PLANT LAYOUT & MATERIAL HANDLING :

PLANT LAYOUT & MATERIAL HANDLING Submitted by K.N.Jakanathan

Definition :
“Plant layout involves the development of physical relationships among building
equipment and production operations which will enable the manufacturing
process to be carried on efficiently” - Morris Plant Layout - placement of
departments, placement of workgroups within departments, placement of
workstations, placement of machines, placement of stock-holding points All
within a facility

Objectives :
3 Objectives Proper and efficient utilization of cubic (i.e. length, width and height)
of available floor space. To ensure that work proceeds from one point to another
without any delay. Provide enough production capacity. Reduce material handling
costs. Reduce hazards to personnel. Utilize labor efficiently. Increase employee
morale. Eliminate conjugation and bottle neck at work. Provide for volume and
product flexibility. Provide ease of supervision and control. Provide for employee
safety and health. [ Reduce accidents ] Allow ease of maintenance. Allow high
machine or equipment utilization. Improve productivity. Reduce Capital
Investment.

Factors Influencing Layout :

4 Factors Influencing Layout Nature of product. Production process. [Including
Waiting Time] Type of machinery. Repairs and maintenance. Human needs. Plant
environment. Materials. Material Handling Equipments. Auxiliary Services. Future
Changes. Factory building.

Types of Layout :
Types of Layout Manufacturing units
► Product or line layout
► Process or functional layout
► Fixed position or location layout
► Combined layout
► Fixed Layout
►Cellular (or) Group Technology Layout
Product oriented Plant Layout (Line Layout) :
Machinery and Materials are placed following the product path.
This type of plant layout is useful when the production process is organized in a
continuous or repetitive way.
Continuous flow: The correct operations flow is reached through the layout
design and the equipment and machinery specifications.
Repetitive flow (assembly line): The correct operations flow will be based in
a line balancing exercise, in order to avoid problems generated by bottle necks.

:
8 The plant layout will be based in allocating a machine as close as possible to the
next one in line, in the correct sequence to manufacture the product. Allocating
line may be of any form, like straight line L shape U shaped S shaped Cont.,

Factory Product layout :

9 Factory Product layout

Product layout :
10 Product layout Product oriented plant layout Advantages: Economy material
handling activities. Mechanization of material handling equipments. Work In
Process almost eliminated. Minimum manufacturing time. Simplification of the
production planning and control systems. Tasks simplification. Greater incentive
for group. Disadvantages: No flexibility in the production process Low flexibility in
the manufacturing times. High capital investment. Difficulty of supervising, since
the person is expert in only one function. Every workstation is critical to the
process.- The lack of personnel or shut down of a machine stops the whole
process. Monotonous work. Difficulty in expansion.

Process oriented plant layout (Functional Layout) :

11 Process oriented plant layout (Functional Layout) This type of plant layout is
useful when the production process is organized in batches. Personnel and
equipment to perform the same function are allocated in the same area. The
different items have to move from one area to another one, according to the
sequence of operations previously established. The variety of products to produce
will lead to a diversity of flows through the facility. The variations in the
production volumes from one period to the next one (short periods of time) may
lead to modifications in the manufactured quantities as well as the types of
products to be produced.

Slide 12:
12 Factory Process layout

Process Layout :
13 Process Layout Process oriented plant layout Advantages: Flexibility in the
production process. Better control of manufacturing cost. No Duplication. Easy to
handle the problems. Better Supervising. [Experts will be there in each
department] Higher Individual incentive. Disadvantages: Manufacturing time
increases. Controlling will be costly and complex. Material handling cost will be
higher. More workspace required. Accumulation of work-in process.

Fixed Layout :
14 Fixed Layout In Fixed product layout, the products generally circulate within
the production facilities (machines, workers, etc.); in this particular type of layout,
the product does not move, the different resources are moved to perform the
operations on the product. This type of layout is commonly found in industries
that manufacture large size products, such as ships or aircrafts. The equipment is
brought to the object being processed, and the object does not move. Example:
Air craft manufacturing. Arranging materials and equipment concentrically around
the production point in their order of use.

Factory Fixed Layout :

15 Factory Fixed Layout Raw Material Machine & Equipment Labour Finished
product AIRCRAFT AIR CRAFT ASSEMBLY

Fixed Layout :
16 Fixed Layout Advantages of stationery Layout: Layout is fully flexible and is
capable of absorbing any sort of change in product and process. Lower labor cost
[People are drawn from functional departments] Saving in time Less floor space
because machines and equipment are in moving position. Most suitable way of
assembling large and heavy products. Disadvantages Of Stationery Layout: Higher
capital investment Unsuitability for manufacturing or assembling small products
in large quantities. It is suitable only in case where the product is big or the
assembling process is complex.
Combined Layout or Mixed Layout :
17 Combined Layout or Mixed Layout Manufacturing concerns where several
products are produced in repeated numbers with no likelihood of continuous
production , combined layout is followed. Generally, a combination of the product
and process layout or other combination are found, in practice, e.g. for industries
involving the fabrication of parts and assembly, fabrication tends to employ the
process layout, while the assembly areas often employ the product layout.

