Om Plant Layout Study

8/6/2019 Om Plant Layout Study

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PLANT LAYOUT A layout is a physical configuration

of departments, work stations and

equipments in the conversionprocess.

It is the spatial arrangement of

physical resources used to create aproduct.


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OBJECTIVES OF PLANT LAYOUT STUDY

1. Minimize investment in equipment

2. Minimize over all production time.

3. Utilize existing space mosteffectively

4. Provide for employee convenience,

Safety and comfort5. Maintain flexibility of arrangement

and operation.

6. Minimize material handling cost


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OBJECTIVES OF PLANT LAYOUT STUDY

7. Minimize variation in types of

material handling equipment.

8. Facilitate the manufacturing

process.


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PLANT LAYOUT STUDY

It is interrelated .

Layout design

Product design

Schedule Design Process Design


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SOME MOST COMMONLY INVOLVEDFACTORS / CONSIDERATIONS

1. Ease of future expansion

2. Flexibility of layout3. Material handling effectiveness

4. Space utilization

5. Safety & Housekeeping

6. Working Conditions


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SOME MOST COMMONLY INVOLVEDFACTORS / CONSIDERATIONS

7. Ease of Supervision & Control

8. Appearance, Promotional value

9. Fit with Company OrganizationStructure

10.

Equipment utilization11. Ability to meet capacity or

Requirements

12. Investment or capital required.


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REEDS SYSTEMATIC PLAN OF ATTACKPLANT LAYOUT PROCEDURE Steps to

be taken

Analyse the production or processes to

be produced Determine the process required to

manufacture the product

Prepare layout planning charts Determine work stations

Analyse storage area requirements


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REEDS SYSTEMATIC PLAN OF ATTACKPLANT LAYOUT PROCEDURE Steps to

be taken

Establish minimum aisle widths

Establish office requirements Consider personnel facilities and

services

Survey plant services Provide for future expansion


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THE MOST POPULAR APPROACHDEVELOPED BY MUTHER - SLP

The procedure applied to:

1. Production2. Transportation

3. Storage

4. Support services5. Office activities etc


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1. Flow of

Material

2. Activity

Relationships

INPUT DATA AND ACTIVITIES

3.RelationshipDiagram

4. SpaceRequirements

5. SpaceAvailable

6. Space RelationshipDiagram

7. ModifyingConsiderations

8. PracticalLimitations

9. Develop LayoutAlternatives

10. Evaluation

Sele

ction

Search

Analysis


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TYPES OF FLOW PATTERNS

Classifications of flow patterns Horizontal or vertical

a) b)

c) d)


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TYPES OF FLOW PATTERNS

Classifications of flow patterns Horizontal or vertical

e)

f)


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TYPES OF FLOW PATTERNS Vertical flow patterna) b) c)


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TYPES OF FLOW PATTERNS Vertical flow patternd) e) f)


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TYPES OF LAYOUT

Four General layout categoriesare:-

1. Fixed or Static product Layout

2. Product layout

3. Process Layout

4. Product Layout


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Fixed position layout It is not feasible to move the

product

Product stays in one location;tools,men,material etc. arebrought to it.


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FIXED PRODUCT LAYOUT

WORK PIECE

Paint

Mill

Weld

Drill

Lathe Grind

AssemblySaw

Stores Warehouse


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PRODUCT LAYOUT

Saw

Saw

Grind

Weld Grind

Mill

Mill

Lathe Mill

Drill Paint

Paint

DrillLathe

Drill

Drill

Assembl

y

Warehous

e

Stores


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Product layout or line

production Appropriate for producing one

standard product in large quantities

Each unit of output require the samesequence of operations frombeginning to end

Work centers and equipments arearranged in a line


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Process layout or layout by

function Work centres and departments are

grouped together according to their

function or type Useful where volume of

manufacture is low and variety is

high Provides tremendous flexibility- no

solid sequencing


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GROUP LAYOUT

Saw

Saw

Grind

Lathe Mill

Paint

Mill

Lathe

Assemb

ly

Warehouse

Stores

Paint

Drill

Drill

Group A

Group B


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ADVANTAGES & LIMITATIONS OFLAYOUTS

Fixed Product Layout

Advantages Limitations1. Material movement is

reduced

2. Promotes Job enlargement

by allowing individuals orteams to perform the wholejob

3. Continuity of Operationsand responsibility resultsfrom team

4. Highly flexible; canaccommodate changes inproduct design, product mixand production volume

5. Independence of productioncenters allows schedulingto achieve min. total prodn

1. Increased movement ofpersonal and equipment.

2. Equipment duplication may

occur3. Higher skill requirements for

personnel

4. General supervisionrequired

5.

Cumbersome and costlypositioning of material andmachinery

6. Low equipment utilization


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Product Layout

Advantages Limitations1. Since the layout

corresponds to thesequence of operations,smooth and logical flow lineresult.

2. Since the work from oneprocess is fed directly intothe next, small in processinventories result.

3. Total production time perunit is short.

4. Since the m/cs are locatedso as to minimize distancesb/w consecutive operations,materials handling is

reduced.

1. A breakdown of onemachine may lead to acomplete stoppage of theline that follows thatmachine.

2. Since the layout isdetermined by the product,a change in product designmay require major

alterations in the layout.3. The pace of production is

determined by the slowestmachine.

4. Supervision is general,rather than specialized.

5. Comparatively high


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Group Layout

Advantages Limitations1. Increased machine

utilization.

2. Team attitude and job

enlargement tend to occur.3. Compromise between

product layout and processlayout, with associatedadvantages

4. Supports the use of general

purpose equipment.5. Shorter travel distances

and smoother flow linesthan for process layout.

1. General supervisionrequired.

2. Higher skill levels required

of employees than forproduct layout.

3. Compromize betweenproduct layout and processlayout with associatedlimitations.

4. Depends on balancedmaterial flow through thecell; otherwise buffers andwork-in-process storage arerequired.

5. Lower machine utilization

than for process layout.


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Process Layout

Advantages Limitations1. Better utilization of

machines can result;consequently fewermachines are required.

2. A high degree of flexibilityexists relative to equipmentor manpower allocations forspecific tasks.

3. Comparatively low

investment in machines isrequired.

4. The diversity of tasks offersa more interesting andsatisfying occupations forthe operator.

5. Specialized supervision is

1. Since longer flow lineusually results, materialshandling is more expensive.

2. Production planing andcontrol system are moreinvolved.

3. Total production time isusually longer

4. Comparatively large amount

of in-process inventoryresult.

5. Space and capital are tiedup by work in process.

6. Because of the diversity ofjobs in specializeddepartments, higher grades


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Space for Future Expansion

Space for FutureExpansion

Copper TeeProduction (Assembly)Operations1. Cu-Wire Rewinding

/ Cleaning2. Winding3. Tying4. Pouching5. Assembling6. Sealing7. QA

QA

Cu-T Moulding

Component Store

Receiving Bay

Raw Matl for Cu-TMoulding

Final Packing AreaFor Cu-T

Finished Product

Store

Quarantine


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Om Plant Layout Study

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