SYSTEMATIC LAYOUT PLANNINGSYSTEMATIC LAYOUT PLANNING

• Systematic Layout Planning (SLP) is a technique developed by Richard Muther and Associates. The 3 fundamental areas of the technique; Relationships; Space and Adjustment, include 10 sub-headings within the process:

• Relationships   1. Collection of Input Data

2. Flow of Materials

3. Activity Relationships

4. Relationship Diagrams

• Space   1. Space Requirements

2. Space Available

3. Space Relationship Diagrams

• Adjustments   1. Modifying Considerations

2. Practical Limitations

3. Evaluation & Final Selection

• This technique combines quantitative measurement of materials movement with non-flow considerations such as noise, fumes, temperature, supervision, communications, personnel comfort and movement. It’s major advantage being that it clearly documents the logic of the layout and easily allows input from all levels of staff.

PLANT 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

• PROVIDE ENOUGH PRODUCTION CAPACITY• REDUCE MATERIAL HANDLING COST• REDUCE CONGESTION IMPEDING MOVEMENT

OF MEN AND MATERIAL• REDUCE HAZARDS TO WORKING PERSONNEL• UTILISE LABOUR EFFICIENTLY• INCREASE EMPLOYEE MORALE• UTILISE AVAILABLE FLOOR SPACE

EFFICIENTLY AND EFFECTIVELY

• REDUCE ACCIDENTS• PROVIDE FOR VOLUME AND PRODUCT

FLEXIBILITY• PROVIDE EASE OF SUPERVISION AND

MAINTENANCE• FACILITATE CO-ORDINATION AND FACE-TO-

FACE COMMUNICATION• PROVIDE FOR EMPLOYEE SAFETY AND HEALTH• ALLOW HIGH MACHINE UTILISATION• IMPROVE PRODUCTIVITY

OBJECTIVES

CRITICAL FACTORS

• MATERIALS– TYPE, AVAILABILITY, PROVISION FOR

STORAGE AND MOVEMENT• PRODUCT

– TYPE I.E. HEAVY,LIGHT, WET OPERARTION (CEMENT), MARKET DEMAND (DECISION ON MACHINERY TYPE)

• WORKERS– MALE, FEMALE (SPECIAL NEEDS), FACILITIES

• MACHINERY– FIXED OR MOBILE POSITION OF MEN,

MACHINERY, JOB TO DECIDE MACHINERY LAYOUT-DEPENDING ON TYPE, VOLUME OF PRODUCTION

CRITICAL FACTORS

• TYPE OF INDUSTRY– SYNTHETIC

• CONSTITUENT ELEMENTS COMBINING TO MAKE THE FINAL PRODUCT E.G. CHEMICAL INDUSTRY

– ANALYTICAL• CONVERSION OF RAW MATERIALS INTO VARIOUS

ELEMENTS E.G. PETROLEUM INDUSTRY

– CONDITIONING• CHANGING IN SHAPE / FORM OR PHYSICAL PROPERTIES

E.G. FOUNDARY, METAL WORKING INDUSTRY

– EXTRACTIVE• INVOLVING SEPARATION OF ONE ELEMENT FROM THE

OTHER E.G. METAL FROM IRON ORE

– EACH OF ABOVE FURTHER CLASSIFIED INTO• INTERMITTENT INDUSTRIES• CONTINUOUS INDUSTRIES

CRITICAL FACTORS

• LOCATION– SIZE AND TERRAIN DECIDES TYPE OF BUILDING– LOCATION DECIDES MODE OF TRANSPORTATION OF

RAW MATERIAL AND FINISHED PRODUCTS– FUEL REQUIREMENT FOR THE PLANT– FUTURE EXPANSION PROVISION

• MANAGERIAL POLICIES– VOLUME OF PRODUCTION AND EXPANSION– EXTENT OF AUTOMATION– MAKING OR BUYING DECISION– RAPID DELIVERY TO CUSTOMERS– PURCHASING POLICY– PERSONNEL POLICIES

PRINCIPLES OF LAYOUT

• PRINCIPAL OF MINIMUM TRAVEL• PRINCIPLE OF SEQUENCE• PRINCIPLE OF USAGE• PRINCIPLE OF COMPACTNESS• PRINCIPLE OF SAFETY AND SATISFACTION• PRINCIPLE OF FLEXIBILITY• PRINCIPLE OF MINIMUM INVESTMENT

