Plant Layout.ppt

8/9/2019 Plant Layout.ppt

1/68

Layout and CapacityPlanning

Introduction.

Objectives of Plant Layout.

Factors affecting Plant Layout.

Types of Plant Layout.

Plant Layout for a Service business.

Plant Layout for a Warehouse.


2/68

Facility Layout Planning

Introduction Objectives Factors Affecting Layout Selection and

esign Types of Plant Layout

Product Layout

Process Layout !ell Layout

Layout for Services


3/68

Introduction Plant layout planning includes decisions regarding the physical

allocation of the econo"ic activity centers in a facility. An econo"ic activity center is any entity occupying space. The objective of plant layout planning is a "ore effective

#or$ flo# at the facility% allo#ing #or$ers and e&uip"entbeing "ore productive.

Facility layout techni&ues apply to the case #here several physical"eans have to be located in a certain area% either industrialprocesses or services.

The objective of the chapter is not only Plant layout but re'layout also("ost co""on situation for a co"pany).

To carry out an appropriate plant layout% it*s i"portant to ta$e intoaccount the business strategic and tactical objectives

+,a"ple- space re&uire"entscost per "/ in 0alls1accessibilityprivacy in offices.


4/68

Introduction To "a$e a decision about layout planning% 2 different

&uestions "ust have an ans#er- Which centers do #e have to consider3

4o# "uch space and capacity is re&uired for each center3 If there is not enough space% productivity "ay be reduced.

Too "uch space is e,pensive and "ay also reduce productivity. 4o# "ust the space be configured at each center3

Space &uantity% shape and the ele"ents of the #or$ center are

related to each other.

Where should each center be located at #ithin the facility3 The allocation of the different centers "ay affect productivity.


5/68

Introduction The plant layout process starts at an aggregate level% ta$ing into

account the different depart"ents. As soon as #e get into the details%the different issues arise% and the original configuration "ay be

changed through a feedbac$ process.

0ost (if not all of the") layouts are designed properly for the initial

conditions of the business% although as long as the co"pany gro#s

and has to be adapted to internal and e,ternal changes% a re'layout isnecessary.

DETALLE

TIEMPO

GRADO DE DETALLE SEGÚN

AVANCE DEL PROYECTO

Fase I

Localización

Fase IV

Instalación

Fase III

Distribución Detallada

Fase II

Distribución General


6/68

Introduction The reasons for a re'layout are based on 5 types of

changes- !hanges in production volu"es.

!hanges in processes and technology.

!hanges in the product.

The fre&uency of the re'layout #ill depend on the

re&uire"ents of the process.


7/68

Introduction Sy"pto"s that allo# us to detect the need for a re'layout-

!ongestion and bad utili6ation of space.

+,cessive stoc$ in process at the facility.

Long distances in the #or$ flo# process.

Si"ultaneous bottle nec$s and #or$stations #ith idle ti"e.

7ualified #or$ers carrying out too "any si"ple operations.

Labor an,iety and disco"fort. Accidents at the facility. ifficulty in controlling operations and personnel.


8/68

Lay Out

Introduction

Objectives

Factors Affecting Layout Selection and

esign

Types of Plant Layout Product Layout

Process Layout

Layout for Services


9/68


10/68

Objectives o Plant Layout The "ain objective consists of organi6ing e&uip"ent

and #or$ing areas in the "ost efficient #ay% and atthe sa"e ti"e satisfactory and safe for the personneldoing the #or$. Sense of ;nity

The feeling of being a unit pursuing the sa"e objective. 0ini"u" 0ove"ent of people% "aterial and

resources. Safety

In the "ove"ent of "aterials and personnel #or$ flo#. Fle,ibility

In designing the plant layout ta$ing into account the changesover short and "ediu" ter"s in the production process and"anufacturing volu"es.


11/68

Objectives o Plant Layout These "ain objectives are reached through the attain"ent of the

follo#ing facts- !ongestion reduction. +li"ination of unnecessary occupied areas.


12/68

Lay Out

Introduction

Objectives


esign


Process Layout

Layout for Services


13/68

Factors aecting PlantLayout The final solution for a Plant Layout has to ta$e into account a

balance a"ong the characteristics and considerations of allfactors affecting plant layout% in order to get the "a,i"u"advantages.

