PLANT LAYOUT & MATERIAL HANDLING

Submitted by
K.N.Jakanathan

Definition

Layout is a Fundamental of every organization and enterprise. Plant layout involves the development of physical relationships among building equipment and production operations which will enable the manufacturing process to be carried on efficiently - Morris

Plant Layout -

placement of departments, placement of workgroups within departments,

Objectives

Proper and efficient utilization of cubic (i.e. length, width and height) of available floor space. To ensure that work proceeds from one point to another without any delay. Provide enough production capacity. Reduce material handling costs. Reduce hazards to personnel. Utilize labor efficiently. Increase employee morale. Eliminate conjugation and bottle neck at work. Provide for volume and product flexibility. Provide ease of supervision and control. Provide for employee safety and health. [ Reduce accidents ] Allow ease of maintenance. Allow high machine or equipment utilization. Improve productivity. Reduce Capital Investment.
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Factors Influencing Layout

Nature of product. Production process. [Including Waiting Time] Type of machinery. Repairs and maintenance. Human needs. Plant environment. Materials. Material Handling Equipments. Auxiliary Services. Future Changes. Factory building.
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P&Q Analysis - Input data and Activities

Definition

Product Flow

Activity relationships

Chart relationship (flow, functional)

Space relationships - Diagram

Adjustment
Project B

Project A

Project C

Evaluation
Selection Implementation

Evaluate alternative arrangements

Systematic Layout Design Process Method - Muther (1973)

Types of Layout

Manufacturing units Product or line layout Process or functional layout Fixed position or location layout Combined layout Fixed Layout Cellular (or) Group Technology Layout

Product oriented Plant Layout (Line Layout)

Machinery and Materials are placed following the product path. This type of plant layout is useful when the production process is organized in a continuous or repetitive way. Continuous flow: The correct operations flow is reached through the layout design and the equipment and machinery specifications. Repetitive flow (assembly line): The correct operations flow will be based in a line balancing exercise, in order to avoid problems generated by bottle necks.
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Cont.,

The plant layout will be based in allocating a machine as close as possible to the next one in line, in the correct sequence to manufacture the product. Allocating line may be of any form, like
straight line L shape

U shaped

S shaped

Factory Product layout

Product layout

Product oriented plant layout Advantages: Economy material handling activities. Mechanization of material handling equipments. Work In Process almost eliminated. Minimum manufacturing time. Simplification of the production planning and control systems. Tasks simplification. Greater incentive for group. Disadvantages: No flexibility in the production process Low flexibility in the manufacturing times. High capital investment. Difficulty of supervising, since the person is expert in only one function. Every workstation is critical to the process.- The lack of personnel or shut down of a machine stops the whole process. Monotonous work. Difficulty in expansion.
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Process oriented plant layout (Functional Layout)

This type of plant layout is useful when the production process is organized in batches. Personnel and equipment to perform the same function are allocated in the same area. The different items have to move from one area to another one, according to the sequence of operations previously established. The variety of products to produce will lead to a diversity of flows through the facility. The variations in the production volumes from one period to the next one (short periods of time) may lead to modifications in the manufactured quantities as well as the types of products to be produced.
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Factory Process layout

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Process Layout

Process oriented plant layout Advantages: Flexibility in the production process. Better control of manufacturing cost. No Duplication. Easy to handle the problems. Better Supervising. [Experts will be there in each department] Higher Individual incentive. Disadvantages: Manufacturing time increases. Controlling will be costly and complex. Material handling cost will be higher. More workspace required. Accumulation of work-in process.

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Fixed Layout

In Fixed product layout, the products generally circulate within the production facilities (machines, workers, etc.); in this particular type of layout, the product does not move, the different resources are moved to perform the operations on the product. This type of layout is commonly found in industries that manufacture large size products, such as ships or aircrafts. The equipment is brought to the object being processed, and the object does not move. Example: Air craft manufacturing. Arranging materials and equipment concentrically around the production point in their order of use.
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Factory Fixed Layout

AIR CRAFT ASSEMBLY Finished product AIRCRAFT

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Fixed Layout
Advantages of stationery Layout: Layout is fully flexible and is capable of absorbing any sort of change in product and process. Lower labor cost [People are drawn from functional departments] Saving in time Less floor space because machines and equipment are in moving position. Most suitable way of assembling large and heavy products. Disadvantages Of Stationery Layout: Higher capital investment Unsuitability for manufacturing or assembling small products in large quantities. It is suitable only in case where the product is big or the assembling process is complex.

