advantages of good layout
TRANSCRIPT
Government College of Engineering, Aurangabad
Advantages of Good Plant Layout
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ADVANTAGES OF GOOD PLANT LAYOUT
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“A good layout results in comfort, convenience, appearance, safety and
profit. A poor layout results in congestion, waste, frustration and
inefficiency.” - MoNaughton Wayne
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What is plant layout?
Basically plant layout is physical arrangement of industrial facilities
Orderly and proper arrangement with the use of available resources i.e., Men, Money, Machines, Materials and Method of production
J. Lundy defines plant layout as follows : “Plant layout ideally involves the allocation of space
and arrangement of equipment in such a manner that overall operation cost can be minimized”
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Over crowding of men, material, machine
and equipment.
Scrap or wastage of material is more.
Difficult to supervise.
More frequent accidents.
When to think about planning a layout?
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Mental or Physical stress in the workers.
Long transportation lines.
Poor utilization of space.
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1. Product Layout ( Line Layout )
2. Process Layout ( Functional Layout )
3. Fixed Position Layout
Types of Plant Layout
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All the equipments and machines are arranged
according the sequence of operations on product.
Here, the layout is dictated by the ‘product’.
Only one type of product is produced in operating area in large number of quantities (Mass Production).
Generally, all assembly lines in different industries follow the ‘Product Layout’.
1. Product Layout
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Example :
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Here, the layout is dictated by the ‘Process’ and not
by the ‘Product’.
In this type of layout, the machines and not arranged according to the sequence of operations but are arranged according to the nature or type of the operations.
The process layout is particularly useful where low volume of production is needed with a greater variety of products
2. Process Layout
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Example 1 :
Example 2 :
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Comparison of two
layoutsProduct Layout Process Layout
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In this type, material or major component remains
stationary because it is too heavy or too big
As product remains fixed at one location other materials, parts, tools, machinery, man power and other supporting equipment’s are brought to this location.
This type of layout is used in the manufacture of boilers, Huge aircrafts, hydraulic and steam turbines and ships etc.
Fixed Position Layout
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Economies in material handling
Direct channels for the flow of materials Cost of material handling is considerably reduced
Lesser manufacturing time As no involvement of backward handling of
materials, considerable saving of time in manufacturing
Advantages of Product Layout
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Lesser work in progress Lesser accumulation of work in progress of
semi finished goods
Proper use of floor space Optimum use of available floor space is
possible Due to non-accumulation of work in progress
Economy in inspection Need for inspection under this method is
much less and can be confined at some crucial points only
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Lesser manufacturing cost Due to less material handling, inspection
cost, and good utilization of available space there is less manufacturing cost
Lesser labour cost Less skills required Routine task is to be carried out under this
method
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Lesser flexibility
Difficult to adopt any changes
Large investment Unavoidable machinery duplication Results in idle capacity and large capital
investments
Disadvantages of Product Layout
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Interruption due to breakdown Stoppages of work due to interdependency on
previous machines Reasons may be breakdown of machine,
irregular supply of material, poor production scheduling and employee absenteeism
Lack of specialization in supervision Due to large variety and large quantity of
machines available in the section, one cannot be expert of all the machines
Hence only general supervision is possible and not the specialized one
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Maximum utilization of machines
Greater flexibility Change in the sequence of operations and
machines can be made without much difficulty
Scope for expansion By installing additional machines without much
difficulty
Advantages of Process Layout
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Specialization in supervision Less variety in machines hence possible
Effective utilization of workers Skilled operators are appointed Leads to effective and efficient use of their
talent and capabilities
Less work stoppages Production schedule is not seriously affected
due to breakdown of any machine Work can be transferred to the other machines
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Coverage of more floor area Material handling is more expensive Higher labor cost due to the
requirement of higher grades of skills Longer total production time Large in-process inventories Increased inspection cost
Disadvantages of Process Layout
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Economies of transportation
Work is not carried from one place to another but fixed at one position
Saving in transportation cost
Different jobs with same layout Different projects
Advantages of Fixed Position Layout
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Production in accordance with specifications Jobs can be performed in accordance with
the specification given by the customer
Scope for flexibility Flexibility for various changes in production
processes and designs of the products
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Large investments
Unsuitable for small products Not suitable for producing and assembling small
products in large quantities
Production process is time consuming Machines and tools etc. take more time to reach the
work place
Highly skilled workers are required
Disadvantages of Fixed Position Layout
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QUESTIONS ARE WELCOMED…