The factors affecting plant layout can be grouped into >categories-

0aterials 0achinery Labor 0aterial 4andling Waiting Ti"e

Au,iliary Services The building Future !hanges


14/68

Factors aecting PlantLayout The factors affecting plant layout can be grouped into

> categories- 0aterials

The layout of the productive e&uip"ent #ill depend on the

characteristics of the product to be "anaged at the facility% as

#ell as the different parts and "aterials to #or$ on.

0ain factors to be considered- si6e% shape% volu"e% #eight% and

the physical'che"ical characteristics% since they influence the

"anufacturing "ethods and storage and "aterial handling

processes.

The se&uence and order of the operations #ill affect plant layoutas #ell% ta$ing into account the variety and &uantity to produce.


15/68


> categories- 0achinery

4aving infor"ation about the processes% "achinery% tools and

necessary e&uip"ent% as #ell as their use and re&uire"ents is

essential to design a correct layout.

The "ethods and ti"e studies to i"prove the processes are

closely lin$ed to the plant layout.


16/68


> categories- Labor

Labor has to be organi6ed in the production process (directlabor% supervision and au,iliary services).

+nviron"ent considerations- e"ployees* safety% light conditions%

ventilation% te"perature% noise% etc. Process considerations- personnel &ualifications% fle,ibility%

nu"ber of #or$ers re&uired at a given ti"e as #ell as the typeof #or$ to be perfor"ed by the".

0aterial 4andling

0aterial handling does not add value to the product1 it*s just#aste.

Objective- 0ini"i6e "aterial handling as #ell as co"bining #ithother operations #hen possible% eli"inating unnecessary andcostly "ove"ents.


17/68


> categories- Labor

Labor has to be organi6ed in the production process (directlabor% supervision and au,iliary services).

+nviron"ent considerations- e"ployees* safety% light conditions%

ventilation% te"perature% noise% etc. Process considerations- personnel &ualifications% fle,ibility%

nu"ber of #or$ers re&uired at a given ti"e as #ell as the typeof #or$ to be perfor"ed by the".

0aterial 4andling

0aterial handling does not add value to the product1 it*s just#aste.

Objective- 0ini"i6e "aterial handling as #ell as co"bining #ithother operations #hen possible% eli"inating unnecessary andcostly "ove"ents.


18/68


19/68


> categories- Au,iliary Services

Support the "ain production activities at the plant-


20/68


> categories- The building

If it has been already selected% its characteristics #ill be a

constraint at the "o"ent of designing the layout% #hich is

different if the building has to be built.

Future changes One of the "ain objectives of plant layout is fle,ibility.

It*s i"portant to forecast the future changes to avoid having an

inefficient plant layout in a short ter".

Fle,ibility can be reached $eeping the original layout as free aspossible regarding fi,ed characteristics% allo#ing the adjust"ent

to e"ergencies and variations of the nor"al process activities.

Possible future e,tensions of the facility "ust be ta$en into

account% as #ell as the feasibility of production during re'layout.


21/68


22/68


23/68

Product Oriented LayOut

'amiones'amiones

(spuela de Ferrocarril


24/68


25/68

Types o Plant Layout Product oriented plant layout

Advantages-


26/68

a& Flu)o en l*nea recta

b& Flu)o en +,-

c& Flu)o en serpent*n

d& Flu)o en +L-

d& Flu)o circular ó en +.-

e& Flu)o en +/-


27/68

Process layout

(spuela de Ferrocarril

'amiones'amiones

0ecepciónFresadoras

1lmac2n

3ateria 4rima

4laneación

3a5uinaria

1utom6tica

Tornos

(smeriladoras

Inspección

(nsamble

1lmac2n

4roducto

1cabado

( m

b a r 5

u e


28/68

Types o Plant Layout Process oriented plant layout (Functional Layout)

This type of plant layout is useful #hen the productionprocess is organi6ed in batches.

Personnel and e&uip"ent to perfor" the sa"e function are

allocated in the sa"e area.

The different ite"s have to "ove fro" one area to anotherone% according to the se&uence of operations previously

established.

The variety of products to produce #ill lead to a diversity of

flo#s through the facility.

The variations in the production volu"es fro" one period to

the ne,t one (short periods of ti"e) "ay lead to "odifications

in the "anufactured &uantities as #ell as the types of

products to be produced.


