Facilities Design
Need
1. When starting a new factory
2. Expansion of existing factory
3. Whether to close down existing facilities
Plant Location Problem
1. Selection of region
2. Selection of community
3. Selection of specific site
Factors Influencing Plant Location
Controllable factors :
1. Proximity to markets
2. Supply of materials
3. Transportation facilities
4. Infrastructure availability
5. Labour and wages
6. Capital
Uncontrollable factors
1. Government policy
2. Climate conditions
3. Supporting industries and services
4. Community and labour attitudes
Study of Plant Layout
Objectives of Good Layout
-Material handling costs.
-Movement of people and material
-Hazards to personnel
-Accidents
- Production capacity
- labour efficiency
- Employee morale
- Space utilization
- Ease of Supervision and Maintenance
The basic objective of layout design is to facilitate a smooth
flow of work, material, and information through the system.
Supporting objectives generally involve the following:
To facilitate attainment of product or service quality.
To use workers and space efficiently.
To avoid bottlenecks.
To minimize material handling costs.
To eliminate unnecessary movements of workers or materials.
To minimize production time or customer service time.
To design for safety.
Principles of plant layout
1. Principle of integration
2. Principle of minimum distance
3. Principle of cubic space utilization
4. Principle of flow
5. Principle of flexibility
6. Principle of safety and satisfaction
7. Principle of minimum handling
Manageria Productio
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Type of
Future Factors
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Availabilit
Type of y of total
building Material area
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equipment
Advantages of plant layout
Economies in handling
Effective use of available area
Minimization of production delays
Improved quality control
Avoidance of bottlenecks
Better production control
Better supervision
Improved utilization of labour
Improved employee morale
Avoidance of unnecessary and
costly changes
Types of Layout
1. Product Layout
4. Fixed Position Layout
2. Process Layout
5. Cellular Manufacturing Layout
3. Combined Layout
1. Product Layout
• Straight Line or Layout for Serialised Manufacture.
• Arrangement of machines in ONE LINE depending on
the sequence of operations.
• Materials are fed in the first machine & finished
products comes out from the last machine.
• Eg:Sugarcane mill and paper mill
It is appropriate for producing one standardized product, usually in
large volume. It is also called as flow-shop layout or straight line
layouts. The machines are arranged according to the progressive
steps by which the product is made.
Example: chemical, paper, rubber, refineries, cement industry.
Product layout
Advantages:
•Mechanization of materials is possible and material handling cost
can be reduced.
•It requires less floor area.
•It facilitates better production control.
•Production bottlenecks are avoided.
Disadvantages:
•Expansion of product line is difficult.
•There is difficulty is supervising.
•Breakdown of equipment disrupts the production.
2. Process layout:
• Functional layout /job lot manufacture or batch
production layout.
• Involves grouping of like machines in one department.
• General purpose machines.
when product having standard features is to be produced in
large volumes.
The specialized machines and equipments are arranged one
after another in the order of sequence required in the
production process.
Process layout:
Advantages :
•Greater Flexibility
•Better and more efficient supervision possible through
specialization
•Capacity of different product line can be expanded easily.
•Better utilization of men and machine.
Disadvantages:
•More floor space
•More work in progress
•More distance travelled by the product.
3. Combined layout
Combination of different types of layout viz. product
layout and process layout.
4. Fixed Position Layout
• Movement of men and machines to the product.
• Bulky product
When due to size, shape and other characteristics constraints, the
products cannot be moved, the machine and operators move
around the product.
Example: construction of a building, assemble of an aircraft or
ship.
Advantages Disadvantages
Saves time and cost in movement
• Production period being very long,
Flexible as changes in job design can capital investment is quite heavy
be easily incorporated • Very large space is required for
More economical when several orders storage of materials and equipment
in different stages are executed • As several operations are carried
Adjustments can be made to meet simultaneously, possibility of
shortage of materials or absence of confusion and conflicts are high
workers.
5. Group layout or Cellular layout:
Grouping technology layout of cellular manufacturing layout is
made for a single part family i.e parts with common
characteristics. In this layout dissimilar machines are grouped
into cells and each cell functions like product layout.
Advantage and Disadvantages:
It reduces material handling cost and simplifies
machine changeovers. It reduces in-process inventory
and automate the production but reduces the
flexibility.
Group layout or Cellular layout:
