Factory Layout & Material Handling

FACTORY LAYOUT & MATERIAL
HANDLING
PRESENTED BY:
ADITYA DESHPANDE
INDUSTRIAL ENGINEERING

OUTLINE
FACTORY LAYOUT
1. Types of Layouts
2. Merits, demerits and applications
3. Principles of designing Plant Layout
MATERIAL HANDLING
1. Principles of Material Handling
2. Material Handling equipments and applications
3
Factory Layout and Material Handling By A. N. Deshpande

FACTORY LAYOUT
 Plant layout is “an arrangement of machines within a factory
so that each operation is performed at point of greatest
convenience.
 It is technique of locating different machines , plant services
so that greatest possible output of high quality at lowest
possible total cost can be available.
 Proper factory layout is key to success. It can be
numerous for same product, but best is which costs
less. These may vary with size and type of plant. 4

FACTORS AFFECTING TYPES OF LAYOUTS
1. Location of various departments
2. Location of production departments in building
3. Position of service departments
4. Premises
5. Size and locational conditions of factory
6. Type of construction
7. Ventilation and air conditioning
8. Lighting
9. Appearance
10. Plant protection
11. Provision for future expansion
12. Sanitary convenience 5

OBJECTIVES OF FACTORY LAYOUT
1. To produce better quality product
2. Max. utilization of floor area
3. To reduce internal transportation of goods from one
place to another
4. Lower cost of scrap and waste
5. Fewer accidents
6. Minimizing production delays
7. Safety- personnel and machines
8. Savings of costs
9. Easy supervision
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PRINCIPLES OF DESIGNING PLANT LAYOUT
1. Principle of overall integration
2. Principle of Minimum distance
3. Principle of Flow
4. Principle of Cubic space
5. Principle of Satisfaction and safety
6. Principle of Flexibility
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TYPES OF PLANT LAYOUTS
1. Line or Product Layout
2. Functional or Process Layout
3. Combination Layout
4. Fixed Position Layout
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1. LINE OR PRODUCT LAYOUT
 Famous in Mass Production
 Only one type of product is operating area which is
standardized and produced in huge quantity
 M/C – arranged in order of their use performing
operations in sequence
 All parts, sub-assemblies are started at right time to be
ready at required time and kept moving until finished
product is available at end of assembling line.
 Also called –Synthetic System
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 Advantages:
1. Less space requirement
2. Minimum handling or transportation
3. Less work in process
4. Better utilization of machines and labour
5. Production control- gets simplified.
 Disadvantages:
1. Mfg. cost rises due to fall in production
2. When model changes, layout requires change
3. All m/c are not used for max. capacity
4. Only for one special product, no flexibility
5. If any machine fails, others have to idle till it gets
repaired.
6. Worker performs single job again & again, no skill of
other m/c
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 Suitability:
For continuous process industries like car or automobile
and chemical industries
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2.FUNCTIONAL OR PROCESS LAYOUT
 Machines are arranged according to their functions i.e.
similar machines are arranged at one location.
 Each department carries particular process and not a
product as in line type.
 Also called- Analytical Layout
 Suitability:
1. This is very useful when low volume of production
is required
2. Where non repetitive activities are done.
3. For job production type.
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 Advantages:
1. Requires less machines
2. Similar jobs produced on similar machines. Supervision is
simple.
3. Flexibility is more than line type.
4. Any breakdown of m/c doesn’t affect production
5. Workers are all rounder knowing all m/c
6. Better control on precision and quality
 Disadvantages:
1. Total production cycle time is more
2. Routing and scheduling is difficult
3. More training for workers
4. Handling and back-tracking of material is too much
5. More floor area requirement
6. Inspection is more so more inspection time and cost causing
delays.
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3. COMBINATION LAYOUT
 Combination of Line and Process Layout
 most modern type of layout
 Possible when item is made in different types and
sizes where m/c arranged as in functional type
but group of m/c are arranged in sequence like
product type.
 Suitability:
Files, hacksaws, wood saws, gear manufacturing,
etc.
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4. FIXED POSITION LAYOUT
 Men, machines are moved to material which is at
one place and product is complete at same
constant place.
 Suitable for aircraft, ship vessel, pressure vessels
 Also called static product layout
 Suitability:
For large items made singly or in very small lots
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 Advantages:
1. Less movement of materials
2. Maximum flexibility
3. Capital is minimum
4. Less total production cost
5. Different no. of projects can be done in same layout
 Disadvantages:
1. Low utilization of m/c and equipment
2. High m/c handling costs
3. Low work content in process
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 It involves movements of materials manually or
mechanically in batches or one item at a time in plant.
Movement may horizontal, vertical or combination of
both.
 It is so important that about 20-50% cost of total
production is of material handling cost.
 Cost of product can lower considerably by proper
material handling equipments.
MATERIAL HANDLING
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PRINCIPLES OF MATERIAL HANDLING
1. To choose production m/c to eliminate need of material
handling as can as.
2. Reduce movements in production
3. Reduce distance moved by choosing shortest routes
4. Employ mechanical aids in manual case to speed up
production
5. Change sequence of operation if required
6. Utilize gravity whenever possible
7. Chose most suitable handling equipment which is safe
at minimum cost.
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Manual
handling
Trolley
Wheel
barrows
Hand
carts
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Mechanical Handling Devices
Lifting & lowering
devices
1.Hoists
2. Elevators
3. Pillar crane
4. Overhead crane
5. Winches
6. Block & tackle
Transportation
devices
1. Hand truck
2. Tractors
3. Skids
4. Pipeline
5. Railways
6. Mine rail road
Combination
devices
1. Spiral chute
2. Lift truck
3. Cranes
4. Fork lift
5. Conveyors
6. Positioning
equipment
7. Marine vehicles

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Thank you!

Factory Layout & Material Handling

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