plant layout pdf

PLANT LAYOUTPLANT LAYOUT

Sub: Operations ManagementSub: Operations Management

Prof Nitin KubdeProf Nitin KubdeProf Nitin KubdeProf Nitin Kubde

INTRODUCTIONINTRODUCTION

The step forward, in the sequence, after location and site decision.The step forward, in the sequence, after location and site decision.

“The floor plan, indicating the location of the various work centres, “The floor plan, indicating the location of the various work centres,

plant, associated offices and supporting facilities.”plant, associated offices and supporting facilities.”

Hence,Hence,

The judicious selection of the location of the plants and machines The judicious selection of the location of the plants and machines

should be in such a way, as to facilitate uninterrupted and quick should be in such a way, as to facilitate uninterrupted and quick

movements of input material through premovements of input material through pre--determined cycle of determined cycle of

operations, till they are transformed as outputs, in the form of products operations, till they are transformed as outputs, in the form of products

and services, with minimum material handling and management, with and services, with minimum material handling and management, with

maximum efficiency and quality of operation leading to minimum maximum efficiency and quality of operation leading to minimum

overall cost of the entire process/ operations.overall cost of the entire process/ operations.

IMPORTANCE OF LAYOUTIMPORTANCE OF LAYOUT

�� Facilitates: Manufacturing process.Facilitates: Manufacturing process.

�� Facilitates quick movements by reduction of Facilitates quick movements by reduction of transportation & waiting time transportation & waiting time

�� Minimises material movement & handling.Minimises material movement & handling.�� Minimises material movement & handling.Minimises material movement & handling.

�� Efficient utilisation of resources:Efficient utilisation of resources:

Men, Materials, Machines.Men, Materials, Machines.

�� Achieves efficiency by effective planning.Achieves efficiency by effective planning.

�� Improves quality of operations by proper selection of Improves quality of operations by proper selection of plant, machinery, operations & sequencing.plant, machinery, operations & sequencing.

1. Types of Production

2. Production System

3. Scale of Production

4. Type of machines

Factors Affecting the

Plant Layout Decision

4. Type of machines

5. Type of Building Facilities

6. Availability of Total Floor Area

7. Possibility of Future Expansion

8. Arrangement of Material Handling Equipment

Material Flow System

� Manufacturing Process includes three basic inputs :

1. Men

2. Machines 2. Machines

3. Materials

� Flow of Material :

Product Layout - Short & Smooth

Process Layout - Long & Complex

Material Flow System

Material Flow System is divided in two parts :

1. Horizontal Flow System

2. Vertical Flow System

Horizontal Flow System

� The Horizontal Flow Systems are devised in the

single story building when the flat floor area is

available.

In this system, the starting point is the receiving � In this system, the starting point is the receiving

(R) of raw material and the terminal point is

shipment (S) of finished goods.

� In between these two points, the materials move

from one work station to another for the

processing.

Horizontal Flow System

Is denoted by the alphabetic letters :

1. “I” type Flow :-

� Shortest route .

� Must have roads on � Must have roads on

both side.

� Plant area has long lengths But short width.

� Difficulty in returning empty containers.

� Absence of rushing of outside transportation.

� Unsuitable for longer production line.

Horizontal Flow System

Is denoted by the alphabetic letters

2. “L” type Flow :-

Horizontal Flow System

3. “U” type Flow :-

� One side road link will

be required.be required.

� Less difficulty in returning the empty containers.

� Possibility of rushing of outside transportation.

� Suitable for longer production line.

� Requires square like floor area.

Horizontal Flow System

4. “S” or inverted “S” type of Flow :-

� Requires roads on both

side.side.

� Absence of rushing of

outside transportation.

� Requires square like floor area.

� Difficulty in returning empty containers.

� Suitable for longer production lines.

Horizontal Flow System

5. “O” type Flow :-

� One side road facility

is required.

Heavy rush of outside � Heavy rush of outside

transportation.

� Easy in returning empty containers.

� Requires square like floor area.

� Suitable for longer production line.

Horizontal Flow System

6. “I” and “U” type Flow :-

Horizontal Flow System

7. “I” and “S” type Flow :-

Horizontal Flow System

8. “I” and “O” type Flow :-

Vertical Flow System

� The vertical Flow System arises in case of multi story

buildings.

� Multi storey building are used where limited land area is

available and the processing is done on light materials available and the processing is done on light materials

with the help of light machines.

Vertical Flow System

� Important Vertical Flow Systems :-

TYPES OF PLANT LAYOUTS

1. Product or Line layout

2. Process or Functional layout

3. Fixed Position or Project layout

4. Combination layout (Mixed layout)

1. PRODUCT OR LINE LAYOUT

ADVANTAGES OF PRODUCT LAYOUT

1. Low cost material handling

2. Smooth and uninterrupted operations

3. Continuous flow of work

4. Optimum use of floor space4. Optimum use of floor space

5. Shorter processing time

6. Simple and effective inspection of work

DISADVANTAGES:

PRODUCT LAYOUT

1. High initial capital investment

2. Heavy overhead charges

3. Lesser flexibility

2.PROCESS LAYOUT

Product B :

Product A :

ADVANTAGES OF PROCESS

LAYOUT

1. Lower initial capital investment

2. The overhead cost are relatively low

3. Supervision can be more effective and specialised

4. Greater flexibility 4. Greater flexibility

DISADVANTAGES OF PROCESS

LAYOUT

1. Material handling costs are high due to backtracking

2. More skilled labour is required

3. More frequent inspection is needed

COMPARISON BETWEEN PRODUCT

AND PROCESS LAYOUT

PRODUCT LAYOUT

1. Investment is high

2. Space requirement is more

3. Manufacturing time

required is more

PROCESS LAYOUT

1. Investment is less

2. Space requirement is less

3. Manufacturing time required

is lessrequired is more

4. Material handling is

maximum

5. Flexibility is high

is less

4. Material handling is minimum

5. Flexibility is less

COMPARISON BETWEEN PRODUCT

AND PROCESS LAYOUT

PRODUCT LAYOUT

6. Inspection is required

7. Less skilled labours are

PROCESS LAYOUT

6.Inspection is not required at

every stage

7. More skilled labours are

required7. Less skilled labours are

required

8. Supervision is required

required

8. Supervision is not required

3.FIXED POSITION OR PROJECT LAYOUT

MANUFACTURING OF SHIP

ADVANTAGES OF FIXED

POSITION LAYOUT

1. It saves time and cost involved on the movement of

work from one work station to another

2. The layout is flexible as change in job design and

operation sequence can be easily incorporatedoperation sequence can be easily incorporated

3. It is more economical when several orders in

different stages of progress are being executed

simultaneously

DISADVANTAGES OF FIXED

POSITION LAYOUT

1. Production period being very long, capital investment

is very heavy

2. Very large space is required for storage of material

and equipment near the productand equipment near the product

4. COMBINATION LAYOUTLathe Milling

painting

Drilling Grinding

Press Boring

B

A

inspection

Shaping Milling

packaging

Cellular layout

D

C

� dairyvideo1

� dairyvideo2

� dairyvideo3

STUDY: DAIRY INDUSTRY

� A dairy is a facility for the extraction and processing of animal milk -- mostly from cows, sometimes from buffalo, sheep, horses or goats -- for human consumption

� Cream and butter

Skim milk� Skim milk

� Cheese

� Whey

� Yogurt

� Milk powders

� Other milk products