INTRODUCTION TO PLANT LAYOUT. INTRODUCTION Among the most important questions in any industry is “How good is the layout we have?” Layout or arrangement of equipment and work areas is the most concem in industrial plants. Plant layout is an industrial fundamental. It determines the efficiency, and in some instances the survival of an enterprise. Inthe context, plant layout enhances the physical arrangement of industrial facilities, This arrangement, either installed or in plan, includes the spaces needed for mat movement, storage, indirect laborers, and all other supporting activites or science, as well as for operating equipment and personne. Therefore, plant layout refers to: 1, Existing arrangement; 2. Proposed new layout plan; and 3. Actual installation, plan’or job. ‘The work of the layout planners covers the: 1. Individual workplace 2. Complete arrangement of industrial property In the industrial revolution, it was realize that there is economy in the arrangement of facilitis improvements were in the: 1. Direction of mechanization of equipment; 2. Orderliness and neatness of shop; 3. Specialization of labor; and 4, Handling of materials between operations During that period, the firm owners hire staff specialists to study plant layout. ‘The early principles: 1. Grouping similar machines and processes together, 2. Providing adequate room around each machine; 3. Living up of work areas in orderly rows; 4, Specifying aileways, and keeping them clean; 5. Bringing material in at one end and moving it in one direction toward the end of the plant, ‘The equation below will link the idea of layout decisions and desired level of production management x (men + materials machinery) = production PLANT LAYOUT OBJECTIVES 1. Arrangement of work areas and equipment that will be the most economical to operate and yet safe and satisfying for employers as related to the above equation. The advantages of a good layout result through savings in operating cost. The reduced cost will come from the following: 8) Reduced risk to health and safety of employees. > Convenience to workers > Equality hazardous and non-hazardous materials ‘Scanned with |CamScannerD) Increased output > Greater output with the same or less cost > Fewer man-hours > Reduced machine-hours ©) Improved morale and worker satisfaction > Eliminating unnecessary movements > Will lighted and ventilated > Proper sequence of work processes 4) Fewer production delays > Balanced operation times and department loads ) Savings in flow space (production, storage, and service areas) > Idle aisles, waiting material excess distances between machines > Placement of power outlets and washrooms, and spreading out stock bins ) Reduced material handling, > Transportation £) Greater utilization of machinery, manpower, and/or services > Labor cost / manpower utilization h) Reduced inventory-in-process > Keeping material moving from various points of operations > Moving faster that reduces the amount of material-in-process i) Sholt{manufacturing time > Shorter distances } Reduce idle material in delays and unnecessary storages 4) Reduced clerical work and indirect labor > Keep the material moving automatically > Reduction of production scheduling and dispatching k)_ Easier and better supervision > Ease and quality of supervision > Location and arrangement of work stations > Work places in a row, mezzanine office > Workplaces in direct sequence 1) Less congestion and confusion Delays of materials Unnecessary movement > Handling materials > Intersecting transport paths m) Reduced hazard to material or its quality > Vibration > Dirt > Separate activities ‘Scanned with |CamScanner1) Easier adjustment to changing conditions > Convenient control location > Future expansion From the foregoing the basic objectives can be resulted as: Over-all integration of all factors affecting the layout Material moving a minimum distance Work flowing through the plant All space effectively utilized Satisfaction and safety for workers AA flexible arrangement that can be easily readjusted ‘The above enumerated objectives can be expressed as principle as: 1. Principle of over-all integration ‘+ The layout is best which integrated the men, materials, machinery, supporting activities, and any other considerations in a way that results in the best compromise. 2. Principle of minimum distance moved © Other things being equal, that layout is best that permits that material to move the ‘minimum distance between operations. 3. Principle of flow Other things being equal, the layout is best that arranges the work area for each operation or process in the same order or sequence that forms, treats, or assembles the materials. 4. Principle of eubie space Economy is obtained by using effectively all cries! ‘space — both vertical and horizontal. 5. Principle of satisfaction and safety Other things being equal, that layout is best which makes work satisfying and safe for workers. 