production management plant location
TRANSCRIPT
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PLANT LOCATION
Module 2
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Introduction
Plant layout planning includes decisionsregarding the physical allocation of theeconomic activity centers in a facility.
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Facility Layout Definition
Afacility layoutis an arrangement of everything neededfor production of goods or delivery of services. Afacility
is an entity that facilitates the performance of any job. It
may be a machine tool, a work centre, a manufacturing
cell, a machine shop, a department, a warehouse, etc.(Heragu, 1997).
http://www.sciencedirect.com/science?_ob=ArticleURL&_udi=B6V0H-4R2GS3S-2&_user=5674735&_coverDate=11%2F05%2F2007&_alid=646172600&_rdoc=2&_fmt=full&_orig=search&_cdi=5647&_sort=d&_docanchor=&view=c&_ct=211&_acct=C000053929&_version=1&_urlVersion=0&_userid=5674735&md5=e47ccd28a13defa3d980826b6a5a91edhttp://www.sciencedirect.com/science?_ob=ArticleURL&_udi=B6V0H-4R2GS3S-2&_user=5674735&_coverDate=11%2F05%2F2007&_alid=646172600&_rdoc=2&_fmt=full&_orig=search&_cdi=5647&_sort=d&_docanchor=&view=c&_ct=211&_acct=C000053929&_version=1&_urlVersion=0&_userid=5674735&md5=e47ccd28a13defa3d980826b6a5a91ed -
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Objectives of Plant Layout The main objective consists of organizing equipment and
working areas in the most efficient way, and at the sametime satisfactory and safe for the personnel doing thework.
Sense of Unity
Minimum Movement of people, material andresources.
Safety
Flexibility
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Objectives of Plant Layout
These main objectives are reached through the attainment of thefollowing facts:
Congestion reduction.
Better adjustment to changing conditions.
Better utilization of the workforce, equipment andservices.
Reduction of material handling activities and stockin process.
Reduction on health risks and increase on workerssafety.
Reduction on delays and manufacturing time, as
well as increase in production capacity.
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Factors affecting Plant Layout
The factors affecting plant layout can be grouped into 8 categories: Materials
Machinery
Labor
Material Handling
Waiting Time Auxiliary Services
The building
Future Changes
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Factors affecting Plant Layout
Materials
Main factors to be considered: size, shape, volume, weight, and the
physical-chemical characteristics, since they influence the
manufacturing methods and storage and material handling
processes.
Machinery
Regarding machinery, we have to consider the type, total available
for each type, as well as type and quantity of tools and equipment.
Its essential as well to know about space required, shape, height,
weight, quantity and type of workers required, risks for thepersonnel, requirements of auxiliary services, etc.
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Factors affecting Plant Layout Labor
Environment considerations: employees safety, light conditions,ventilation, temperature, noise, etc.
Process considerations: personnel qualifications, flexibility, numberof workers required at a given time as well as the type of work to beperformed by them.
Material Handling
Material handling does not add value to the product; its just waste!
Objective: Minimize material handling as well as combining withother operations when possible, eliminating unnecessary and costlymovements.
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Factors affecting Plant Layout The factors affecting plant layout can be grouped into 8
categories: Waiting time - Stock
Objective: Continuous Material Flow through the facility, avoiding
the cost of waiting time.
Resting time to cool down or heating up.Auxiliary Services
Support the main production activities at the plant:
Related to labor: Accessibility paths, fire protection installations,
supervision, safety, etc.
Related to material: quality control. Related to machinery: maintenance and electrical and water lines.
The auxiliary services represent around 30% of the space at a facility.
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Factors affecting Plant Layout The factors affecting plant layout can be grouped into 8
categories: The building
If it has been already selected, its characteristics will be a constraint
at the moment of designing the layout, which is different if the
building has to be built.
Future changes
One of the main objectives of plant layout is flexibility.
Its important to forecast the future changes to avoid having an
inefficient plant layout in a short term.
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Plant Location
Criterion WeightingPossible Factory Location
A B C D EPROXIMITYTO:
Skilled labour 7 2 14 3 21 0 0 1 7 4 28
A pool of unskilled labour 8 5 40 2 16 0 0 4 32 2 16
A motorway 7 3 21 2 14 1 7 3 21 4 28
An airport 4 1 4 3 12 4 16 2 8 2 8
The sea / a river 0 2 0 5 0 5 0 2 0 1 0
Housing 5 4 20 3 15 0 0 3 15 4 20
Amenities 5 3 15 2 10 0 0 2 10 3 15
Potential for expansion 7 2 14 1 7 5 35 3 21 2 14
Availability of grants/incentives 8 1 8 2 16 5 40 1 8 3 24
Safety 2 3 6 2 4 5 10 2 4 2 4
Planning constraints 5 2 10 3 15 5 25 4 20 2 10
Environmental impact 4 3 12 2 8 4 16 1 4 2 8
TOTAL 164 138 149 150 175
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Process Layouts
General purpose & flexible resources
Lower capital intensity & automation
Higher labor intensity
Resources have greater flexibility Processing rates are slower
Material handling costs are higher
Scheduling resources & work flow is more complex
Space requirements are higher
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Process layout
Receiving Grin-
Mills ders
Raw matl. Large number
of
storage Assem- low volume
bly products
Drills
Planers
Finished
Inspec-
goodsLathes Automatics tion storage
Part A
Part B
Facility Layout
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Product Layouts
Specialized equipment
High capital intensity & wide use of
automation
Processing rates are faster
Material handling costs are lower
Less space required for inventories Less volume or design flexibility
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Product layout
Raw matl. Fabrication
Rec- storage line-part B
eiving Fabrication Planer
line-part A
Finished Lathe
goods Drillstorage Mill
Mill
Drill
Grinder
Mill
Assembly line Automatic
Facility Layout
Small numberofhigh volumeproducts
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Advantages: Reduced material handling activities.
Work In Process almost eliminated.
Minimum manufacturing time.
Simplification of the production planning and control systems. Tasks simplification.
Disadvantages:
No flexibility in the production process.
Low flexibility in the manufacturing times.
High capital investment.
Every workstation is critical to the process.- The lack of personnel or
shut down of a machine stops the whole process.
Monotonous work.
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Cellular Plant Layout
L M
D G
M M
D G
L L
L G
ASSEMBLY
CELL 3
ASSEMBLY
CELL 2
ASSEMBLY
CELL 1
Group Technology
Each cell manufactures products
belonging to a single family.
Cells are autonomous manufacturing
units which can produce finished parts.
Commonly applied to machined parts.
Often single operators supervising
machines in a cell, with robots for
materials handling.
Productivity and quality maximised.
Throughput times and work in progresskept to a minimum.
Flexible.
Suited to products in batches and where
design changes often occur.
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Other Plant Layouts
PRODUCT
MATERIAL
MATERIAL
LABOUR
LABOUR
COMPONENTS
COMPONENTS
Fixed Position Layout (right)
Single large, high cost components or
products.
Product is static. Labour, tools andequipment come to the work rather than
vice versa.
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CIA 1The groups shall name themselves based on any production management concept
(No two groups shall have the same name)
Each member of the group shall give a write up of about 200 words on the concept
(Members shall not repeat or copy any of their team mates content)
Date of Submission: 10/12/2012
In case two or more groups have the same names, by mistake or coincidence
the group that submits first shall be final and the others have to repeat !!
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CIA COMPONENT 2The groups shall identify an industry and product (No two groups shall work on
the same product or industry)
The groups to report on the following
Plant location (Factors affecting location-To be justified)
Plant layout (Factors affecting layout-To be justified, with suggested layout diagram)
The report must clearly indicate the individuals contribution.
Date of Submission: 10/12/2012
In case two or more groups have worked on the same product or industry,by mistake or coincidence the group that submits first shall be final and the
others have to repeat !!