TYPES

• PROCESS LAYOUT, FUNCTIONAL LAYOUT OR JOB SHOP LAYOUT

• PRODUCT / LINE PROCESSING OR FLOW LINE LAYOUT

• FIXED POSITION / STATIC LAYOUT• CELLULAR MANUFACTURING (CM) OR

GROUP TECHNOLOGY (GT) LAYOUT• COMBINATION / HYBRID LAYOUT

PROCESS LAYOUT

• GROUPING TOGETHER OF SIMILAR MACHINES IN ONE DEPARTMENT

• MATERIAL MOVES FROM ONE GROUP OF MACHINES TO THE OTHER

• MOVEMENT OVER LONGER DISTANCE AND ALONG CRISS-CROSS PATHS

• MAY ALSO INVOLVE PART FINISHED INVENTORY WAITING

BEST SUITED FOR INTERMITTENT TYPE OF PRODUCTION/LIGHT AND HEAVY INDUSTRIES

PRODUCTION SUB-SYSTEM

RECEIVING

STORAGE

OPERATION A OPERATION B

OPERATION COPERATION DSHIPPING

INFORMATION FLOWS

INTERMITTENT FLOW PRODUCTION SYSTEM (JOB SHOP )

WIP

WIP WIP

WIP

FINISHED GOODS

EDP CONTROL SYSTEMS

RAW MATERIALS

MATERIAL FLOW

FINISHED GOODS

• 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

• ADVANTAGES– REDUCED INVESTMENT ON MACHINES, BEING

GENERAL PURPOSE MACHINES– GREATER FLEXIBILITY IN PRODUCTION– BETTER AND MORE EFFICIENT SUPERVISION– GREATER SCOPE OF EXPANSION– BETTER UTILISATION OF RESOURCES– HADLING BREAKDOWN OF EQUIPMENT

EASIER-JOBS CAN BE TRANSFERRED TO OTHER MACHINES

– FULL UTILISATION OF MACHINERY

PROCESS LAYOUT

• LIMITATIONS– DIFFICULTY IN MOVEMENT OF

MATERIALS– LAYOUT REQUIRES MORE SPACE– DIFFICULTY IN PRODCUTION CONTROL– PRODUCTION TIME INCREASED

BECAUSE OF EXTRA TRAVEL– ACCUMULATION OF WORK-IN-PROCESS

AT DIFFERENT MACHINES

PROCESS LAYOUT

PRODUCT LAYOUT

• MACHINES ARRANGED IN A LINE DEPENDING UPON SEQUENCE OF OPERATIONS

• MATERIAL MOVES IN A LINE FROM THE FIRST MACHINE TO THE FINISHED PRODUCT ON THE LAST MACHINE.

• INVESTMENT HIGHER AS COMPARED TO PROCESS LAYOUT

BETTER SUITED FOR STANDARDISED PRODUCTS ON A MASS SCALE PRODUCTION. EX CHEMICALS,PAPER

FINISHED GOODS

MATERIAL FLOW

RAW MATERIALS

PRODUCTION SUB-SYSTEM

RECEIVING

STORAGE

OPERATION A

OPERATION B

OPERATION C

OPERATION D

SHIPPING

EDP CONTROL SYSTEMS

INFORMATION FLOWS

CONTINUOUS FLOW PRODUCTION SYSTEM (FLOW SHOP)

• 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

PRODUCT LAYOUT

• ADVANTAGES– REDUCTION IN MATERIAL HANDLING COST

DUE TO MECHANISATION– LAYOUT AVOIDS PRODUCTION BOTTLENECKS– ECONOMY IN MANUFACTURING TIME– BETTER PRODUCTION CONTROL– REQUIRES LESS FLOOR AREA PER UNIT OF

PRODUCTION– WORK-IN-PROGRESS IN REDUCED– EARLY DETECTION OF MISTAKES

PRODUCT LAYOUT

• LIMITATIONS– LAYOUT INFLEXIBLE– LAYOUT EXPENSIVE– DIFFICULTY IN SUPERVISION– EXPANSION IS DIFFICULT– ANY BREAKDOWN ALONG THE LINE

CAN DISRUPT TOTAL PRODUCTION

PRODUCT LAYOUT

FIXED POSITION LAYOUT

• MOVEMENT OF MEN & MACHINERY TO THE PRODUCT

• PRODUCT REMAINS STATIONARY– COST OF MOVING PRODUCT IS HIGH,BEING

BULKY

BEST SUITED FOR BULKY & HEAVY PRODUCTS EX.SHIPS, AEROPLANES ETC.