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Combined Layout or Mixed Layout

Manufacturing concerns where several products are produced in repeated numbers with no likelihood of continuous production , combined layout is followed. Generally, a combination of the product and process layout or other combination are found, in practice, e.g. for industries involving the fabrication of parts and assembly, fabrication tends to employ the process layout, while the assembly areas often employ the product layout.
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Factory Combined Layout

C o m b i n e d

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P-Q Analysis
Q u a n t i t y

Product Layouts Fixed Position Layouts

Mixed Layouts

Process Layouts
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Number of different products

CELLULAR OR GROUP TECHNOLOGY LAYOUT

Work cells

Definition:

Group of equipment and workers that perform a sequence of operations over multiple units of an item or family of items.

Looks for the advantages of product and process layouts:

Product oriented layout: Efficiency Process oriented layout: Flexibility Grouping outputs with the same characteristics to families, and assigning groups of machines and workers for the production of each family.
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Group Technology

CELLULAR OR GROUP TECHNOLOGY LAYOUT

In a cellular layout the design is not according to the functional characteristics of equipment, but rather by self-contained groups of equipment (called cells), needed for producing a particular set of goods or services. Group technology, or cellular manufacturing, classifies parts into families so that efficient mass-production-type layouts can be designed for the families of goods or services.
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Cellular Layout
Process (Functional) Layout
A cluster or cell
T T M M T T M M T T D D CG SG D D CG SG D SG D CG CG SG D T T M T M D

Group (Cellular) Layout

M D

T
M

Similar resources placed together

Resources to produce similar products placed together

CL or GT: BENEFITS
Advantages

Lower work-in-process Inventories Reduced material handling costs. Shorter flow times in production. Simplified production planning. (MEN, MATERIAL ETC.) Overall performance increased by lowering production costs & improving on time delivery. Improved Quality.

Disadvantages

Reduced manufacturing flexibility & potentially increased machine downtime. Duplicate pieces of machinery may be needed so as to avoid movement of parts between cells.
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Break Even Analysis

Use fixed position

Use process

Use cell Use product or GT

Volume

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EXAMPLE OF SYSTEMATIC LAYOUT PLANNING: REASONS FOR CLOSENESS

5
6

Share same price

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EXAMPLE OF SYSTEMATIC LAYOUT PLANNING: IMPORTANCE OF CLOSENESS

Closeness
Absolutely necessary

Line code

Numerical weights 16

E
I O U X

Especially important
Important Ordinary closeness OK Unimportant Undesirable

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4 2 0 80
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EXAMPLE OF SYSTEMATIC LAYOUT PLANNING: RELATING REASONS AND IMPORTANCE

2 A 6

3 U -U --

4 I 4 I 1 U --

Note here that the (1) Credit Dept. and (2) Saree Dept. are given a high rating .

5 A 100 6 A 400 1,6 X 300 1 X here that Note 100 1 the (2) Saree

Reason for rating Number

Dept. and100 the (5) Jwellry Dept. are given a high rating of A.
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EXAMPLE OF SYSTEMATIC LAYOUT PLANNING: INITIAL RELATIONSHIP DIAGRAM

1 I 2

E 4

U
5

A Note here again, Depts. (1) and (4) are linked together, and Depts. (2) and (5) are linked together by multiple lines or required transactions.

The number of lines here represent paths required to be taken in transactions between the departments. The more lines, the more the interaction between departments.
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EXAMPLE OF SYSTEMATIC LAYOUT PLANNING: INITIAL AND FINAL LAYOUTS

2 3
20 ft

1
50 ft

4 Note in the Final Layout that Depts. (1) and (5) are both not placed directly next to Dept. (2).
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Initial Layout
Ignoring space and building constraints

Final Layout
Adjusted by square footage and building size

Re-layout

A good plant layout involves not only the designing and installing of the layout for the first time but also revision of existing layout. The best layout becomes obsolete over a period of time.

