om plant layout study
TRANSCRIPT
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PLANT LAYOUT A layout is a physical configuration
of departments, work stations and
equipments in the conversionprocess.
It is the spatial arrangement of
physical resources used to create aproduct.
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OBJECTIVES OF PLANT LAYOUT STUDY
1. Minimize investment in equipment
2. Minimize over all production time.
3. Utilize existing space mosteffectively
4. Provide for employee convenience,
Safety and comfort5. Maintain flexibility of arrangement
and operation.
6. Minimize material handling cost
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OBJECTIVES OF PLANT LAYOUT STUDY
7. Minimize variation in types of
material handling equipment.
8. Facilitate the manufacturing
process.
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PLANT LAYOUT STUDY
It is interrelated .
Layout design
Product design
Schedule Design Process Design
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SOME MOST COMMONLY INVOLVEDFACTORS / CONSIDERATIONS
1. Ease of future expansion
2. Flexibility of layout3. Material handling effectiveness
4. Space utilization
5. Safety & Housekeeping
6. Working Conditions
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SOME MOST COMMONLY INVOLVEDFACTORS / CONSIDERATIONS
7. Ease of Supervision & Control
8. Appearance, Promotional value
9. Fit with Company OrganizationStructure
10.
Equipment utilization11. Ability to meet capacity or
Requirements
12. Investment or capital required.
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REEDS SYSTEMATIC PLAN OF ATTACKPLANT LAYOUT PROCEDURE Steps to
be taken
Analyse the production or processes to
be produced Determine the process required to
manufacture the product
Prepare layout planning charts Determine work stations
Analyse storage area requirements
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REEDS SYSTEMATIC PLAN OF ATTACKPLANT LAYOUT PROCEDURE Steps to
be taken
Establish minimum aisle widths
Establish office requirements Consider personnel facilities and
services
Survey plant services Provide for future expansion
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THE MOST POPULAR APPROACHDEVELOPED BY MUTHER - SLP
The procedure applied to:
1. Production2. Transportation
3. Storage
4. Support services5. Office activities etc
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1. Flow of
Material
2. Activity
Relationships
INPUT DATA AND ACTIVITIES
3.RelationshipDiagram
4. SpaceRequirements
5. SpaceAvailable
6. Space RelationshipDiagram
7. ModifyingConsiderations
8. PracticalLimitations
9. Develop LayoutAlternatives
10. Evaluation
Sele
ction
Search
Analysis
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TYPES OF FLOW PATTERNS
Classifications of flow patterns Horizontal or vertical
a) b)
c) d)
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TYPES OF FLOW PATTERNS
Classifications of flow patterns Horizontal or vertical
e)
f)
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TYPES OF FLOW PATTERNS Vertical flow patterna) b) c)
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TYPES OF FLOW PATTERNS Vertical flow patternd) e) f)
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TYPES OF LAYOUT
Four General layout categoriesare:-
1. Fixed or Static product Layout
2. Product layout
3. Process Layout
4. Product Layout
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Fixed position layout It is not feasible to move the
product
Product stays in one location;tools,men,material etc. arebrought to it.
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FIXED PRODUCT LAYOUT
WORK PIECE
Paint
Mill
Weld
Drill
Lathe Grind
AssemblySaw
Stores Warehouse
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PRODUCT LAYOUT
Saw
Saw
Grind
Weld Grind
Mill
Mill
Lathe Mill
Drill Paint
Paint
DrillLathe
Drill
Drill
Assembl
y
Warehous
e
Stores
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Product layout or line
production Appropriate for producing one
standard product in large quantities
Each unit of output require the samesequence of operations frombeginning to end
Work centers and equipments arearranged in a line
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Process layout or layout by
function Work centres and departments are
grouped together according to their
function or type Useful where volume of
manufacture is low and variety is
high Provides tremendous flexibility- no
solid sequencing
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GROUP LAYOUT
Saw
Saw
Grind
Lathe Mill
Paint
Mill
Lathe
Assemb
ly
Warehouse
Stores
Paint
Drill
Drill
Group A
Group B
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ADVANTAGES & LIMITATIONS OFLAYOUTS
Fixed Product Layout
Advantages Limitations1. Material movement is
reduced
2. Promotes Job enlargement
by allowing individuals orteams to perform the wholejob
3. Continuity of Operationsand responsibility resultsfrom team
4. Highly flexible; canaccommodate changes inproduct design, product mixand production volume
5. Independence of productioncenters allows schedulingto achieve min. total prodn
1. Increased movement ofpersonal and equipment.
2. Equipment duplication may
occur3. Higher skill requirements for
personnel
4. General supervisionrequired
5.
Cumbersome and costlypositioning of material andmachinery
6. Low equipment utilization
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ADVANTAGES & LIMITATIONS OFLAYOUTS
Product Layout
Advantages Limitations1. Since the layout
corresponds to thesequence of operations,smooth and logical flow lineresult.
2. Since the work from oneprocess is fed directly intothe next, small in processinventories result.
3. Total production time perunit is short.
4. Since the m/cs are locatedso as to minimize distancesb/w consecutive operations,materials handling is
reduced.
1. A breakdown of onemachine may lead to acomplete stoppage of theline that follows thatmachine.
2. Since the layout isdetermined by the product,a change in product designmay require major
alterations in the layout.3. The pace of production is
determined by the slowestmachine.
4. Supervision is general,rather than specialized.
5. Comparatively high
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ADVANTAGES & LIMITATIONS OFLAYOUTS
Group Layout
Advantages Limitations1. Increased machine
utilization.
2. Team attitude and job
enlargement tend to occur.3. Compromise between
product layout and processlayout, with associatedadvantages
4. Supports the use of general
purpose equipment.5. Shorter travel distances
and smoother flow linesthan for process layout.
1. General supervisionrequired.
2. Higher skill levels required
of employees than forproduct layout.
3. Compromize betweenproduct layout and processlayout with associatedlimitations.
4. Depends on balancedmaterial flow through thecell; otherwise buffers andwork-in-process storage arerequired.
5. Lower machine utilization
than for process layout.
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ADVANTAGES & LIMITATIONS OFLAYOUTS
Process Layout
Advantages Limitations1. Better utilization of
machines can result;consequently fewermachines are required.
2. A high degree of flexibilityexists relative to equipmentor manpower allocations forspecific tasks.
3. Comparatively low
investment in machines isrequired.
4. The diversity of tasks offersa more interesting andsatisfying occupations forthe operator.
5. Specialized supervision is
1. Since longer flow lineusually results, materialshandling is more expensive.
2. Production planing andcontrol system are moreinvolved.
3. Total production time isusually longer
4. Comparatively large amount
of in-process inventoryresult.
5. Space and capital are tiedup by work in process.
6. Because of the diversity ofjobs in specializeddepartments, higher grades
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Space for Future Expansion
Space for FutureExpansion
Copper TeeProduction (Assembly)Operations1. Cu-Wire Rewinding
/ Cleaning2. Winding3. Tying4. Pouching5. Assembling6. Sealing7. QA
QA
Cu-T Moulding
Component Store
Receiving Bay
Raw Matl for Cu-TMoulding
Final Packing AreaFor Cu-T
Finished Product
Store
Quarantine
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