PLANT LAYOUT AND TYPES OF PRODUCT LAYOUT

• PLANT LAYOUT AND TYPES OF PRODUCT LAYOUT
  PRODUCTION AND OPERATION MANAGEMENT
• BY SHAHSI AGGARWAL
• NET MANAGEMENT
• OPERATION MANAGEMENT
• MEANING OF PLANT LAYOUT
• PLANT LAYOUT REFERS TO THE ARRANGEMENT OF MACHINERY,EQUIPMENT AND OTHER INDUSTRIAL FACILITIES  SUCH AS RECEIVING AND SHIPPING DEPARTMENT,TOOL ROOM,MAINTENANCE ROOMS AND EMPLOYEE AMENITIES FOR ACHIEVING QUICKEST AND SMOOTH PRODUCTION.
• THE SUBJECT OF PLANT LAYOUT NOT ONLY COVERS THE INITIAL LAYOUT OF MACHINES AND OTHER FACILITIES BUT ALSO INCLUDES IMPROVEMENT/REVISION
• KNOWLES AND THOMAS,” PLANT LAYOUT INCLUDES THE FOLLOWING:-
• PLANNING AND ARRANGING MANUFACTURING MACHINERY,EQUIPMENT AND SERVICES FOR THE FIRST TIME IN COMPLETELY NEW PLANTS
• THE IMPROVEMENT IN LAYOUT ALREADY IN USE IN ORDER TO INTRODUCE NEW METHODS AND IMPROVEMENT IN MANUFACTURING PROCEDURES.
• OBJECTIVES OF A GOOD LAYOUT

1. PROVIDE ENOUGH PRODUCTION CAPACITY
2. REDUCE MATERIAL HANDLING COSTS
3. REDUCE CONGESTION
4. REDUCE HAZARDS TO PERSONNEL
5. UTILIZE LABOUR EFFICIENCY
6. INCREASE EMPLOYEE MORALE
7. REDUCE ACCIDENTS
8. UTILIZE AVAILABLE SPACE EFFICIENTLY AND EFFECTIVELY
9. PROVIDE EACH OF SUPERVISION
10. FACILITATE CO ORDINATION AND FACE TO FACE COMMUNICATION
11. PROVIDE EMPLOYEE SAFETY AND HEALTH
12. ALLOW EASE OF MAINTENANCE
13. ALLOW HIGH MACHINERY /EQUIPMENT UTILIZATION
14. IMPROVE PRODUCTIVITY

• FACTORS INFLUENCING FACILITY LAYOUT
• PRIMARILY THE LAYOUT OF A PLANT IS INFLUENCED BY THE RELATIONSHIP AMONG MATERIALS,MACHINERY AND MEN AND OTHER FACTORS ALSO INFLUENCE.
• MATERIALS:

1. NEED TO PROVIDE FOR THE STORAGE AND MOVEMENT OF THE RAW MATERIALS IN PLANT UNTIL THEY ARE CONVERTED INTO FINISHED PRODUCT
2. MOVED MANUALLY/MECHANICAL OPERATIONS/CHEMICAL PROCESSING
3. PROPER STORAGE ROOMS AND MOVEMENT EQUIPMENT
4. INITIAL INVESTMENT AND RECURRING COST ON MATERIAL EQUIPMENT CRANES,TROLLY AND PIPELINE . IT ALSO DEPENDS ON THE TYPE OF MATERIAL USE-LIQUID,SOLD/GAS AND THE AVAILABILITY

5. FOR DETERMINING BEST PATH THE FLOW CHARTS ARE DR AWNS TO VISUALIZE THE MOVEMENT OF MATERIALS.

• PRODUCT:-

1. NATURE OF THE PRODUCT:-HEAVY/LIGHT/BIG/SMALL/LIQUID/SOLID
2. PRODUCT MOVES FROM WORK STATION TO OTHER WORKS STATION
3. IN THE MANUFACTURE OF LOCOMOTIVES AND IN SHIP BUILDING THE PRODUCT IS STATIONERY
4. POSITION OF THE PRODUCT IN RELATION TO OTHER PRODUCT MATTERS
5. SALE AND DEMAND ALSO EXERCISE INFLUENCE ON THE PLANT LAYOUT
6. EXPERTS ARE OF THE OPINION THAT PLANT  LAYOUT SHOULD BEGIN FROM PRODUCT

• WORKER:_

1. SHOULD ALSO CONSIDER THE TYPE,POSITION AND REQUIREMENT OF THE EMPLOYEE
2. POSITION OF THE EMPLOYEE
3. EMPLOYEE FACILITIES HEALTH AND RELATED. SAFETY

