copy of facility location 1

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Facility LayoutFacility Layout



IntroductionIntroduction

– Facility layout refers to the physical arrangement of

production facilities.

– The facility layout plan institutionalizes the fundamentalorganizational structure.

– It is the configuration of department, work centers &

equipment in the conversion process.



DefinitionDefinition

• According to Moore:

“Plant layout is a plan of an optimum arrangements

of facilities including personnel, operating

equipment, storage space, material handling

equipments and all other supporting services along

with the design of best structure to contain all thesefacilities.”



Plant layoutPlant layout

• A floor plan for determining and arranging the desired

machinery and equipment of a plant

• It permits

– The quickest flow of materials in processing the product• From the receipt of the raw materials to the

shipment of the finished product

– At the lowest cost, and – With the least amount of handling



Objectives

• The primary goal of the plant layout is to

maximize the profit by arrangement of all the

plant facilities to the best advantage of total

manufacturing of the product.



Objectives

• Provide enough production capacity

• Reduce material handling cost

• Reduce congestion impeding movement of men andmaterial

• Reduce hazards to working personnel

• Utilize labour efficiently

• Increase employee morale• Utilize available floor space efficiently and

effectively



• The objectives of plant layout are:

– Streamline the flow of materials to the plant.

– Facilitate the manufacturing process. – Maintain high turnover of process inventory.

• Minimize material handling

• Effective utilization of men, equipment and space.

• Flexibility of manufacturing, operations & arrangements

• Provide for employee convenience, safety and comfort

Objectives



Basic Types of Layout

Product Layout

Process or Functional Layout

822/06/11



Vvolume-variety characteristics

Low VOLUME High

H i g h

V A R I E T

Y

L o w

Fixedposition layout

Process layout

Cell layout

Product layout



Product layout

• Machines arranged in a line depending upon sequence

of operations

•Material moves in a line from the first machine to thefinished product on the last machine.

• Investment higher as compared to process layout

Better suited for standardised products on a mass scale production. Exchemicals,paper



Product Layout

• Plant & machinery layout is designed to cater to

continuous flow of Materials.

• The position and order in the sequence for amachine performing particular operation is fixed.

• Once a machine is in line, it cannot perform any

operation , which is not designated in the

sequence of operations.

• There is a continuous flow of material during the

production process from start to finish.

18-12-2007 11



FINISHED GOODS

MATERIAL FLOW

RAW MATERIALSPRODUCTION SUB-SYSTEM

RECEIVING

STORAGE OPERATION A

OPERATION B

OPERATION C

OPERATION D

SHIPPING

CONTROL

SYSTEMS

INFORMATION

FLOWS

CONTINUOUS FLOW PRODUCTION SYSTEM (FLOW SHOP)



Examples of product layout

• Assembly line for air-conditioner

• Car manufacturing unit

• Car washes and

• Canteen facilities

• Laundry.



Important Considerations

All machines placed at points demanded by sequence of operation

No crossing over of one line with the other Materials may be fed where they are required for

assembly but not necessarily all at one point

All operations including assembly, testing and packing

included in the line



Classificationand

marking of

clothes

Washing

MachineDryer

Steam

press

StorageArea for

Pressed

clothes

Delivery

Counter

Product layout of laundry

• To produce one standard product in large volumes.• Each unit produced undergoes same sequence of operations and uses same

flow of work.• The work centers and equipments are arranged in a line for continuous

operation.



Advantages• To workers:

– Reduce effort – Minimizes manual material handling

– Reduces accidents

– Provide better working conditions

• To the management: – Reduce labor cost

– Enhance productivity

– Reduce cost per unit

– Gain competitiveness in manufacturing



Contd……

• In manufacturing:

– Minimizes the movement between work centers

– Reduced manufacturing cycle

• In production control:

– Uniform and uninterrupted flow of materials

– Helps carrying out production activities within the

predetermined time period

– Effectiveness in production



Contd……

• Reduced material handling cost due to mechanized handling

flow and straight flow.

