5. Facility Layout

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Facility Layout and Basic Formats

Process Layout

Layout Planning

Assembly Line balancing

Service Layout

OBJECTIVES

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FACILITYLAYOUT

Facility layout can be defined as configuration of departments, workcenters and equipment, machinery with focus on flow of materials orwork through production systems.

Factors considered in Plan Layout

Machines.

Equipments.

Work-stations.

Customer service areas.

Tooling.

Rest rooms.

Lunch rooms.

Coffee/tea base.

Toll cribs, ailes. 3

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LAYOUTPLANNING

Involves decisions about physical arrangement ofeconomic activity centers within a facility..

Important things to be taken care are:

Type of Centers.

Space and capacity for each center.

Configuration of each centers space.

Location of each center in terms of Relative andAbsolute location.

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NEEDFORLAYOUTDECISIONS.

Layout decisions Need:

To determine long run efficiency in operations.

It establishes organizations competitive priorities in

regards to capacity, flexibility, cost, processes,quality of work life, customer contact and image (incase of service organizations).

To achieve strategic advantage that supports

differentiation, low cost, fast response or flexibility.

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OBJECTIVES: GOODPLANTLAYOUT

Higher utilization of space,equipment,flexibility andpeople.

Improved flow of materials, productioncapacity,information,people.

Employee morale and safe working conditions.

Reduced material handling, bottleneck center,health hazards and accidents.

To provide product, volume flexibility, ease ofsupervision, allow ease of maintenance.

To facilitate effective co ordination and face to facecommunication.

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FACTORSINFLUENCINGLAYOUTCHOICES

Materials. (Cranes, trolleys, conveyors, pipelines)

Product. (Nature and type)

Workers. (Gender, Position, Facilities)

Machinery and equipments. Type of industry.

Location.

Managerial policies.

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PRINCIPLESOFPLANTLAYOUT

1. 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.

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BASIC PRODUCTION LAYOUT FORMATS

Process Layout (also calledjob-shoporfunctional layout)

Product Layout (also called flow-shop layout)

Group Technology (Cellular) Layout

Fixed-Position Layout

Combination or Hybrid Layout9

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SPECIFICATIONSOFPROCESSLAYOUT.

The raw material flows through differentdepartments wherein the equipments andmachineries are already fixed.

Its also known as functional or batch production

layout.

Distance needs to be short.

Departments should be located in accordance withthe principle sequence of operations.

Convenience for inspection and supervision.

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ADVANTAGESANDDISADVANTAGESPROCESSLAYOUT.

Advantages. Reduced investment on machinery.

Greater flexibility in production.

Greater scope for expansion.

Better utilization of man and machines. Easier to handle breakdown by transferring work to

another department.

Greater incentive to specialized worker to increase hisproductivity

Disadvantages. Difficulty in movement of materials.

Requires More floor space.

Production time increases due to more travelling andaccumulation of work-in-progress.

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PRODUCTLAYOUT/STRAIGHTLINELAYOUT

Product moves through a series of special purposemachinery.

Raw Materials fed into the first machine andfinished product comes out of the last.

characteristics:-

Machines and equipments should be placed at the pointdemanded by the sequence.

No line crossing.

All operations included in the line.Materials may be fed where they are required, but notnecessarily all at one point.

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ADVANTAGESANDDISADVANTAGES.

Advantages

Reduction in material handling.

Avoids production bottlenecks.

Saves manufacturing time.

Facilitates better production control. Requires less floor area.

Reduced WIP, minimized investment.

Early detection of mistakes is possible.

Greater incentives to a group of workers. Disadvantages.

Inflexible and expensive.

Difficulty in supervision and expansion.

Any Breakdown disrupts the whole system.13

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FIXEDPOSITIONLAYOUT/STATICLAYOUT.

Machines and tools are moved to the product,which in turn remains stationary.

E.G:-

Construction of buildings, Dams, Bridges,

Service industries like hospitals, scan centers etc.

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ADVANTAGES

Men and machines can be used for a wide variety ofoperations to produce different products.

Low yearly investment.

Pride for workers.

Avoids high costs, and difficulty in transportations.

DISADVANTAGES.

High initial investment.

Large quantity of production is not possible.

Requires high degree of workers and employeeexpertise.

Time consuming. 15

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CELLULARMANUFACTURINGLAYOUT/GROUPTECHNOLOGYLAYOUT.

Machines are grouped into cells, and they functionlike a product layout with a larger shop or processlayout.

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Advantages.

Lower WIP inventory.

Reduced material handling cost.

Shorter flow times in production.

Simplified PPC. Increased operator responsibilities.

Improved visual control.

Fewer tooling changes facilitating quicker setups.

Disadvantages Less flexibility

Increased machine downtime.

Duplicate equipments is essential to avoid transportation ofparts between cells.

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COMBINATION/HYBRIDLAYOUT

A combination of product and process layout, withan emphasis on either according to the productproduced.

E.G:-

Soap manufacturing, two wheelers.

ULTIMATELY PROFIT IS WHAT MATTERS.

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SERVICE FACILITY LAYOUTS

It is specially designed to bring together servicesand customers.

Provisions of easy entrances, gangways, busytrough fares.

Two types of service facility layouts

Totally designed around customer receiving servicefunction.

Totally designed around technologies and machinery.

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PLANTUTILITIES

Plant Lighting.

Characteristics.

Sources.

Natural

Artificial.

Features to be considered.

Type of illumination.

Type of light source.

Quality and intensity of light. Glare and its effects.

Color of walls and ceilings.

Maintenance. 20

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PLANTUTILITIES

Ventilation.

Methods

Importance.

General ventilation.

Local exhaust ventilation.

Sources.

Natural.

Artificial/mechanical.

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PLANTUTILITIES

Air conditioning.

Objectives.

Types.Depending on season.

Depending on purpose.

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PLANTUTILITIES

Industrial sanitation.

Noise control.

Importance

Methods

Control at source.

Control by enclosures.

Control by absorption.

Control through protection of ears.

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ASSEMBLYLINES

It refers to progressive assembly linked by somematerial handling device.

Commonly referred material handling devices:-

Conveyor belts.

Overhead cranes.

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ASSEMBLYLINE BALANCING.

Workstation cycle time time between twosuccessive units coming off the end of theassembly line.

C = production time per day / required output per day.

Precedence relationship principle of sequence.

Theoretical min. no. of workstations.

Nt = sum of the task times (T) / cycle time (C)

Efficiency = T / (Na x C).

Na = actual no. of workstations.

If efficiency is unsatisfactory, then rebalance usingdifferent rule.s

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Prof.S.Gan

guly

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5. Facility Layout

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