29/68

4roduct

Flo"

P-Q Analysis

Diagram activity relationships

'hart relationship !flo" functional&

(stablish space re5uirements /pace 1vailability

Diagram space relationships

4ractical Limitations

3aintenance

7'

3at. 8andling/pace 1vailability

4ro)ect 4ro)ect 4ro)ect1 9 '

(valuate alternative arrangements

Detail selected layout install

INSTALACION

Definition

1nalysis

/ynthesis

(valuation

/election

Implementation

1d)ustment

/L4 3ethod

3uther !#$:;&


30/68

Cellular Layout

Process (Functional) LayoutProcess (Functional) Layout Group (Cellular) LayoutGroup (Cellular) Layout

Similar resources placed

together

esources to produce similar

products placed together

! ! !

"

" " !

"

SG CG CG

SG

D D D

D

! ! ! CG CG

! ! ! SG SG

" " D D D

" " D D D

# cluster

or cell


31/68

Types o Plant Layout Wor$ cells

efinition- Croup of e&uip"ent and #or$ers that perfor" a se&uence of

operations over "ultiple units of an ite" or fa"ily of ite"s.

Loo$s for the advantages of product and process

layouts- Product oriented layout- +fficiency

Process oriented layout- Fle,ibility

Croup Technology

Crouping outputs #ith the sa"e characteristics to fa"ilies% andassigning groups of "achines and #or$ers for the production of

each fa"ily.


32/68

Lay Out

Introduction

Objectives


esign


Process Layout

Layout for Services


33/68

Plant Layout or a ServiceBusiness 0ost of the concepts and techni&ues e,plained here

can be applied to any plant layout% including services. +,a"ples- Line =alancing for


34/68

Plant Layout or a ServiceBusiness Service =usinesses have a "ore direct custo"er

focus- The custo"er% #ith hisher presence% creates the #or$ flo#.

The #or$load forecast and the activities planning is not as

accurate as it is in a "anufacturing environ"ent.

7ueues- Seasonal and heterogeneous de"and- e,ecution ti"e can be

variable.

Services are intangible- adjust"ent bet#een de"and and production

can not be done through inventory "anage"ent.

7ueues are for"ed by people- higher i"plications for the layout.


35/68

Plant Layout or a ServiceBusiness Plant layout for an office-

The "aterial that flo#s a"ong depart"ents and #or$stationsis basically infor"ation. This can be done through- Individual conversations face to face.

Individual conversations through telephone or co"puter.

0ail and other physical docu"ents. +lectronic "ail.

0eetings and discussion groups.

Interphones.

The layout solution is dictated by #or$ers and physical

docu"entation "ove"ents.


36/68

Plant Layout or a ServiceBusiness Plant layout for a co""erce-

Objective- 0a,i"i6e the net benefit per "/ of shelves. If sales are directly related to the e,position of products to the

custo"er% the objective #ill consist of e,posing as "any

products as possible to the custo"ers in the available space.

This has to ta$e into account to leave enough space for the"ove"ent a"ong shelves% not "a$ing the layout unco"fortable

for the custo"er.

Aspects- Allocation of daily consu"ption products at the periphery.'

Allocation of i"pulsive purchase and high profit "argin productsin pro"inent places.

+li"inate aisles that allo# the custo"ers to go fro" one ro# to

other #ithout going through the" co"pletely.


37/68

Plant Layout or a ServiceBusiness Plant layout for a co""erce-

Aspects- Clobal organi6ation of the available space-

Allocation of attraction products on both sides of a ro#% and

dispersion of the" to increase the e,position of adjacent products.

;se the end of a ro# as a place for e,position. !reation of the business i"age through a careful selection of the first

section #here the custo"ers are getting into the facility.

Allocation of products in the e,position areas- This aspect re"ains #ithin the co""ercial function. It is called

"erchandising.


38/68

'afeter*a

'afeter*a

Three


39/68

Plant Layout or a are!ouse Objective- Opti"al relationship bet#een space and "aterial handling costs.

Aspects to be considered- cubic space utili6ation% storing e&uip"ent and "ethods%

"aterial protection% allocation of different parts% etc.

A #arehouse layout is "ore co"plicated #hen- The different custo"er orders ta$e into account a high nu"ber of references.

There are fre&uent orders of lo# nu"ber of units for the sa"e product. In this cases% the "aterial handling costs for each roundtrip "ove #ould be e,cessively

high.