• Perfect line balancing which eliminates bottlenecks and idle

capacity.• Manufacturing cycle is short due to uninterrupted flow of

materials.

• Simplified production, planning and control.

• Small amount of work in process inventory.

• Unskilled workers can learn and manage the production.



Disadvantages:

Inflexible & expensive layout

Difficulty in supervision

Expansion is difficult

Any breakdown along the line can disrupt total

production

Requires heavy capital investment.



Process layout

• It is also known as functional layout.

• It is recommended for batch production.

• All machines performing similar type of

operations is grouped at one location.



Functional or process layout

• Here machines performing same type of operations are installed at one place .i.e. plant isgrouped according to functions e.g. all drilling

machines are located at one place known asdrilling section.

• This type of layout is most appropriate for intermittent (JOB and BATCH ) type of

manufacturing systems where small qty’s of alarge range of products are to be manufacturede.g. machine tools etc.



Process Layout Examples

• Car servicing

• Hospital-Patient requiring various tests

• Garment factory producing half sleeve shirts,full sleeve shirts, pants and suits.

• Office buildings, schools, universities,

hospitals, aerodrome, library, book store or amusement centers are planned on this basis.

22



Important considerations

– Distance between departments as small as

possible

– Departments to be located as per sequence of operation

– Convenience for inspection as well as

supervision



Process layout

Lathe 1

Lathe 2

Lathe 3

Milling

Machine

Fitting Table 1

Fitting Table 2

Fitting Table 3

Welding M/C - 1

Welding M/C - 2

Paint Shop

Side Entry

Main Entry

Work Shop OfficeAir

Compressor

Product A

Product B

• Flow of work is not standardized

• Plant produces a variety of products• Some of the processes / operations

might be common.



Advantages

Each production unit of the system works independently and is notaffected by the happenings in another section of the plant.

Scope for more skilled labour leads to better quality in production.

Wide flexibility in production facilities.

Machine breakdown doesn’t disrupt production.

Lower capital investment. (Less duplication of machines).

Better utilization of resources

Full utilization of machinery



Disadvantages

More material handling.

Longer processing time:- as more time s required for materialhandling, transportation n inspection.

Requires substantial production planning and control.

Requires more floor space.Inspection s more frequent n costlier.

Requires highly skilled labour creating difficulty in labour procurement.

Production time increased because of extra travel

Accumulation of work-in-process at different machines



Fixed position layout

• Movement of men & machinery to the product

• Product remains stationary

– Cost of moving product is high,bulky

Best suited for bulky & heavy products ex.Ships, aeroplanes etc.



18-12-2007 28

Fixed Position Layout

• The material remains in a fixed position , but

the machinery, tool workmen etc are brought to

the material



AIRCRAFT ASSEMBLY

FINISHED PRODUCT

(AIRCRAFT)

RAW MATERIALS

MACHINE &

EQUIPMENT

LABOUR

FIXED POSITION OR STATIC LAYOUT



Fixed position layout

• Fixed-position layout is used for products, which areeither very big in size (weight/volume) or very criticaland it is not feasible or desirable to move the product and

product remains in one position only.

• Men, materials, equipment and tools are brought to the product for execution of the work.

• Building of space shuttle, turbines, aircrafts and ship usefixed-position layout as it is not feasible to move these

products due to their size or weight.



18-12-2007 31

Fixed Position Layout

• Employed in large project type organisation

• Example

• ISRO

• Helicopter

• Nuclear engg. Division of BHEL



Advantages

• Men/machinery can be moved for a wide varietyof operations producing different products

• Worker identifies himself with the product &takes pride when the work is completed

• Investment on layout is small

• High cost & difficulty in transporting a bulky job

avoided



Mixed layouts

Mixed layouts – pure basic layouts can be used in different

departments in one organisation.