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Reasons for Re-Layout

Product Design Change. New Product Production. Changes in volume of demand. Facilities become obsolete. Rearranging the department within the factory. Consideration of safety. Change in location of market. Poor worker environment. Cost reduction. Technology Advancement. Improvement in layout technology.
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Plant locations influence Plant layout

Location may affect make/buy decisions. Location near the source. Location near the transport facilities. Easy Power supply. Cheap labour. Climate. Waste disposal facility.

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Material handling systems

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Role of material handling in logistics

As the science is getting developed new modern equipments are getting introduced in material handling area. It is accelerating the activity of loading and unloading. These equipments are used for the movement of material over a short distance. The bulk handling of the material takes place in shipyards, ports, airports etc.
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Material handling Operation steps

Unloading the incoming material from transport vehicle. Moving the unloaded material to assigned storage places in warehouses. Lifting the material from the storage place during order picking. Moving the material for inspection & packing. Loading the boxes on transport vehicle.
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Material Handling Efficiency

Designing the system for continuous flow of material. No idle time. Going in for the standard equipments it reduces the cost. If possible use gravitational force.
continuous material movement is most economical

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Selecting Material handling Equipment

Volume of operations. Speed of handling. Productivity. Nature of product. Size, shape, weight of the product. Nature of equipment.

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Commonly used equipments in industry

Fixed Path
Conveyors

Variable Path

Wheeled trolley Forklift truck. Overhead cranes

Auxiliary

Variable path

Wheeled trolley two wheeled and four wheeled trolleys are used for transferring boxes from one place to another place within the organization. Trolleys have wide range of sizes and shapes. Organizations decide as per their requirement. Overhead cranes - these are used for movement of heavy items but for a shorter distances. The movement is controlled by a person having controls in his hand. Many times it is a computerized activity. These cranes are installed on the fixed girders near the ceiling.
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Wheeled Trolley

Overhead Crane inside the factory

Overhead cranes outside the factory

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Forklift truck this is highly useful in material handling activity. It got invented after II world war. The main advantages are, Movement of larger loads over a longer distance. Moving the load vertically also. Movement of loads vertically and horizontally, exactly positioning for loading and unloading operations. It can transfer the load in any direction.

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Fixed Path

Conveyors these are used where continuous flow of material is essential. It is used in mass production activity on production shop floor also. conveyors are widely used in automated warehouses in big retail shops.

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Wheel conveyors the small wheels made out of steel or plastic bearing. The load is kept on the bearings and either pushed or gravitational force is utilized for the forward movement of the material. Roller conveyor these are mainly used in docks for faster unloading of the goods. They are like wheel conveyors but powered rollers are used.

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Belt conveyor these are commonly used for material movement. It is used in mass production activity. Chain conveyor this is mainly used for movement of heavy material. It is used in mass production activity also. Pallets are kept on the chain and stoppers are provided for carrying out the production related work.

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Wheel Conveyor

Belt Conveyor

Chain Conveyor

Roller Conveyor

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 LIFT
These are used to lift the heavy materials vertically. It is useful to lift to upper floor.

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Auxiliary

Clamps These are used for mainly clamping and picking the material in large volumes. It can have more number of trailers. eg. Clip, metal mesh, Hooks, rings, oblong links. Riggings These are used for picking and placing the materials. It is lengthy depends on use. eg. Chains, ropes, wires.
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Riggings,Clamps,Chains,oblong links

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Factors influencing material handling equipments

Required path of travel (fixed or variable) Nature of the material. Physical characteristics of the building. Space requirement of handling equipment. Required handling capacity. Cost consideration.

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Relation between plant layout and Material Handling

Close relation between plant layout and Material Handling. Material Handling methods influence the layout and factory building. Material Handling is to be considered as an integral part of plant layout to design low cost handling system. Good Material Handling is resulted based on the arrangement of production equipment, location of departments, logical sequence of operations, location of stores, tools. Material Handling system/equipment can be selected only after the appropriate floor plan. Plant layout considers the points for material receiving and shipping of products Careful arrangement of work centers and storage areas Consider horizontal or vertical material transportation

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Thank you

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