6. Principle of flexibility Other things being equal, that layout is best that can be adjusted and rearranged at minimum cost and convenience NATURE OF PLANT LAYOUT PROBLEMS Four classes: Planning a complete new plant Expanding or moving on an existing plant Rearranging a present layout Minor adjustment to existing layout eer ‘Scanned with |CamScannerCHAPTER 2 ‘Types of Plant Seven ways of relating the three elements of production. To realize production, at least one of the three elements must be moved. Classic types of Layout 1. Layout by fixed position (fixed material location) A. The material is in fixed location. B. The major components are in the fixed place. C. Tools, machinery, men and other material are brought to it. 2. Layout-by-process (layout-by-function) ‘A. Operations by same process are grouped together. B, Similar operations and equipment are grouped according to the process or function they perform. 3. Line production (Layout-by-product) A. One product or one type of product is produced in one area. B. The material moves C. The layout places one operation immediately adjacent to the next. D. The equipment is arranged according to the sequence of equation. Most Layout are Combinations Which type to use? 1. Layout-by-process are mostly used for medium quantity producers. 2. Fixed location is used for assembly because of expensive machines. 3. Line production for huge quantities and standardized products, for forming and treating, also, for major component with its assembled parts in assembly operations. 4, Layout by fixed position or fixed material location will be used when: 5. Layout-by-product in line production will be used when: Line Production as a Goal A. Practical B. Easiest and fastest way to get the job done one operation immediately after, and immediately adjacent to the next. ‘Scanned with |CamScannerRequirements for Line Production 1. Quantity on set up economy ® . The quantity of the product or production line must be large enough so that the saving per price will be more than the cost of set up. 2. Balance ‘© itis for ultimate in flow, ease, and speed,each operation should take the save amount of time. 3. Continuity © Itis for the purpose of a smooth flow of production. Assignment: 1. Pure Line Production not always Practical? 2. Economics by type of layout Scanned with |\CamScannereparrar £ 1 4#73:Plant and Facilities Planning ¢ Decigy SO The below shows the relationship of the elements of production. Management X (men + materials + machinery) = Production Objectives: . The study of this subject is towards equipment of work areas and €4uipment that will be the most economical to operate and yet safe and satisfying for employees. It is an arrangement of productive men, materials, machines, and their supporting activities that will produce a product at a cost low enough to sell at a profit in a competitive market. A good layout bring advantages that result to saving operating cost. Reduced cost come from: 1. Reduced Risk to Health and Safety of Employees 2 Improved Morale and Worker Satisfaction 3. Increased Output 4. Fewer Production Delays 5. Savings in Floor Space (Production, Storage, and Service Areas) 6. Reduced Material Handling it Greater Utilization of Machinery, Manpower, and or .” Services 8. Reduced Inventory-in-Process 9. Shorter Manufacturing Time 10. Reduced Clerical Work and Indirect Labor 11. Easier and Better Supervision 12. Less Congestion and Confusion 13. Reduced Hazard to Material or its Quality 14, Easier Adjustment to Changing Conditions 15. Miscellaneous Other Advantages Scanned wth G camscannerBasic Objectives 1. Over-all integration of all factors affecting the lay out 2. Material moving a minimum distance 3. Work flowing through the plant 4. All space effectively utilized 5, Satisfaction and Safety for Workers 6. Flexible arrangement that can be easily re-adjusted 1. Principle of Over-all Integration - That layout is best which integrates the men, materials, machinery, supporting activities, and any other considerations in a way that results in the best compromise. 2. Principle of Minimum Distance Moved Other things being equal, that layout is best that permits the material to move the minimum distance between operations. oO 3. Principles of Flow Other things being equal, that layout is the best that arranges the work area for each operation or process in the same order or sequence that forms, treats, or assembles the materials. 4, Principle of Cubic Space Economy is obtained by using effectively of available space-both vertical and horizontal. Scanned with @ camscanner5. Principle of Satisfaction and Safety Other things being equal, that layout is the best which makes work satisfying and safe for workers. 6. Principle of Flexibility Other things being equal, that layout is the best that can be adjusted and rearranged at a minimum cost and inconvenience. Nature of Plant-Layout Problems 4. Planning a complete new plant 2. Expanding or moving to an existing plant 3. Rearranging a present layout 4. Minor Adjustments to existing layout Scanned with |\CamScanner