Example: A hospital would be arranged on process-layout principles. Within individual departments different

layouts are used e.g. x-ray department probably process,

surgical theatres fixed-position and the blood-processing

lab a product layout.



Combined layout

• Combination of product & process layout with anemphasis on either

• Generally adopted in industry

• In fabrication plants including assembly,fabrication tends to employ process layout whileassembly areas employ product layout – Soap manufacturing industry employs product line for

manufacturing of soap, but ancillaries such as heating,manufacturing of gleycerine, power house etc. Are arranged onfunctional basis.



F.P.

F.P.

G.C.

G.C.

G.C.

H.T.

H.T.

G.G.

G.G.

RAW MATERIAL

RAW MATERIAL

P R O C E S S L

A Y O U T

FINISHED

PRODUCTS

(GEARS)

F.P. = FORGING PRESS G.C. = GEAR CUTTING

H.T. = HEAT TREATMENT FURNACE G.G. = GEAR GRINDING MACHINE

COMBINATION LAYOUT OR HYBRID LAYOUT FOR GEAR MANUFACTURING

PRODUCT LAYOUT



Combination layout

• In an industrial plant, it is difficult to confine to one typeof layout only i.e. process or product layout.

• It becomes necessary to use process layout for some of the activities and to use product layout for certain other

activities in the same plant.

• Cement manufacturing may need process layout for raw-material preparation, which require crushing, grindingand mixing of the various raw-materials such as lime-stone, clay, bauxite and iron-ore.



Combination layout

• Once the raw materials are prepared and converted intoraw-meal by mixing different raw materials in

predetermined proportion, production processes such as pre-heating, pre-calcining, calcinations for conversion of

raw-meal into clinker and cooling of clinker would use product layout.

• Within the plant, workshop activities are arranged byusing process layout, whereas the packing and dispatch

operations of the cement through trucks need productlayout.



Combination layout

• If different modes of dispatches are adopted such as dispatch byrail (both by bags and bulk containers), sea (bags and bulk loading) or by road in trucks (bags) or in bulk containers, thedispatch operations would need process layout.

•In cases of repairs of kiln in a cement plant, which cannot bemoved, a fixed layout is to be used.

• It is clear from the example of cement plant that a big plant needsapplication of all the three types of layouts for differentapplications or a combination of all the layouts for meeting the

requirements of its total operations.



Clay

Yard

BauxiteYard

Iron ore

Yard

Lime StoneYard

Raw

Mill

ESP

Cyclone

Chimney

BlendingSt

oragecyclone

Inlet chamber

Of kiln

Rotary kiln

Clinker cooler

Cement

Mill

Combination layout – case of a cement plant

Process layout for a portion of

Cement plant

Product layout for a portion of

Cement plant



Cellular manufacturing (cm) layout

• Grouping of machines into cells

• Cells function somewhat like product layoutwithin a larger shop or process layout

• Each cell in the cm formed to produce a single part / a few parts – All with common characteristics which usually requires

similar machines and settings

• Flow of parts within the cell can take many forms



18-12-2007 41

Group Technology

• This is philosophy that seeks to exploit the

commonality in manufacturing and uses this as a

basis for grouping components and resources. This is

also known as cellular manufacturing.

• Pioneered by Russians

• Mid volume & mid variety scenario

• 70% of mfg. industry may fall under this category)