Factory Combined Layout :

18 Factory Combined Layout 1 1 1 2 2 2 4 4 4 Combined Milling Grinding 3
Painting Packing

P-Q Analysis :
19 P-Q Analysis Product Layouts Fixed Position Layouts Mixed Layouts Process
Layouts Quantity Number of different products

CELLULAR OR GROUP TECHNOLOGY LAYOUT :

20 CELLULAR OR GROUP TECHNOLOGY LAYOUT Work cells Definition: Group of
equipment and workers that perform a sequence of operations over multiple
units of an item or family of items. Looks for the advantages of product and
process layouts: Product oriented layout: Efficiency Process oriented layout:
Flexibility Group Technology Grouping outputs with the same characteristics to
families, and assigning groups of machines and workers for the production of
each family.

CELLULAR OR GROUP TECHNOLOGY LAYOUT :

21 CELLULAR OR GROUP TECHNOLOGY LAYOUT In a cellular layout the design is
not according to the functional characteristics of equipment, but rather by self-
contained groups of equipment (called cells), needed for producing a particular
set of goods or services. Group technology, or cellular manufacturing, classifies
parts into families so that efficient mass-production-type layouts can be designed
for the families of goods or services.

Slide 22:
Cellular Layout Process (Functional) Layout Group (Cellular) Layout Similar
resources placed together Resources to produce similar products placed together
A cluster or cell

CL or GT: BENEFITS :
23 CL or GT: BENEFITS Advantages Lower work-in-process Inventories Reduced
material handling costs. Shorter flow times in production. Simplified production
planning. (MEN, MATERIAL ETC.) Overall performance increased by lowering
production costs & improving on time delivery. Improved Quality. Disadvantages
Reduced manufacturing flexibility & potentially increased machine downtime.
Duplicate pieces of machinery may be needed so as to avoid movement of parts
between cells.

Break Even Analysis :

24 Break Even Analysis Fixed layout Process Layout Cell or GT layout Product
layout costs Volume Use fixed position Use process Use cell or GT Use product

SYSTEMATIC LAYOUT PLANNING :

25 SYSTEMATIC LAYOUT PLANNING Systematic Layout Planning (SLP) is an
organized approach to facility Layout planning. The heart of SLP is the Activity
Relationship Chart and Diagrams that neatly summarize vast amounts of
quantitative and Qualitative information.

EXAMPLE OF SYSTEMATIC LAYOUT PLANNING: REASONS FOR CLOSENESS :

26 EXAMPLE OF SYSTEMATIC LAYOUT PLANNING: REASONS FOR CLOSENESS 26
Justification Code

EXAMPLE OF SYSTEMATIC LAYOUT PLANNING: IMPORTANCE OF CLOSENESS :

27 EXAMPLE OF SYSTEMATIC LAYOUT PLANNING: IMPORTANCE OF CLOSENESS 27
Priority code

EXAMPLE OF SYSTEMATIC LAYOUT PLANNING: RELATING REASONS AND

IMPORTANCE :
28 EXAMPLE OF SYSTEMATIC LAYOUT PLANNING: RELATING REASONS AND
IMPORTANCE 28 From 1. Credit department 2. Saree department 3. Wine
department 4. Camera department 5. jewelry department -- U 1 I 1,6 A -- U 1 X 1
X To 2 3 4 5 Area (sq. ft.) 100 400 300 100 100 Closeness rating Reason for rating
Letter Number

EXAMPLE OF SYSTEMATIC LAYOUT PLANNING:INITIAL RELATIONSHIP

DIAGRAM :
29 EXAMPLE OF SYSTEMATIC LAYOUT PLANNING:INITIAL RELATIONSHIP DIAGRAM
29 The number of lines here represent paths required to be taken in transactions
between the departments. The more lines, the more the interaction between
departments. Note here again, Depts. (1) and (4) are linked together, and Depts.
(2) and (5) are linked together by multiple lines or required transactions.

EXAMPLE OF SYSTEMATIC LAYOUT PLANNING:INITIAL AND FINAL LAYOUTS :

30 EXAMPLE OF SYSTEMATIC LAYOUT PLANNING:INITIAL AND FINAL LAYOUTS 30
Note in the Final Layout that Depts. (1) and (5) are both not placed directly next
to Dept. (2).

Re-layout :
31 Re-layout A good plant layout involves not only the designing and installing of
the layout for the first time but also revision of existing layout. The best layout
becomes obsolete over a period of time.

