The document discusses plant layout and its importance. It defines plant layout as the arrangement of machinery, equipment, and furniture within a factory to allow for the quickest material flow at the lowest cost. The main types of layouts discussed are product layout, process layout, and fixed position layout. Product layout arranges machines in sequential order of operations. Process layout groups similar machines together. Fixed position layout moves workers and machines to stationary products. Recent trends include using computer programs to help design complex layouts more efficiently.
The document discusses plant layout and its importance. It defines plant layout as the arrangement of machinery, equipment, and furniture within a factory to allow for the quickest material flow at the lowest cost. The main types of layouts discussed are product layout, process layout, and fixed position layout. Product layout arranges machines in sequential order of operations. Process layout groups similar machines together. Fixed position layout moves workers and machines to stationary products. Recent trends include using computer programs to help design complex layouts more efficiently.
The document discusses plant layout and its importance. It defines plant layout as the arrangement of machinery, equipment, and furniture within a factory to allow for the quickest material flow at the lowest cost. The main types of layouts discussed are product layout, process layout, and fixed position layout. Product layout arranges machines in sequential order of operations. Process layout groups similar machines together. Fixed position layout moves workers and machines to stationary products. Recent trends include using computer programs to help design complex layouts more efficiently.
The document discusses plant layout and its importance. It defines plant layout as the arrangement of machinery, equipment, and furniture within a factory to allow for the quickest material flow at the lowest cost. The main types of layouts discussed are product layout, process layout, and fixed position layout. Product layout arranges machines in sequential order of operations. Process layout groups similar machines together. Fixed position layout moves workers and machines to stationary products. Recent trends include using computer programs to help design complex layouts more efficiently.
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GROUP 3
PLANT LAYOUT AND
INDUSTRIAL SAFETY PLANT LAYOUT DEFINITION
Plant layout refers to the arrangement of
physical facilities such as machinery, equipment, furniture etc. with in the factory building 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 material to the shipment of the finished product. IMPORTANCE OF PLANT LAYOUT
• It is long-term commitment • It facilitates the production process, minimizes material handling, time and cost, and allows flexibility of operations • It facilitates easy production flow, makes economic use of the building, promotes effective utilization of manpower, and provides for employee’s convenience, safety, comfort at work, maximum exposure to natural light and ventilation. • It affects the flow of material and processes, labor efficiency, supervision and control, use of space and expansion possibilities . FACTORS INFLUENCING PLANT LAYOUT
1.Factory building - The nature and size of the
building determines the floor space available for layout. While designing the special requirements, e.g. air conditioning, dust control, humidity control etc. must be kept in mind.
2.Nature of product - Product layout is suitable for
uniform products whereas process layout is more appropriate for custom-made products. 3. Production process - In assembly line industries, product layout is better. In job order or intermittent manufacturing on the other hand, process layout is desirable.
4. Type of machinery - General purpose machines are often
arranged as per process layout while special purpose machines are arranged according to product layout.
5. Repairs and maintenance - Machines should be so
arranged that adequate space is available between them for movement of equipment and people required for repairing the machines. 6. Human needs - Adequate arrangement should be made for cloakroom, washroom, lockers, drinking water, toilets and other employee facilities, proper provision should be made for disposal of effluents, if any.
7. Plant environment - Heat, light, noise, ventilation and other
aspects should be duly considered, e.g. paint shops and plating section should be located in another hall so that dangerous fumes can be removed through proper ventilation etc. Adequate safety arrangement should also be made.
quality, employee facilities and delivery schedules should be considered while deciding plant layout. TYPES OF LAYOUT
1. PRODUCT OR LINE 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 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. ADVANTAGES OF PRODUCT LAYOUT
• Low cost of material handling, due to straight and short route and absence of backtracking • Smooth and continuous operations • Continuous flow of work • Lesser inventory and work in progress • Optimum use of floor space • Simple and effective inspection of work and simplified production control • Lower manufacturing cost per unit
DISADVANTAGES OF PRODUCT LAYOUT
• Higher initial capital investment in special purpose machine (SPM)
• High overhead charges • Breakdown of one machine will disturb the production process. • Lesser flexibility of physical resources. 2. PROCESS OR FUNCTIONAL LAYOUT 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. ADVANTAGES OF PROCESS LAYOUT:
• Lower initial capital investment is required.
• There is high degree of machine utilization, as a machine is not blocked for a single product • The overhead costs are relatively low • Breakdown of one machine does not disturb the production process. • Supervision can be more effective and specialized. • Greater flexibility of resources.
DISADVANTAGES OF PROCESS LAYOUT:
• Material handling costs are high due to backtracking
• More skilled labor is required resulting in higher cost. • Work in progress inventory is high needing greater storage space • More frequent inspection is needed which results in costly supervision 3. FIXED POSITION OR LOCATION 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. ADVANTAGES OF FIXED POSITON 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.
DISADVANTAGES 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. 4. COMBINED OR GROUP LAYOUT A combination of process & 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 RECENT TRENDS IN PLANT LAYOUT
Plant layout is the art and science of bringing to gather men, materials, methods and supporting facilities in the form of a given arrangements that suits individuals industrial activity to have the benefits of profits maximizations through economy, efficiency, effectiveness and productivity.
1. The use of computerized facilities design
The various techniques have been developed and used in layout engineering such as ALDEP (Automated layout design program), CORELAP (Computerized relationship layout planning), CRAFT (computerized related allocation of facilities technique), CALP (computer Aided layout planning) etc. These and other programme can save time and effort in large and complex layout problems.