Solutions for this proble"- Aggregation of units for several orders% or establish"ent of

opti"al routes for each order.

Click to add title

$ones $ones Control

station Shipping

doors

!ractortrailer

!ractor

trailer

%&erflo'

Feeder

linesFeeder

lines


40/68

Lay Out

Introduction

Objectives


esign


Process Layout

Layout for Services


41/68

Syste"atic LayoutPlanning


42/68

4roduct

Flo"

P-Q Analysis

Diagram activity relationships

'hart relationship !flo" functional&

(stablish space re5uirements /pace 1vailability

Diagram space relationships

4ractical Limitations

3aintenance

7'

3at. 8andling/pace 1vailability

4ro)ect 4ro)ect 4ro)ect1 9 '

(valuate alternative arrangements

Detail selected layout install

INSTALACION

Definition

1nalysis

/ynthesis

(valuation

/election

Implementation

1d)ustment

/L4 3ethod

3uther !#$:;&


43/68

Types o Plant Layout Process oriented plant layout

It*s essential to design a fle,ible plant layout% ta$ing intoaccount as #ell the need of fle,ibility for the "aterial

handling e&uip"ent to be used.

0ain disadvantage of this layout- Lo# operations and "aterial handling efficiency #hen

co"paring to a plant layout oriented to the product.

On the other hand% technology develop"ent is facilitating

getting over this disadvantage (i.e.' !B! +&uip"ent).

Analysis

ecision to be "ade-


44/68


Analysis If it e,ists a clear "aterial flo# that carries out "ore volu"e

than anyone else% the layout could be si"ilar to a Product

oriented plant layout.

The "ain factor for the analysis is the "aterial handling and

transportation costs a"ong the different #or$ing areas.

So"eti"es% &uantitative infor"ation relative to "aterial handling

flo#s is not available% or it*s not the "ain factor to be

considered% being the &ualitative factors the "ost i"portant

ones in this case.


45/68


Analysis Process-

Infor"ation gathering.

Plan develop"ent.

7uantitative criteria- transportation costs.

7ualitative criteria- closeness priorities.

Infor"ation gathering We have to $no# the space re&uire"ents by #or$ing area.

e"and forecast E production plan E #or$ing hours E nu"ber of

#or$ers and e&uip"ent. !onsider de"and and production fluctuations.


46/68


Analysis Infor"ation gathering

Wor$ing area space.

Static area (Se)- Physical space for e&uip"ent and

#or$stations. Cravitation area (Sg)- Allocation of tools and "aterials.

Area #here operators develop their #or$.

+volution area (Sv)- Space to allo# operators and

"aterial "ove"ents.

St=Se+Sg+S

Sg=Se!n S="Se+Sg#!$

n=n%&'e( )* aessi'le si,es $=in,%st(y )e**iient "./-0#


47/68



Available space.

Total available area at the plant.

ivide the area at a first approach to esti"ate eachsection.

When perfor"ing the detailed layout% it*s re&uired to have

"ore accurate shapes adjusted to the reality.

When the objective is the reduction of "aterial handling

costs% #e can solve the proble" in &uantitative ter"s- It*s re&uired to $no# the "aterial flo# a"ong depart"ents

or areas% distances a"ong the" and "eans of

transportation.


48/68



When the objective is the reduction of "aterial handling

costs% #e can solve the proble" in &uantitative ter"s-

Traffic intensity "atri,- Bu"ber of "aterial handling"oves a"ong depart"ents (infor"ation provided by

historical data% route sheets and production plans).

istance "atri,- istances a"ong areas at the plant and

places #here the different #or$ing areas could be

allocated. !ost "atri,- !ost of "aterial transportation.' It depends

on the type of e&uip"ent to be used.


49/68



So"eti"es% &uantitative infor"ation is not available% or the

i"portance of distance a"ong areas depends on &ualitative

factors (i.e.' a hospital 'ray roo" "ay be close to the

trau"a "edicine roo").

Plan develop"ent Once the si6e of the different areas have been deter"ined%

the ne,t step is to organi6e the different areas #ithin the

e,istent facility% or to deter"ine the desired shape for thefacility construction.

There are "ultiple possible solutions% so the selected one #ill

be the a good one that co"plies #ith the "a,. nu"ber of

constraints.

