Plant lay out [facilities layout]  Arrangement of various production resources and support services in a plant Importance of plant

layout  Quality and Cost of the product  Safety  Lead-time  It is a strategic decision which is dynamic by nature
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Objectives of Plant layout  improved Productivity Improvement of QCD (lead-time) Space utilization min loss of material due to mix-up or spillage Safety Easier and less handling
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Less inventory, smooth flow, no stagnancy  Better working conditions Flexibility Equipment on wheels

Need to look at Layout occurs due to: 1. New plant 2. Change in product design 3. New product 4. Obsolescence of facilities 5. Change in the production system (output characteristics) 6. Change in the safety standards 7. Improvement
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Principles of Layout 1. Principle of Minimum movement  Principle of Flow The process flow diagram unidirectional without backtracking 2. Principle of Space Inventory on chutes mezzanines
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3. Principle of Safety and health (isolate the process, easy evacuation, contain the pollution, provide specific safety measures) 4. Principle of Flexibility Equipment on wheels 5. Principle of Interdependence Customer and supplier closer
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6. Principle of Overall integration Men, machines, space and materials 7. Principle of Min investment Min space, min inventory, maximum utilization of all resources

Symptoms Of Bad Layout 1. Congestion of material and men on the floor 2. Bottlenecks 3. Mental and physical strain on operatives, frequent tension between operatives, between operatives and supervisors 4. Frequent accidents
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5. Mat. handling by skilled operatives 6. Frequent mix up in material and subsequent rework 7. Delayed deliveries to the customers

Layout Factors 1. Material factor design, variety, quantity of product, nature of material like physical state, hazard, operations and their sequence 2. Man factor: no of workers & supervisors, safety, man power utilization, service and help 3. The machinery factor includes the process, production equipment, tools and their utilization
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4. The movement factor include inter and interdepartmental movement and handling at various operations, storage and inspections, material handling equipment 5. The waiting factor - includes permanent and temporary storage, delays and their location 6. The service factor service related to employee facilities, material, equipment maintenance
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What Are Conventional Types Of Layout: Line Layout/product layout, Process/function layout, Static/fixed position Layout

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1 2 4

LINE /PRODUCT LAYOUT 1 2 3 4 P Q R STORE 1 STORE 2 STORE 3 STORE 4

P Q R

FUNCTION/PROCESS LAYOUT
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R/M

STATIC LAYOUT

GROUP TECHNOLOGY LAYOUT

Product Layout [Line Layout]  Product focused  Equipment as per sequence of operations & one machine for one operation  Material moves from machine to machine  Suitable for mass production Function Layout [Process Layout]  Process focused
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Equipment as per process/function, material moves from department to department in batches  Suitable for batch production

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Fixed Position [Static] Layout  Material does not move  Suitable for one off production

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Group Technology Layout  Synthesis of line layout and function layout  general purpose machines arranged according to line layout  Cell Layout, family of items is processed in one cell  Suitable for JIT production  Cell Layout is also suitable for FMS production.
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MAJOR ASSEMBLY

SUB ASSEMBLY I

SUB ASSEMBLY II

A1 A2 B1

C1 C2 C3 D1 D2

A3 A4 C4 D3 D4

C5 B2 A5 D5
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M1 CELL B

M2

M1

M2 M3

CELL C

M5

M4

M2 M3

M1

M1

M2 M3

CELL A M4 M5

CELL D

M5

D4

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GROUP TECHNOLOGY LAYOUT

STATION II

STATION III ASSEMBLY LINE STATION I

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LAYOUT COMPARISON FACTORS PRODUCTION SYSTEM

LINE/PRODUCTLAYOU FUNCTION T /PROCESS LAYOUT

FIXED POSITION LAYOUT

CELL LAYOUT

MASS

BATCH

ONE OFF

JIT

SPACE FOR INVENTORY

LESS

HIGH

DEPENDS ON PRODUCT NA

LESS

MATERIAL HANDLING SYSTEM

AUTOMATIC

SEMI AUTO

LOW COST AUTO

FLEXIBILITY IMPACT OF BREAK DOWN QALITY OF OUTPUT

VERY LOW HIGH

BETTER LOW

BETTER LOW

HIGH HIGH

HIGH

DOUBTFUL

BETTER

HIGH

INCENTIVE SYSTEM

GROUP

INDIVIDUAL

INDIVIDUAL

PRODUCTIVTY INCENTIVES

EQUIPMENT ARRANGEMENT

PRODUCT FOCUSSED AND AS PER SEQUENCE OF OPERATIONS

PROCESS FOCUSSED AND AS PER FUNCTIONS OF EQUIPMENT

FLEXIBLE

AS PER SEQUENCE OF OPERATIONS FOR FAMILY OF PARTS WITHIN A CELL

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Process of preparation for layout/ layout change 1. Draw flow diagram of the process 2. Collect information about layout factors study what materials go in to the process. By 80 20 rule identify critical items for layout 3. Keep principles of layout in mind 4. Prepare templates or models for machines 5. Prepare a floor plan for the shop floor 6. Set lay out objectives
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7. Use layout tools like  Templates  Models  Computers  Process Chart  Flow diagram  Machine data cards 8. Prepare layout for various sections
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9. Prepare several options of detailed layout 10.Discuss with user departments 11.Recommend 12.Implement 13.PDCA

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OFFI CES

DIS PA TC H

ST ORE

sli TIN P LA TE ST ORE

P RT MA TL W P I

I N K S P A C K I N G

pres s N PT G L NE I R/ M S T 0 R E

N ec s k 0.5T

pres s S

Sh oulde s r 1.0 T

pres s B

Bottoms 1.0 T

s litting

s litting

O F F I C E S Q C

S l tte s i r 1,2,3, 4 FINISH E D GO OD S ST ORE

S lit ma terial stock

B O D Y S T O C K

B 1

B 2

B O D Y

pack

pack
M A N EN N CE I T A

UNDER I NSP ECTIO N PT

TO O L RO O M AN D D EV ELO P ME

1 7/01/0 4

LAY OUT - BEFORE

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O F ICES F

S TO RE

TOOL ROO M AN D D EV L E OPMENT

sli W IP PRT

PRINT DONE

ma inte nan ce
S lit I cut TIN P LA TE S TORE S lit II cut

P TG LINE B B S N

B 1 B 2 P

pm

qc

P P

SH OU LD R E S

U DER IN S N PECTI O N

F IN IS HED GO O D S

I N K S

D IS P A TCH

L AY OUT - AFTER

17/ 01/ 04

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