CARAVAN, BATON and MIXED CELLS

Operator andproduct

move from station

to

station

Operators arefixed but

products move

from

station to station

Products movefrom station

to station and

operators move

between stations

CARAVAN CELLS

BATON CELLS

MIXED CELLS

CELLULAR MANUFACTURING



1 2

3

45

1 2 3

1 2

34

21

CELL # 3

CELL # 4

CELL # 1CELL # 2

PRODUCTION OPERATION PRODUCT OR MATERIAL FLOW

CELLULAR MANUFACTURING

LAYOUT

PART D

PART Y

PART X

PART A

PART B

3



-1111 -1111

2222 - 2222

A s s e m

b l y

3333 - 3333

4444 - 4444

Lathe

Lathe

Mill

Mill

Mill

Mill

Drill

Drill

Drill

Heattreat

Heat

treat

Heat

treat

Gearcut

Gear

cut

Grind

Grind

Cellular Manufacturing Layout

CM LAYOUT



CM LAYOUTADVANTAGES

• LOWER WORK-IN-PROCESS INVENTORIES

– REDUCED MATERIAL HANDLING COSTS

– SHORTER FLOW TIMES IN PRODUCTION

– SIMPLIFIED PRODUCTION PLANNING (MEN,MATERIAL ETC.)

– OVERALL PERFORMANCE OFTEN INCREASES BY

LOWERING PRODUCTION COSTS & IMPROVING ON-

TIME DELIVERY

– IMPROVED QUALITY

Ad f C ll l L



Advantages of Cellular Layout

• PPC becomes simpler

• Material handling becomes easier

• Traceability improves• Employees are able to relate better.

• Helps in implementing SGA, Kaizen an

JIT

C ll l L E l



Cellular Layout- Examples

• Reliance industries- HDPE & LDPE

• Titan Industry

• ABB( Industrial fans & blowers)

CM l t i i i



CM layout limitations

• Reduced manufacturing flexibility & potentially

increased machine downtime

• Duplicate pieces of machinery may be needed so asto avoid movement of parts between cells



Service facility layout

• Main difference between service and manufacturingfacility is to bring together customers & services inmany service facilities

• Facilities to provide for – Easy entrance from the freeways and busy thoroughfares

– Large well organised and amply illuminated parking areas etc.

• Hotels, cinema halls etc have different areas to cater to

the comfort & convenience of customers

ENTRANCEEXIT



PARKING AREAPARKING AREA

PARKING AREA PARKING AREA

HOSPITAL WARDS

HOSPITAL WARDS

HOSPITAL WARDS

SURGERY, RADIOLOGY,

I.C.U., TECH SERVICES

DOCTORS

LOUNGE /

OFFICES

ADMIN. OFFICE

NURSES

LOUNGECAFETERIA

CASUALTY DEPT / INPATIENT DEPT

ENTRANCE EXIT

CASUALTY DEPT / INPATIENT DEPT

ENTRANCEEXIT

A I S

L E S /

G A N

G W A

Y S

P A R K

I N G

A R E

A

P A R K I N G A

R E

A

SERVICE FACILITY LAYOUT ( HOSPITAL LAYOUT )



• Layout important to achieve client-customer goal of fast service – FAST SERVICE SUPPORTED BY POINT OF SALE SYSTEM,

SCANNERS, SELF SERVICE TO PROVIDE SPEED AS WELL ASREDUCE COST, atms BY BANKS ETC.

• Flow line approach followed in fast food service

• Process line layout occurs in many services like medical clinics,offices etc.




• Generally, as in manufacturing

– Line layout preferred in high volume,

standardised products• Fast food service

– Process layout preferred in service operations

also

• General offices, banks, general hospitals, municipal

offices etc.




SERVICE WAITING LINE MODULES

SINGLE CHANNEL,

SINGLE PHASE MODULE

WAITING LINE SERVICE

FACILITY

MULTIPLE CHANNEL,

SINGLE PHASE MODULE

SERVICE

FACILITYWAITING LINE

SINGLE CHANNEL,

MULTIPLE PHASE MODULE

WAITING LINE SERVICE

FACILITY

SERVICE

FACILITY

WAITING LINE

MULTIPLE CHANNEL,

MULTIPLE PHASE MODULE

L l i



Layout planning methodology

• Travel chart method

• Load-distance analysis method

• Systematic layout planning method

• Analysing layouts with computers – Aldep (automated layout designing programme)

– Corelap (computerised relationship layout planning)

– Craft (computerised relative allocation of facilitiestechnique)

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