4 7 1 l i


50/68

4


51/68


52/68


Analysis 7uantitative criteria- Transportation costs.

With the infor"ation gathered in the previous 5 "atri,es% the

objective is to "ini"i6e the transportation costs.

Total Transportation !ost-

Objective- Finding the co"bination of dij that "ini"i6es !!C.

This for"ula is co"plicated for co""on cases% due to the

nu"ber of different possibilities (i.e.' for 8@ sections% the

alternatives #ould be 5%G/>%@@@).

TTCC 11 ti) ,i) i)


53/68


54/68


Analysis 7uantitative criteria- Transportation costs.

In practice% #e have to ta$e into account certain constraints

and circu"stances that have to be considered% apart fro" the

&uantitative criteria of the transportation costs.

Once this infor"ation is ta$en into account% the ne,t step #ill

be to perfor" the spatial design of the different depart"ents.


55/68

l


56/68


Analysis 7ualitative criteria- !loseness priorities.

Techni&ue- Syste"atic Layout Planning (SLP)- +,a"ple.

T Pl L


57/68




/#

/%//E

/;/

Initial Diagram

T Pl L


58/68




/#

/E/%/

//;

First iteration

T Pl L


59/68




/;

//%/

/#/E

/econd iteration !might be the optimum&

T Pl t L t


60/68


etailed layout +&uip"ent and "achinery layout #ithin each area or

depart"ent% getting a detailed layout of installations and all

ele"ents.

There could appear so"e issues li$e scales% elevators% colu"ns%

floor resistance% roof height% etc. not considered in previousstages% that could "a$e necessary the revie# of the solution.


61/68

#ellular Layout

T Pl t L t


62/68


efinition- Croup of e&uip"ent and #or$ers that perfor" a se&uence of

operations over "ultiple units of an ite" or fa"ily of ite"s.

Loo$s for the advantages of product and process

layouts- Product oriented layout- +fficiency

Process oriented layout- Fle,ibility

Applies the principles of Croups* Technology to

0anufacturing- Crouping outputs #ith the sa"e characteristics to fa"ilies% and

assigning groups of "achines and #or$ers for the production of

each fa"ily.

T Pl t L t


63/68


Applies the principles of Croups* Technology to0anufacturing- So"eti"es% these outputs #ill be final products or services1

so"e other ti"es% they #ill need to integrate to a final product. In this case% the #or$ cells #ould need to be located close to the

"ain production line% to facilitate the asse"bly of the co"ponent atthe "o"ent and place re&uired.


64/68


Applies the principles of Croups* Technology to0anufacturing- Hirtual Wor$ !ells- identifying and dedicating certain e&uip"ent

to the production of certain fa"ilies of outputs% but #ithout

grouping the" physically #ithin the cell- The only issue is the identification of e&uip"ent and fa"ilies of

products% #ithout perfor"ing an internal layout of the cell.


65/68


Applies the principles of Croups* Technology to0anufacturing- Steps to follo#-

Select product fa"ilies.

eter"ine #or$ cells.

etail the #or$ cells* internal organi6ation or layout.


66/68

T Pl t L t


67/68


Applies the principles of Croups* Technology to0anufacturing- A co"ponent that does not use all "achines #ithin its #or$ cell

can be accepted% as #ell as a "achine that does not process all

co"ponents in its group.

4o#ever% it*s essential to avoid that a co"ponent or "achine

interacts #ith other "achine or co"ponent outside of its cell. If it*s not possible avoid this situation% the solution #ill be duplicating

the piece of e&uip"ent% or process the ite" in "ore than one cell.'

So"eti"es a residual cell "ight be needed to absorb a co"ponent

li$e this or to include a general type of e&uip"ent that #e can notduplicate.

T Pl t L t


68/68


Applies the principles of Croups* Technology to0anufacturing- In general% the steps to follo# to reorgani6e the layout #ill be-

Inco"patible e&uip"ent "ust be located in separate cells.

+ach co"ponent should be produced only in 8 cell.

+ach type of e&uip"ent should be located only in 8 cell.

Invest"ent in duplicating e&uip"ent should be "ini"i6ed.

The #or$ cell should be li"ited to a reasonable si6e.

Date post:	01-Jun-2018
Category:	Documents
Upload:	madhu-vignesh
View:	218 times
Download:	0 times

Plant Layout.ppt

Documents