AIRCRAFT ASSEMBLYFINISHED PRODUCT (AIRCRAFT)

RAW MATERIALS

MACHINE & EQUIPMENT

LABOUR

FIXED POSITION OR STATIC LAYOUT

FIXED POSITION LAYOUTADVANTAGES

• MEN/MACHINERY CAN BE MOVED FOR A WIDE VARIETY OF OPERATIONS PRODUCING DEFFERENT 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

CELLULAR MANUFACTURING (CM) LAYOUT

• GROUPING OF MACHINES INTO CELLS • CELLS FUNCTION SOMEWHAT LIKE

PRODUCT LAYOUT WITHIN 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

1 2

3

45

1 2 3

1 2

34

21

CELL # 3

CELL # 4

CELL # 1 CELL # 2

PRODUCTION OPERATION PRODUCT OR MATERIAL FLOW

CELLULAR MANUFACTURING LAYOUT

PART D

PART Y

PART X

PART A

PART B

3

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

CM LAYOUTLIMITATIONS

• REDUCED MANUFACTURING FLEXIBILITY & POTENTIALLY INCREASED MACHINE DOWNTIME

• DUPLICATE PIECES OF MACHINERY MAY BE NEEDED SO AS TO AVOID MOVEMENT OF PARTS BETWEEN CELLS

COMBINED LAYOUT

• COMBINATION OF PRODUCT & PROCESS LAYOUT WITH AN EMPHASIS ON EITHER

• GENERALLY ADOPTED IN INDUSTRY• IN FABRICATION PLANTS INCLUDING

ASSEMBLY, FABRICATION TENDS TO EMPLOY PROCESS LAYOUT WHILE ASSEMBLY 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 ON FUNCTIONAL BASIS.

F.P.

F.P.

G.C.

G.C.

G.C.

H.T.

H.T.

G.G.

G.G.

RAW MATERIAL

RAW MATERIAL

PR

OC

ES

S L

AY

OU

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

SERVICE FACILITY LAYOUT

• MAIN DIFFERENCE BETWEEN SERVICE AND MANUFACTURING FACILITY IS TO BRING TOGETHER CUSTOMERS & SERVICES IN MANY 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

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 LOUNGE

CAFETERIA

CASUALTY DEPT / INPATIENT DEPT

ENTRANCE EXIT

CASUALTY DEPT / INPATIENT DEPT

ENTRANCEEXIT

AIS

LE

S /

GA

NG

WA

YS

PA

RK

ING

AR

EA

PA

RK

ING

AR

EA

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 AS REDUCE 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.

SERVICE FACILITY LAYOUT

• 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 FACILITY LAYOUT

SERVICE WAITING LINE MODULES

SINGLE CHANNEL, SINGLE PHASE MODULE

WAITING LINE SERVICE FACILITY

MULTIPLE CHANNEL, SINGLE PHASE MODULE

SERVICE FACILITY

WAITING LINE

SINGLE CHANNEL, MULTIPLE PHASE MODULE

WAITING LINE SERVICE FACILITY

SERVICE FACILITY

WAITING LINE

MULTIPLE CHANNEL, MULTIPLE PHASE MODULE

LAYOUT PLANNING

• NEED FOR FUTURE REVISIONS CAUSED DUE TO EXPANSIONS, TECHNOLOGICAL ADVANCES, IMPROVED LAYOUTS ETC

• MAJOR CRITERIA FOR SELECTING AND DESIGNING LAYOUTS– MATERIAL HANDLING COST

• MATERIAL HANDLING COSTS MINIMISED BY USING MECHANISED MATERIAL HANDLING EQUIPMENTS

– WORKER EFFECTIVENESS• GOOD LAYOUT PROVIDES WORKERS WITH A

SATISFYING JOB AND PERMITS THEM TO WORK MORE EFFECTIVELY AT THE HIGHEST SKILL LEVEL

• GOOD COMMUNICATION SYSTEM AND WELL PLACED SUPPORTING ACTIVITY LOCATIONS IMPORTANT

LAYOUT PLANNINGMETHODOLOGY

• 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 FACILITIES TECHNIQUE)

THANK YOU

REFERENCES

• PRODUCTION & OPERATIONS MANAGEMENT: ASWATHAPPA / BHAT

• MODERN PRODUCTION / OPERATIONS MANAGEMENT: BUFFA / SARIN

• PRODUCTION OPERATIONS MANAGEMENT: LEVIN / MCLAUGHLIN et al