·         MACHINERY:-

• THE TYPE OF PRODUCT,ITS VOLUME OF PRODUCTION,TYPE OF PROCESS AND MGMT POLICY DETERMINE THE SIZE AND TYPE OF THE MACHINERY TO BE  INSTALLED
• TYPE OF INDUSTRY:-
• TYPE OF THE INDUSTRY AND METHOD OF MANUFACTURE
• TYPE OF INDUSTRY:-

1. EXTRACTIVE INDUSTRIES:-SEPARATION OF ONE ELEMENT FROM ANOTHER IN THE CASE OF METAL FROM THE ORE
2. A CONDITIONING INDUSTRY: INVOLVE A  CHANGE IN THE FORM OR PHYSICAL PROPERTIES
3. ANALYTICAL INDUSTRY:CONVERTS RAW MATERIAL INTO VARIOUS ELEMENTS
4. SYNTHETIC INDUSTRY: ALSO CALLED ASSEMBLING: PRODUCTION OF A PRODUCT BY THE USE OF VARIOUS ELEMENTS
5. INDUSTRIES MAY ALSO BE CLASSIFIED: CONTINUOUS INDUSTRIES AND INTERMITTENT INDUSTRIES

• LOCATION:-
• THE LOCATION ALSO INFLUENCES ITS LAYOUT

1. SIZE AND TERRAIN OF THE SITE DETERMINE THE TYPE OF BUILDING WHICH IN TURN INFLUENCES LAYOUT
2. LOCATION OF THE PLANT DETERMINE THE MODE OF TRANSPORTATION
3. MAY ALSO BE DETERMINED BY THE FUEL REQUIREMENTS
4. PLANT LAYOUT MAY ALSO PROVIDE STORAGE FACILITY AND ALSO CONSIDER THE REQUIREMENT OF POWER GENERATION
5. DEMAND FOR FUTURE EXPANSION

• MANAGERIAL POLICIES:-
• THE VOLUME OF PRODUCTION AND PROVISION FOR EXPANSION
• THE EXTENT OF AUTOMATION
• MAKING OR BUYING A PARTICULAR COMPONENT
• DESIRE FOR RAPID DELIVERY OF GOODS TO CUSTOMERS
• PERSONNEL POLICIES
• PRINCIPLES OF LAYOUT

1. THE PRINCIPLE OF MINIMUM TRAVEL
2. PRINCIPLE OF SEQUENCE
3. PRINCIPLE OF USAGE
4. PRINCIPLE OF COMPACTNESS
5. PRINCIPLE OF SAFETY AND SATISFACTION
6. PRINCIPLE OF FLEXIBILITY
7. PRINCIPLE OF MINIMUM INVESTMENT

• TYPES OF LAYOUT
• REFERS TO THE ARRANGING AND GROUPING OF MACHINES WHICH ARE MEANT TO PRODUCE GOODS. GROUPING OF MACHINES IS DONE ON DIFFERENT LINES AND IS INFLUENCED BY VARIOUS FACTORS.
• TYPES OF PLANT LAYOUT:-

1. PROCESS OF LAYOUT
2. PRODUCT LAYOUT
3. FIXED POSITION LAYOUT
4. CELLULAR MANUFACTURING
5. COMBINATION LAYOUT

• PROCESS LAYOUT
• ALSO CALLED THE FUNCTIONAL LAYOUT

1. LAYOUT FOR JOB LOT MANUFACTURE OR BATCH PRODUCTION
2. GROUPING TOGETHER OF LIKE MACHINES IN ONE DEPARTMENT
3. MACHINES PERFORMING SIMILAR FUNCTIONS ARE KEPT IN ONE DEPARTMENT
4. LIKE MACHINE PERFORMING DRILLING FUNCTION KEPT IN DRILLING DEPARTMENT
5. MATERIAL WOULD MOVE LONG DISTANCES AND ALONG CRISSCROSSING PATHS
6. AT ONE STAGE THE MATERIAL MAY BE TAKEN TO SEPARATE BUILDING FOR HEAT TREATMENT AND THEN BROUGHT BACK FOR GRINDING
7. MACHINES ARE CALLED GENERAL PURPOSE AND ALLOTMENT OF WORK IN SUCH A MANNER THAT NO MACHINE IS IDEAL
8. SUITABLE FOR INTERMITTENT TYPE OF PRODUCTION

• PRINCIPLES

1. THE DISTANCE BETWEEN DEPARTMENT NEEDS TO BE SHORT
2. LIKE MACHINES ARE GROUPED IN ONE DEPARTMENT,DEPARTMENT SHOULD BE LOCATED IN ACCORDANCE WITH THE PRINCIPLES OF SEQUENCE
3. CONVENIENCE FOR INSPECTION
4. CONVENIENCE FOR SUPERVISION

• ADVANTAGES

1. REDUCED INVESTMENT OF MACHINES
2. GREATER FLEXIBILITY IN THE PRODUCTION
3. BETTER AND MORE EFFICIENT SUPERVISION
4. GREATER SCOPE FOR EXPANSION
5. BETTER UTILIZATION OF MEN AND MACHINES
6. EASIER TO HANDLE BREAKDOWN OF EQUIPMENT
7. FULL UTILIZATION OF EQUIPMENT
8. THE INVESTMENT OF EQUIPMENT WOULD BE LOW
9. GREATER INCENTIVE TO INDIVIDUAL WORKERS TO INCREASE HIS PERFORMANCE

• DISADVANTAGES

1. DIFFICULTY IN THE MOVEMENT OF MATERIALS
2. REQUIRE MORE FLOOR SPACE
3. DIFFICULTY IN PRODUCTION CONTROL
4. PRODUCTION TIME IS MORE AS WORK IN PROGRESS

• PRODUCT LAYOUT

1.     STRAIGHT LINE LAYOUT/LAYOUT FOR SERIALIZED MANUFACTURE

2.     A PRODUCT LAYOUT INVOLVES THE ARRANGEMENT OF MACHINES IN ONE LINE DEPENDING ON SEQUENCE OF OPERATIONS.

3.     MATERIAL ARE FED INTO FIRST MACHINE AND FINSIHED PRODUCT COME OUT OF THE LAST MACHINE

4.     SPECIAL PURPOSE OF MACHINE. FOLLOWED IN STANDARDISED PRODUCTS ON MASS SCALE CHEMICAL.PAPER,SUGAR ,RUBBER ETC

5.     INVESTMENT IS HIGHER

6.     GROUPING OF MACHINES ON THE BASIS OF PRODUCT LINE:

7.     ALL THE MACHINES TOOLS OR OTHER EQUIPMENT MUST BE PLACED IN SEQUENCE

8.     NO POINTS WHERE ONE LINE CROSSES ANOTHER LINE

9.     MATERIALS MAY BE FED WHERE THEY ARE REQUIRED FOR ASSEMBLY

10.  ALL THE OPERATIONS INCLUDING ASSEMBLY,TESTING AND PACKING SHOULD BE INCLUDED

11.  LINE LAYOUT OR PRODUCT LAYOUT

• ADVANTAGES

1. REDUCTION IN MATERIAL HANDLING DUE TO MECHANIZATION
2. AVOIDS PRODUCTION OBSTACLES
3. BETTER PRODUCTION CONTROL
4. LESS FLOOR AREA PER UNIT OF PRODUCTION
5. WORK IN PROGRESS IS REDUCED
6. GREATER INCENTIVE TO RAISE THEIR LEVEL OF PERFORMANCE

• DISADVANTAGE

1. INFLEXIBILITY
2. EXPENSIVE
3. DIFFICULTY O SUPERVISION
4. DIFFICULTY IN EXPANSION
5. ANY BREAKDOWN WILL DISRUPT THE WHOLE SYSTEM

• COMPARISON
• PRODUCT LAYOUT

1. ONE OR FEW STANDARDIZED PRODUCT
2. HIGHLY AUTOMATION AND HUGE INVESMTNENT
3. SPECIAL PURPOSE MACHINES
4. LESS FLEXIBILITY
5. REDUCTION IN MATERIAL HANDLING COST
6. LOW SPACE REQUIREMENT
7. TIMELY DETECTION OF DEFECTIVES
8. WORK IN PROGRESS IS LESS

• PROCESS LAYOUT

1. MANY PRODUCTS ARE PRODUCED IN SMALL QUANTITY
2. LESS AUTOMATION
3. MORE FLEXIBILITY
4. GENERAL PURPOSE MACHINES
5. MATERIAL HANDLING COST IS HIGH
6. MORE SPACE
7. MORE WIP
8. DELAYED DETECTION OF DEFECTIVE PRODUCTS

• FIXED POSITION LAYOUT

1.  A PRODUCTION TECHNIQUE IS USED TO ASSEMBLE PRODUCTS THAT ARE TOO LARGE,BULKY OR FRAGILE TO SAFELY OR EFFECTIVELY MOVE TO LOCATION FOR COMPLETION
2. FIXED POSITION LAYOUT PERSONNEL,SUPPLIES AND EQUIPMENT ARE BROUGHT TO THE SIT E WHERE THE PRODUCTS WILL BE ASSEMBLED RATHER THAN PRODUCT BEING MOVER THROUGH AN ASSEMBLY LINE OR SET OF ASSEMBLY STATIONS.
3. ARE TYPICALLY EMPLOYED IN LARGE PROJECTS TYPE ORGANIZATION.
4. LIKE NUCLEAR ENGINEERING DIVISION OF BHEL
5. LIKE BUILDING DAMS,SHIP BUILDING,AIRCRAFT,AEROSPACE,FARMING ,DRILLING FOR OIL,HOME REPAIR AND AUTOMATED CAR WASHES ETC

