It is the configuration of departments, work centers and equipment in the conversion process.
PLANT LAYOUT Operation ManagementObjectives Show
This unit teaches you about:
Structure:
INTRODUCTION: Plant layout problems are fundamental to all kinds of organizations and are experienced in all kinds of undertakings. For instance, a housewife must arrange her kitchen, a retailer must arrange his counter and display items in a manner that facilitates movement, and attracts the attention of customers. The office management positions furniture and interiors in such a way that it facilitates the flow of work. A manufacturing organization must arrange its facilities, so as to assist the smooth flow of products. The simple meaning of the word ‘layout’ is an arrangement. Plant layout is the physical configuration of departments, work stations and equipment in the conversion process. It is the spatial arrangement of physical resources to create the product. It is a set of those activities which locate and move the work table in a way that all inputs of equipment, raw materials, machines, tools, fixtures and workers are given a proper place. Professor F.G. Moore says, “A good plant layout is one which allows materials rapidly and directly for processing. This reduces transport handling, electrical and other costs down per remit, space requirements are minimised and it reduces idle machine and idle man time.” Professors Knowles and Thomson defined the phrase ‘plant layout’ as something that stands for:1) Planning and arranging manufacturing machinery, equipment and services for the first time in completely new plants and 2)Improvements in the layouts already in use in order to introduce new methods and improvements in manufacturing procedures. According to James Lundy, ‘Layout identically involves the allocation of space and arrangement of equipment in such a manner that overall operating costs are minimised. Though layout stands for the arrangement of facilities, every arrangement need not be called a sound plant layout.’ NEED FOR PLANT LAYOUTThe need for plant layout becomes inevitable on several occasions backed by rational causes and forces. Of these, the most significant ones are described as follows:
SIGNIFICANCE OF PLANT LAYOUTPlant layout is both the art and science of planning the processing of a product unit in the most effective manner, through the shortest possible distance and time. Put in other words, it is the array of production machinery, work centres and collateral facilities and activities for the purpose of achieving efficiency in manufacturing a product or supplying consumer services. A plant layout is the arrangement of the production processes, storeroom, stock room, tool room, material- handling equipment, racks and sub-stores, employee services and all other accessories that are required for facilitating the production in the factory. As it encompasses production and service facilities and provides for the most effective utilisation of the men, materials and machines constituting the process, it is a master plan or blueprint for coordinating all operations performed inside the factory. In precise terms, it involves the ideal and judicious allocation of space and arrangement of equipment in such a manner that overall operating costs are minimised Plant layout signifies the arrangement of machinery, equipment and other industrial facilities like recurring storage and supply of raw materials, supplies and final products, tool room, maintenance room, employee amenities such as restrooms, canteens, crèches and material-handling equipment so as to attain the highest efficiency of the production flow. Plant layout is the integrating phase of the design of the production system ESSENTIALS OF A GOOD PLANT LAYOUTPlant layout is the method of allocating machines and equipment to various production processes and other necessary services involved in the transformation process of a product within the available space of the factory. The requisites of a sound plant layout are unique. A good layout brings home comforts and convenience, safety, efficiency, compactness and profits. On the other hand, a poor Layout drives home congestion, inefficiency, rigidity and reduced profits. The following are the requisites of a good plant layout.
