Presented by•Rahul Chakraborty•Sourabh Banargee•Partha Chatterjee•Debadrita Dey•Debashree Chatterjee

PLANT LAYOUT

Plant layout refers to the arrangement of physical facilities such as machines, equipment, tools, furniture etc. in such a manner so as to have quickest flow of material at the lowest cost and with the least amount of handling in processing the product from the receipt of raw material to the delivery of the final product.

Definition

Proper and efficient utilization of available floor space Transportation of work from one point to another point

without any delay Proper utilization of production capacity Reduce material handling costs Utilize labour efficiently Reduce accidents Provide for volume and product flexibility Provide ease of supervision and control Provide for employee safety and health Allow easy maintenance of machines and plant. Improve productivity

Objectives Of Good Plant Layout

Product or line layoutProcess or functional layoutFixed position or location layout

Combined or group layoutCellular layout

Types Of Layout

In this type of layout the machines and equipments are arranged in one line depending upon the sequence of operations required for the product. It is also called as line layout. The material moves one machine to another machine sequentially without any backtracking or deviation i.e. the output of one machine becomes input of the next machine. It requires a very little material handling. It is used for mass production of standardized products.

Product Or Line Layout

Low cost of material handling, due to straight and short route and absence of backtracking.

Smooth and continuous operationsContinuous flow of workLesser inventory and work in progressSimple and effective inspection of work

and simplified production control Optimum use of floor space

Lower manufacturing cost per unit

Advantages of Product layout

Higher Initial capital investment in special purpose machine (SPM)

High overhead chargesBreakdown of one machine will

disturb the production process.Lesser flexibility of physical

resources.

Disadvantages of Product layout

The assembly line developed for the Ford Model T had immense influence on the world. What was worked out at Ford was the practice of moving the work from one worker to another until it became a complete unit, then arranging the flow of these units at the right time and the right place to a moving final assembly line from which came a finished product. Regardless of earlier uses of some of these principles, the direct line of succession of mass production and its intensification into automation stems directly from what we worked out at Ford Motor Company between 1908 and 1913.

Ford Motor Company (1908-1915)

In this type of layout the machines of a similar type are arranged together at one place. This type of layout is used for batch production. It is preferred when the product is not standardized and the quantity produced is very small.

Process Layout

Lower initial capital investment is required.There is high degree of machine utilization, as a

machine is not blocked for a single productThe overhead costs are relatively lowBreakdown of one machine does not disturb the

production process.Supervision can be more effective and

specialized.Greater flexibility of resources.

Advantages Of Process Layout

Material handling costs are high due to backtracking

More skilled labour is required resulting in higher cost.

Work in progress inventory is high needing greater storage space

Disadvantages Of Process Layout

A combination of process layout & product layout is known as combined layout.

Manufacturing concerns where several products are produced in repeated numbers with no likelihood of continuous production.

Combined Layout

Fixed position layout involves the movement of manpower and machines to the product which remains stationary. The movement of men and machines is advisable as the cost of moving them would be lesser. This type of layout is preferred where the size of the job is bulky and heavy. Example of such type of layout is locomotives, ships, boilers, generators, wagon building, aircraft manufacturing, etc.

Fixed Position Or Location Layout

The investment on layout is very small.

The layout is flexible as change in job design and operation sequence can be easily incorporated.

Adjustments can be made to meet shortage of materials or absence of workers by changing the sequence of operations.

Advantages Of Fixed Position Layout

As the production period being very long so the capital investment is very high.

Very large space is required for storage of material and equipment near the product.

As several operations are often carried out simultaneously so there is possibility of confusion and conflicts among different workgroups.

Disadvantages Of Fixed Position Layout

Cellular manufacturing is a type of layout where machines are grouped according to the process requirements for a set of similar items (part families) that require similar processing. These groups are called cells. Therefore, a cellular layout is an equipment layout configured to support cellular manufacturing. Processes are grouped into cells using a technique known as group technology (GT). Workers in cellular layouts are cross-trained so that they can operate all the equipment within the cell and take responsibility for its output. Sometimes the cells feed into an assembly line that produces the final product. An automated version of cellular manufacturing is the flexible manufacturing system (FMS). With an FMS, a computer controls the transfer of parts to the various processes, enabling manufacturers to achieve some of the benefits of product layouts while maintaining the flexibility of small batch production.

Cellular Layout

Cost. Cellular manufacturing provides for faster processing time, less material handling, less work-in-process inventory, and reduced setup time, all of which reduce costs.

Flexibility. Cellular manufacturing allows for the production of small batches, which provides some degree of increased flexibility. This aspect is greatly enhanced with FMSs.

Motivation. Since workers are cross-trained to run every machine in the cell, boredom is less of a factor. Also, since workers are responsible for their cells' output, more autonomy and job ownership is present.

Advantages Of Cellular Layout

Royal Enfield's manufacturing operations go through a series of modernization and improvement efforts, with a number of automated processes. The Company has put in place modern manufacturing practices like Cellular layouts, Statistical process controls and Flexible manufacturing systems. The Chennai manufacturing facility has received the ISO 9001 certification and for managing its operations in a clean and safe environment, it has obtained the ISO 14001-quality certification.

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