• ADVANTAGES

1. IT SAVES TIME AND COST INVOLVED ON THE MOVEMENT OF WORK FROM ONE WORK STATION TO ANOTHER
2. THE LAYOUT IS FLEXIBLE AS CHANGES IN JOB DESIGN AND OPERATION SEQUENCE CAN BE EASILY INCORPORATED

• DISADVANTAGE

1. PRODUCTION PERIOD BEING VERY LARGE,CAPITAL INVESTMENT IS VERY HEAVY
2. VERY LARGE SPACE IS REQUIRED FOR STORAGE OF MATERIAL AND EQUIPMENT NEAR THE PRODUCT
3. AS SEVERAL OPERATIONS ARE OTHER CARRIED OUT SIMULTANEOUSLY THERE IS POSSIBILITY OF CONFUSION AND CONFLICTS AMONG DIFFERENT WORK GROUPS,

• GROUP TECHNOLOGY LAYOUT IN OPERATION MANAGEMENT

1. IS THE ANALYSIS AND COMPARISON OF ITEMS TO GROUP THEM INTO FAMILIES SIMILAR CHARACTERS TICS
2. COMBINATION OF THE PRODUCT LAYOUT AND PROCESS LAYOUT
3. IF THERE ARE M MACHINES AND N COMPONENTS WILL BE DIVIDED INTO NUMBER OF MACHINE COMPONENT CELLS SUCH THAT ALL THE COMPONENTS ASSIGNED TO CELLS ARE ALMOST PROCESSED WITH IN  THAT CELL ITSELF
4. THE OBJECTIVE IS TO MINIMIZE THE INTER CELL MOVEMENT
5. THIS TECHNIQUE IS USEFUL FOR COMPANIES THAT PRODUCE VARIETY OF PARTS IN SMALL BATCHES TO ENABLE THEM TO TAKE ADVANTAGE AND ECONOMIES OF FLOW LINE LAYOUT

• THE APPLICATION F GROUP TECHNOLOGY INVOLVES TWO BASIC STEPS :-

1. DETERMINE COMPONENT FAMILIES
2. APPLYING GROUP TECHNOLOGY TO ARRANGE THE PLANT EQUIPMENT USED TO PROCESS A PARTICULAR FAMILY COMPONENT  AND THIS REPRESENT SMALL PLANTS WITH IN THE PLANTS

·         PROCESS ARE GROUPED INTO CELLS USING A TECHNIQUE AS GROUP TECHNOLOGY

1.     IDENTIFYING PARTS ( SIZE,SHAPES AND FUNCTION ) AND SIMILAR PROCESSES CHARACTERS TICS ( TYPE OF PROCESSING REQUIRED ,AVAILABLE MACHINERY THAT PERFORMS THIS TYPE OF PROCESS AND PROCESSING TECHNIQUE)

2.     WORKERS ARE CROSS TRAINED SO THAT THEY CAN OPERATE ALL THE EQUIPMENT WITH IN THE CELL AND TAKE RESPONSIBILITY OF THE FINAL PRODUCT,

3.     THE GROUP TECHNOLOGY REDUCES THE PRODUCTION PLANNING  TIME FOR JOBS AND IT REDUCES THE SET UP TIME.

4.     IN GROUP TECHNOLOGY THE OBJECTIVE IS TO MINIMIZE THE COST OF TRANSPORTATION AND COST OF EQUIPMENT

• ADVANTAGE
• COMPONENT STANDARDIZATION AND RATIONALIZATION
• RELIABILITY OF ESTIMATES
• EFFECTIVE MACHINE OPERATION
• CUSTOMER SERVICES
• CAN DECREASE :
• PAPER WORK AND OVERALL PRODUCTION TIME
• WORK IN PROGRESS AND WORK MOVEMENT
• OVERALL COST
• LIMITATION
• MAY NOT BE FEASIBLE FOR ALL SITUATIONS
• IF THE PRODUCT MIX IS COMPLETELY DISSIMILAR THEN WE MAY NOT HAVE MEANINGFUL CELL FORMATION
• COMBINATION LAYOUT

1. ONE FIRM MAY USE A PROCESS LAYOUT FOR THE PROCESS ALONG WITH ASSEMBLY IN ONE AREA
2. OR
3. FIXED POSITION LAYOUT MAY BE USED FOR ASSEMBLY OF ITS FINAL PRODUCT
4. AND ASSEMBLY LINE TO USE FOR COMPONENTS