Production & Operation Management

Topic : Facility Layout

By: Ajay MishraJeev Sewa Sansthan Group of Institutions for

women,

( Faculty of Management)

Facility Layout Planning and arranging manufacturing machinery, equipment and services for the first time in completely new plants.

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

Objectives of a good LayoutProvide enough

production capacity.Reduces handling costs.Reduces congestion.Reduces hazards to

personnel.Utilizes labour efficiently.Increase employee

morale.Reduce accidents.Utilizes available space

efficiently and effectively.

Provide for volume and product facility.

Provide ease for supervision.

Facilitate co-ordination communication.

Provide safety and health.Allow ease of maintenance.Allow high

machine/equipment utilization.

Improve productivity.

FACTORS INFLUENCING FACILITY LAYOUT

MATERIALS (Type of raw materials and availability)

PRODUCT (Type of product and its position)

WORKER (Type , position and requirements)MACHINERY(Product, volume and process)INDUSTRY (Type of industry: Synthetic,

Analytical, Conditioning and Extractive)LOCATION (Factor of production)MANAGERIAL POLICIES ( volume, provision

for expansion, automation, making or buying decisions, desire for rapid delivery, purchasing policy and personnel policies)

Principles of Layout

Principle of minimum travelPrinciple of sequencesPrinciple of usagePrinciple of compactnessPrinciple of safety and satisfaction

Principle of flexibilityPrinciple of minimum investment.

Types of layoutProcess layout or functional or job shop

layout.

Product layout or line processing layout.

Fixed position layout or static layout.

Cellular manufacturing layout or Group Technology layout .

Combination layout or Hybrid layout.

Process layout

The distance between departments should be as short as possible.

Machines should be grouped in accordance with the principle of sequence of operation.

Convenience for inspection.Convenience for supervision.

Process Layout or Functional Layout

Inward good stores

PlanersAutomatics Grinders

Packing and ShippingMilling

machinesCentral

inspection

Area

Heat treatment shop

Raw Material holding stores

Drilling

shop Assembly Finished goods storage

Electro plating shop

Training Shop

(Lathes)Painting shop

Advantages of Process layoutReduced investment of machine.Greater flexibility.Better and efficient supervision.Scope for expansion as the capacity can be

easily increased.Better utilisation of men and machine.Easier to handle breakdown of equipment. Full utilisation of equipments.Investment of equipment would be

comparatively lower.Greater incentive to individual worker .

Disadvantages of Process Layout.Difficulty in the movement of material.

Requires more space.Difficult in production control.More production time as work in progress has to travel from place to place.

Accumulation of work in progress at different places.

Product Layout (Straight Line)

All the machine tool and equipment must be placed at the point demanded by the sequences of operations.

There should be no points where one line crosses another line.

Materials may be fed where they are required for assembly but not necessarily all at one point.

All the operations , including assembly, testing and packing should be included in the line.

Receiving

Raw Materials stores

Fabrication line for part C

Fabrication for part B

Packing and shipping

Raw Material

Fabrication line for Part A

Finishingt goods store

WC- 1 WC-2 WC-3 TEST

Assembly line for the product

Finished goods

Line Layout or Product Layout

Product Layout (advantages)Reduction in material handling cost due to

mechanization.Avoid production bottleneck. Economy in manufacturing time.Better production control.Require less floor area per unit of

production.Work-in-progress is reduced and so on

investment.Early detection of mistakes.Greater incentive to a group of workers to

raise their level of performance.

Product Layout (disadvantages)Product layout is known for its inflexibility.

This is an expensive layoutDifficulty in supervision.Expansion is also difficult.Breakdown can disrupt the whole system.

Fixed position layout

Movement of men and machine to the product.

Product remain stationary.Material or major components

remain in a fixed location.Cost of moving the machine and

men is lesser than the cost of moving the product.

Fixed Position Layout

Raw MaterialMachine &

Finished ProductEquipment

(Aircraft)

Labour

Aircraft Assembly

Fixed Position Layout (Advantages)

Men and machine can be used for a wide variety of operations producing different products.

The investment on layout is very small.

The worker identifies himself with the product and takes pride in it when the work is complete.

The high cost of, and difficulty in transporting a bulky product are avoided.

Combined layout Group technology layout or Hybrid

layout)

Forging Press

Forging Press

Gear Cutting Machine

Gear cutting Machine

Gear cutting Machine

Heat Treatment

Heat Treatment

Gear Grinding Machine

Gear Grinding Machine

Finished Output

RawMat.

Process layout

Product Layout