Reasons for Re-Layout :

32 Reasons for Re-Layout Product Design Change. New Product Production.
Changes in volume of demand. Facilities become obsolete. Rearranging the
department within the factory. Consideration of safety. Change in location of
market. Poor worker environment. Cost reduction. Technology Advancement.
Improvement in layout technology.

Plant location’s influence Plant layout :

33 Plant location’s influence Plant layout Location may affect make/buy decisions.
Location near the source. Location near the transport facilities. Easy Power
supply. Cheap labour. Climate. Waste disposal facility.

Material handling systems :

34 Material handling systems

Slide 35:
35 As the science is getting developed new modern equipments are getting
introduced in material handling area. It is accelerating the activity of loading and
unloading. These equipments are used for the movement of material over a short
distance. The bulk handling of the material takes place in shipyards, ports,
airports etc. Role of material handling in logistics

Slide 36:
36 Unloading the incoming material from transport vehicle. Moving the unloaded
material to assigned storage places in warehouses. Lifting the material from the
storage place during order picking. Moving the material for inspection & packing.
Loading the boxes on transport vehicle. Material handling Operation steps

Slide 37:
37 Designing the system for continuous flow of material. No idle time. Going in for
the standard equipments – it reduces the cost. If possible use gravitational force.
continuous material movement is most economical Material Handling Efficiency

Slide 38:
38 Volume of operations. Speed of handling. Productivity. Nature of product. Size,
shape, weight of the product. Nature of equipment. Selecting Material handling
Equipment

Slide 39:
39 Commonly used equipments in industry – lift Fixed Path Conveyors Wheeled
trolley Variable Path Forklift truck. Overhead cranes Auxiliary path Auxiliary
materials Rigging, Clamps

Slide 40:
40 Wheeled trolley – two wheeled and four wheeled trolleys are used for
transferring boxes from one place to another place within the organization.
Trolleys have wide range of sizes and shapes. Organizations decide as per their
requirement. Overhead cranes - these are used for movement of heavy items but
for a shorter distances. The movement is controlled by a person having controls in
his hand. Many times it is a computerized activity. These cranes are installed on
the fixed girders near the ceiling. Variable path

Slide 41:
41 Wheeled Trolley Overhead Crane inside the factory Overhead cranes outside
the factory

Slide 42:
42 Forklift truck – this is highly useful in material handling activity. It got invented
after II world war. The main advantages are, Movement of larger loads over a
longer distance. Moving the load vertically also. Movement of loads vertically and
horizontally, exactly positioning for loading and unloading operations. It can
transfer the load in any direction.

Fixed Path :
43 Fixed Path Conveyors – these are used where continuous flow of material is
essential. It is used in mass production activity on production shop floor also.
conveyors are widely used in automated warehouses in big retail shops.

Slide 44:
44 Wheel conveyors – the small wheels made out of steel or plastic bearing. The
load is kept on the bearings and either pushed or gravitational force is utilized for
the forward movement of the material. Roller conveyor – these are mainly used
in docks for faster unloading of the goods. They are like wheel conveyors but
powered rollers are used.

Slide 45:
45 Belt conveyor – these are commonly used for material movement. It is used in
mass production activity. Chain conveyor – this is mainly used for movement of
heavy material. It is used in mass production activity also. Pallets are kept on the
chain and stoppers are provided for carrying out the production related work.

Slide 46:
46 Wheel Conveyor Belt Conveyor Chain Conveyor Roller Conveyor

Slide 47:
47 LIFT These are used to lift the heavy materials vertically. It is useful to lift to
upper floor.

Slide 48:
48 Clamps These are used for mainly clamping and picking the material in large
volumes. It can have more number of trailers. eg. Clip, metal mesh, Hooks, rings,
oblong links. Riggings These are used for picking and placing the materials. It is
lengthy depends on use. eg. Chains, ropes, wires. Auxiliary

Slide 49:
49 Riggings,Clamps,Chains,oblong links

Factors influencing material handling equipments :

50 Factors influencing material handling equipments Required path of travel
(fixed or variable) Nature of the material. Physical characteristics of the building.
Space requirement of handling equipment. Required handling capacity. Cost
consideration.

Slide 51:
51 Relation between plant layout and Material Handling Close relation between
plant layout and Material Handling. Material Handling methods influence the
layout and factory building. Material Handling is to be considered as an integral
part of plant layout to design low cost handling system. Good Material Handling is
resulted based on the arrangement of production equipment, location of
departments, logical sequence of operations, location of stores, tools. Material
Handling system/equipment can be selected only after the appropriate floor plan.
Plant layout considers the points for material receiving and shipping of products
Careful arrangement of work centers and storage areas Consider horizontal or
vertical material transportation

Slide 52:
52 Thank you