BASIC PRINCIPLE OF PLANT LAYOUTIn order to achieve the objectives of an ideal plant layout, the design engineers are to follow certain principles, which can be called fundamentals of a good plant layout. Whilst the techniques employed are industrial engineering techniques, the process is a creative one, which cannot be set down with any finality. The process is one in which experience plays a very great role. Further, it is impossible to define a ‘good’ layout with any precision. However, there are certain criteria, which may be satisfied by a layout. These fundamental parameters or principles are described as under. An alert manager cares for these fundamentals because he wants to get the best out of everyone despite the constraints and restraints under which he is working. The Principle of Integration:An effective plant layout must be capable of integrating all the pertinent factors affecting the factory layout such as materials, men, machines, methods, and all the supporting activities in the most logical and balanced manner. It implies a perfect fusion to give a sense of compactness. It is essential that all these factors of production must be procured in the right quantity and proportion at the right time. It is so because, the aim is to get the best out of each factor of production so as to reduce the overall cost and improve the quality. Objectives of a plant layout:
ADVANTAGES OF A GOOD PLANT LAYOUT:A good layout can provide a number of advantages to the workers and the management. Some of these are listed below: Advantages to the worker:
Advantages in terms of manufacturing costs:
Advantages in production control and supervision:
TYPES OF PLANT LAYOUT:The layout of the manufacturing system can be classified into three main categories as follows:
Line or product layout:Here, the position of a particular machine/equipment is determined at some definite stage or place where the machine is required to perform some operations from a sequence of operations designed to manufacture the product. It is assumed that materials are transferred into products through a series of integrated operations arranged in the order of sequence. The position or the order in the sequence for a machine performing a particular operation is fixed. Once a machine is in line, it cannot perform any operation which is not designed in the sequence of operations. This layout can be in the shape of the ‘line’ or ‘U’. Here, equipment or machines are arranged according to the needs of the product and in the same sequence, according to the operations necessary for the manufacture of the product. There is a continuous flow of material during the production process from start to finish. This type of layout is used for the continuous type of manufacturing systems, producing items of the same type on a mass scale, for example, textile, sugar, petroleum, paper, etc. Principles:While grouping machines according to product type, the principles that need to be kept in mind are as follows:
Advantages:
Disadvantages:
PROCESS OR FUNCTIONAL LAYOUT:In this layout, more emphasis is given to specialisation or functional homogeneity of various components of the system. All operations of a similar nature are grouped together in the same department or are part of the factory. Here, machines performing the same type of operations are installed at one place, i.e., the plant is grouped according to the functions. For example, all drilling machines are located at one place known as the drilling section. Similarly, operations are classified into different sections such as milling, molding, packaging, etc. This type of layout is most appropriate for intermittent jobs and batch-type manufacturing systems where small quantities of a large range of products are to be manufactured, e.g., machine tools, custom-made furniture, etc. PrinciplesWhile grouping machines according to process type, certain principles must be kept in mind. These are:
Advantages
Disadvantages:
According to Sergeant Florence, the location should be explained as the degree of dissimilarity between the geographical distribution of the industry and the population of the country. In case the location factor works out to be unity, it means that the industry is evenly distributed. When it is above unity, the region is said to have more industry than due to it, but if it is less than unity, it means that the region does not have sufficient share of the industry. The coefficient of localisation indicates the tendency of a particular industry to concentrate or disperse in a particular area. It can be worked out by dividing the deviations of the regional proportion of workers in a particular industry by the regional proportion of workers in all industries. Industries, which are concentrated in some regions, have a high coefficient of localisation. The theory given by Sergeant Florence has been criticised on many grounds. This theory explains only the existing state of distribution of industries in a country. It is not concerned at all with providing any guidelines for the future location of industries. FIXED-POSITION LAYOUTS
CELLULAR MANUFACTURING (CM) LAYOUT
Groupings are determined by the operations needed to perform work for a set of similar items, or part families that require similar processing.
HYBRID (MIXED) LAYOUTS
SUMMARYThis unit deals with the fundamentals of plant layout and essentials of a good plant layout. Plant layout is the physical configuration of departments, work stations and equipment in the conversion process. It is the spatial arrangement of physical resources to create the product. It is a set of those activities which locate and move the work table in a way that all inputs of equipment, raw materials, machines, tools, fixtures and workers are given a proper place. A good plant layout is one which allows materials rapidly and directly for processing. This reduces transport handling, electrical and other costs down per remit, space requirements are minimised, and it reduces idle machine and idle man time. We have also discussed about types of plant layout and their respective advantages. QUESTIONS
REFERENCES:
Is the configuration of departments work centers and equipment?Layout refers to the configuration of departments, work centers, and equipment, with particular emphasis on movement of work (customers or materials) through the system.
What is process layout in operations management?A process layout is a type of facility layout. Organizations often use process layouts to design floor plans and arrange equipment for maximized efficiency. Plants with a process layout may arrange work stations, machinery, tools and other equipment in groups according to the functions they perform.
What is facility layout?Facility layout is an arrangement of different aspects of manufacturing in an appropriate manner as to achieve desired production results. Facility layout considers available space, final product, safety of users and facility and convenience of operations.
What are the layout types of production departments?There are four main types of facility layouts: process, product, fixed-position, and cellular. The process layout arranges workflow around the production process.
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