faseela - facility layout

8/6/2019 Faseela - Facility Layout

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A plant layout refers to thearrangement of machinery, equipment

and other industrial facilities such as

receiving and shipping departments, toolrooms, maintenance rooms and

employee amenities for the purpose of

achieving the quickest and smoothest

production at the least cost.


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According to Knowles and

Thomson Plant layout involves... planning and arranging

manufacturing machinery,

equipment, and service for the firsttime in completely new plants;

The improvements in layouts

already in use in order to introduce

new methods and improvements in

manufacturing procedures.


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OBJECTIVES OF GOOD LAYOUT

Provide enough production capacity.

Reduce material handling costsTo ensure proper utilization of available

floor space.

Utilize labour efficiently.Increase employee morale.

Reduce accidents.

Provide for volume and product flexibility.

Allow ease of maintenance.Improve productivity.

Provide for employee safety and health.


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FACTORS INFLUENCING FACILITY LAYOUT

Materials

The type and size of storage, type of

material equipment cranes, trolleys and

pipelines depend upon:

The type of raw materials used, i.e.whether the raw materials are liquid or

solid, light or heavy, small or large.

The availability or scarcity of materials

even when this is affected by seasonal

variations and market conditions.


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A plant layout should be planned

after bearing in mind the particular

handling or moving equipment whichmay be required in the manufacturing

process.

The usual way of taking the raw materialfactor into account is to draw flow charts

to visualize the paths of materials flow or

movements, and then to eliminate cross-

covers, long distances and backtrackings. The best path is thus

determined, around which the layout is

planned.


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Product

A layout is designed with the

ultimate purpose of producing a product.The type of product (whether the product

is heavy or light, big or small, liquid or

solid) and its position in relation to theplant location influence the layout. The

position of the product in relation to the

other factors of production deserves

consideration in planning a layout of aplant.


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The sales/demand also exercises

some influence on the plant layout. The

sales/demand for a product determinesthe volume of production and therefore

the quality and size of the equipment,

the area of storage space, and otherfacilities which in turn, determine the

type of layout.

A plant layout must be the

expression of a purpose. This purpose is

the efficient and effective production of a

product or product line.


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Worker

The layout designer should also

consider the type, position and

requirements of employees. Employee

facilities, such as health and relatedservices, feeding and related services,

locker rooms influence the layout

significantly. Employee safety


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Machinery

The type of product, the volume of its

production, the type of process andmanagement policy determines the size and

type of the machinery to be installed which in

turn influences the plant layout. Production

is the combination and manipulation of men,materials and machines. These elements may

be combined in various ratios and in various

ways in the course of the production activity.

The ratio in which these elements are used

depends on their relative costs and on the

production processes selected.


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Industry

According to the manufacturing

process industries can be classifiedinto four types:

Synthetic;

Analytical:Conditioning

Extractive


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Extractive Industries: - involve the

separation of one element from another, as

in the case of metal from the ore.

Conditioning Industries: - involves change

in form or physical properties. (metalworking industries, leather tanning

concerns condition their raw materials to

have end products.)

Analytical Industries: - converts raw

materials into various elements or

constituent parts.


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Synthetic Industry: - it is also called

the assembling industry, involves the

production of a product by the use of

various elements. (The chemical

industry and the paper industry are

synthetic industries.)

The layout designer should keep in

mind the type of industry and the

method of the manufacturing process

while planning a layout.


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Location

The site selected for the location of

plant influences its layout in more thanone way.

First, the size of the site determines the

type of building which in turn, influencesthe layout.

Second, the location of the plantdetermines the mode of transportation,

depending upon the distances from the

source of raw materials and market to the

plant.


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Third, a plant location may be

determined in part by the fuel

requirements of the concern. (Layoutmust consider the requirements of power

generation.)

Fourth, the demand for future

expansion influences the plant layout.


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Managerial Policies

Management policies significantly

influence plant layout. The following are suchmanagerial policies:

The volume of production and provision of

expansion.

The extent of automation.

Making or buying a particular component.

Desire for rapid delivery of goods to

customers. Purchasing policy.

Personnel policies.


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Many top management policies

determine the plant layout objectives and

the scope of plant activities. The plantengineer must have clear and complete

understanding of those top management

policies that have bearing on plant layoutobjectives.


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PRINCIPLES OF LAYOUT

1. The Principle OfMinimum Travel

Men and materials should travel theshortest distance between operations so

as to avoid waste of labour and time and

minimize the cost of materials handling.

2. Principle Of Sequence

Machinery and operations should be

arranged in a sequential order. Thisprinciple is best achieved in product

layout, and efforts should be made to have

it adopted in the process layout.


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3. Principle of Usage

Every foot of available space should

be effectively utilised. This principleshould receive consideration in towns and

cities where land is costly.

4. Principle of Compactness

There should be a harmonious fusion

of all the relevant factors so that the final

layout looks well integrated and compact.


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5. Principle Of Safety And Satisfaction

The layout should contain built in

provisions for safety for the workmen. Itshould also be planned on the basis of the

comfort and convenience of the workmen

so that they feel satisfied.

6. Principle Of Flexibility

The layout should permit revisions

with the least difficulty and at minimumcost.


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7. Principle OfMinimum Investment

The layout should result in

savings in fixed capital investment, notby avoiding installation of the

necessary facilities but by an intensive

use of available facilities.


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IMPORTANCE OF FACILITY LAYOUT

Economies In Handling

Nearly 30 to 40% of themanufacturing cost is accounted for by

materials handling. Every effort should,

therefore, be made to cut down on thiscost. Long distance movements should be

avoided and specific handling operations

must be eliminated.


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Effective Use Of Available Area

Every inch of the plant area is

valuable (especially in urban areas).Efforts should be made to make use of

the available area by planning the layout

properly. Some steps for achieving thisend are: location of equipment and

services in order that they may perform

multiple functions; developments of up-

to-date work areas; and operator jobassignments for a full utilization of the

labour force.


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Minimum Equipment Investment

Investment on equipment can be

minimised by planned machine balanceand location, minimum handling

distances, by the installation of general

purpose machines and by plannedmachine loading. A good layout provides

all these advantages.


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Better Production Control

Production control is concerned with

the production of a product of the righttype at the right time and at a reasonable

cost. A good plant layout is a requisite of

good production control and provides theplant control officers with a systematic

basis upon which to build organisation

and procedures.


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Better Supervision

A good plant layout ensures better supervision

in two ways:

Determining the number of workers to be

handled by a supervisor.

Enabling the supervisor to get a full view of

the entire plant at one glance.

Improved Utilization Of Labour

Labour is paid for every hour it spends in the

factory. The efficiency of a management lies in

utilising the time for productive purpose. A

good plant layout is one of the factors in

effective utilisation of labour. It makes possible


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individual operations, the process and flow of

materials handling in such a way that the time

of each worker is effectively spent on productiveoperations.

Improved Employee Morale

Employee morale is achieved whenworkers are cheerful and confident. Morale

depends upon:

Better working conditions.

Better employee facilities.Reduced number of accidents.

Increased earnings.

Plant layout has a bearing on all these.


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Avoidance Of Unnecessary AndCostly Changes

A planned layout avoids frequent

changes which are difficult and costly.

The incorporation of flexibility elements

in the layout would help in the

avoidance of revisions.


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faseela - facility layout

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