plant layout.pptx

8/16/2019 plant layout.pptx

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Chapter 2

Plant Design

1


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Basics of plant Layout;

Study of Plant Layout;

Ergonomics and Industrial

Safety

2

Contents of the Chapter


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Basics of plant Layout;Study of Plant Layout;

3

Plant Layout


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Plant layout refers to the arrangement ofphysical facilities such as machines,

equipment, tools, furniture etc.

In such a manner so as to have quickest

ow of material at the lowest cost and with

the least amount of handling in processingthe product from the receipt of raw material

to the delivery of the nal product.

Denition


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!roper and e"cient utili#ation of availa$le

oor space.

%educe material handling costs.

!rovide ease of supervision and control.

&llow easy maintenance of machines and

plant.

'

Objecties


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It is not necessary that layout engineer dealwith only new layout

(ome of the e)amples of re layout pro$lems are

*hanges in design part. this calls for changes in

the process and may require some alterations

in the e)isting layout

+ayout change due to change in method of

production

!ypes of layout Problems


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-)pansion in production capacity

%eduction in production capacity

iversication i.e. addition of new product

!lanning a new facility or new department

(hifting of a new department

%eplacing a equipment with advanced

technology

/

"ont#


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(ome machines are heavily loaded andsome are remain idle for long periods

-)cessive handling $y skilled workers

+ong production cycles (tock control di"culties !oor utili#ation of availa$le space elays in deliver -)cessive fatigue on workers !oor house keeping di"culty in supervision and control

0

Symptoms of bad layout


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Idle workers and equipment

$stacles in material ow

ottlenecks in production acktracking

"ont#


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4he various tools and techniques used in

preparation of plant layout are

1. !rocess ow chart

2. 5achine data cards

3. 4emplates

. (cale models

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$nalytical tools for plant layout


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1. !rinciple of overall integration

2. !rinciple of minimum distance

3. !rinciple of ow. !rinciple of cu$ic space

'. !rinciple of satisfaction and safety

. !riniple of e)i$ility

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Principles of plant layout


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&ccording to this principle, the $est layout is

one which integrates the resources

,supporting activities and any other such

factors results in the $est compromise

12

%&Principle of oerallintegration


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&ccording to this principle, other things

$eing equal, the $est layout is one in which

men and materials have to move minimum

distance $etween operations

13

'&Principle of minimum distance


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7urther said that, other things $eing equal,

the $est layout is one which arranges the

work area for each operations or processes

in the same order or sequences that forms,

treats or assem$les the materials

1

(&Principle of )lo*


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&ccording to this the $est layout is one

which all the availa$le space $oth vertical

and hori#ontal is most economically and

e8ectively used

1'

+&Principle of cubic space


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&ccording to this other things $eing equal,

the $est layout is one which makes work

satisfying, pleasant and safer for workers

1

,&Principle of satisfaction andsafety


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It means that the $est layout is one which

can $e adopted and rearranged at minimum

cost with least inconveniences

1/

-&Principle of e.ibility


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4ype of industry

4ype of products

9olume of production Inuence of processes

10

)actors inuencing layout


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Industries are classied according to theirprocesses of manufacture. the process of

manufacture can $e classied into four categories

I. (ynthetic process e). production of cement $y

mi)ing limestone and clay

II. &nalytical process opposite to synthetic process.

it is $raking up of a material into several parts

e) rening of petroleum

1

%& !ype of industry


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III. *onditioning process: in conditioning

process the raw form of material is

changed into desired product

I9. -)tractive process: In this process $y

applying heat desired product is e)tracted

from the original raw material e):manufacture of aluminum from $au)ite

26

"ont#


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4ype of product means whether the product

is heavy or light, large or small, liquid or

solid

21

'&!ype of products


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&ccording to this while plant layout is $eing

done it should $e kept in mind that what

volume is required to $e processed in this

case it should $e seen that

;o$ production

atch production

5ass production

22

(&/olume of production


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Is the process through which the material

passes in the concern. much care should $e

given to the material handling pro$lem,

position of storeroom and tool room

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+&Inuence of processes


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!ypes of Plant Layout

2


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)i.ed Position Layout

Process Layout

Product Layout

"ellular Layouts

2'

!ypes Of Layouts


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)i.ed Position Layout

2

• 4his is also called the pro


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2/

)I0ED POSI!IO1 O2 LO"$!IO1L$3O4!

%aw5aterial

&ir *raft &ssem$ly7inished !roduct

>&ircraft?

5achines@

-quipment

+a$our


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"ont&&&

20

• 4his type of layout is suita$le when one or a few

pieces of identical heavy products are to $emanufactured and when the assem$ly consists of

large num$er of heavy parts, the cost of

transportation of these parts is very high


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Process Layout

2

•&ll machines performing similar type of operations are

grouped at one location in the process layout e.g., alllathes, milling machines, etc. are grouped in the shop

will $e clustered in like groups.

•!rocess layout is normally used when the production

volume is not su"cient to


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Process Layouts

Process Layout –products travelto dedicated process centers

5illing

$ssembly6 !est

7rinding

Drilling

Plating

A36


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31

P2O"ESS L$3O4!


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Product Layout

A33

2a*materialsor

customer

)inis9ed

item

Station '

Station '

Station (

Station (

Station +

Station +

5aterial and:orlabor

Station

%




4sed for 2epetitie or "ontinuous Processing


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3

Product or Line Layout

!roduct &

!roduct

!roduct *

(tep 1

(tep 1

(tep 1

(tep 2

(tep 2

(tep 2

(tep 3

(tep 3

(tep 3

(tep

(tep

(tep


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"ellular Layouts – 5achines are grouped into a cell that can process items

that have similar processing requirements – ased on Droup technology which involves grouping items

with similar design or manufacturing characteristics into

part families

*ould $e considered as mini product layouts

*an improve and simplify a functionalEprocess layout

7le)i$le

uplicates some resources

A3'


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Part families• !art families with

similarity in shape• !art families with

similarity inmanufacturingprocess


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Original Process Layout

CA B Raw materials

Assembly

1

2

3

4

5

6 7

8

9

10

11

12


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"ellular Layout

3

6

9

Assembly

12

4

8 10

5

7

11

12

A C B

Raw materials

Cell 1 Cell 2 Cell 3


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1

End

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