted across the top of the matrix arranged so that the feet between the
locations is monotonic nondecreasing from left to right.
Along the vertical axis of the matrix the combinations of the machines, taking
two at a time, are plotted so that the number of trips between the centers is
monotonic nonincreasing from top to bottom.
Thus, the maximum load-path is in the north-east corner of the matrix, while
the minimum at the south-west corner.
This fact enables the designer in eliminating the undesirable alternatives.
The resulting layout can be presented schematically as below:
DR A K SHARMA, IITR
DR A K SHARMA, IITR
12
Factor Analysis Method
Ranking Method
DR A K SHARMA, IITR
DR A K SHARMA, IITR
OTPTIMIZING EVALUATION:
1. Linear Programming
2. Line Balancing
3. Level Curve Method
DR A K SHARMA, IITR
13

Plant Layout

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Objectives of Facility Layout

1. OBJECTIVES FOR MANUFACTURING OPERATIONS LAYOUTS:

Conform to site and building constraints.

Objectives of Facility Layout

Objectives of Facility Layout

2. (Addl.) OBJECTIVES FOR WAREHOUSE OPERATIONS LAYOUTS:

3. (Addl.) OBJECTIVES FOR SERVICE OPERATIONS LAYOUTS:

Promote efficient loading and unloading of shipping vehicles.

Provide for customer comfort and convenience.

Provide for effective stock picking, order filling, and unit

Provide appealing setting for customers.

Allow ease of inventory counts.

Allow attractive display of merchandise.

Objectives of Facility Layout

Principles of Plant Layout

4. (Addl.) OBJECTIVES FOR OFFICE OPERATIONS LAYOUTS:

1. PRICIPLE OF OVERALL INTEGRATION:

Principles of Plant Layout

Principles of Plant Layout

5. PRICIPLE OF SATISFACTION AND SAFETY:

4. PRICIPLE OF CUBIC SPACE:

Factors Influencing Plant Layout

Factors Influencing Plant Layout

Factors influencing any layout can be grouped into the following:

Factors influencing any layout can be grouped into the following:

1. The Material Factor:

4. The Movement Factor:

Inter and Intradepartmental transport,

5. The Waiting Factor:

Permanent and temporary storages, and

Production equipment and tools,

6. The Service Factor:

Factors Influencing Plant Layout

Factors Influencing Plant Layout

Factors influencing any layout can be grouped into the following:

7. The Building Factor:

Hard to pin down quality responsibility.

Interdependental inspection and friction over quality.

Quality is fixed responsibility of individual workers.

8. The Change Factor:

Major Steps in Layout Design

Phases in Layout design:

1. Statement of the problem

2. Collection of basic data on

3. Calculation of production rate and equipment requirements

Major Steps in Layout Design

6. Development of block plan, plot plan, and detailed layout.

Major Steps in Layout Design

Major Steps in Layout Design

Major Steps in Layout Design

Five Major Flow Patterns:

Flow Process Chart

This chart summarizes the flow and activity of a component

It includes information about time required and distance

Information are obtained from the process design department

A separate route sheet is required for each part. Flow process

Various symbols are used as an aid in developing a flow

Major Steps in Layout Design

Multi-product Process Chart

Multi-product process chart is used when a large variety of

A multi-product process chart is used to combine the

In a multi-product process chart only two symbols are

Multi-product Process Chart

From-to chart (or Travel chart) is used to represent the