Pm408
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The document discusses facility layout and describes different types of layouts. It begins by defining facility layout as the allocation of space and arrangement of equipment to minimize operating costs. The objectives of a good layout are then outlined, such as reducing costs, improving efficiency, and increasing productivity. Key factors that influence layout decisions are also identified, including materials, products, workers, and machinery. The main types of layouts - process, product, and combination - are then described and their advantages and disadvantages compared. Specific examples of process and product layouts are provided.
Pm408
- 1. Material & Operation Management Topic : Facility Layout BY: PRANIT SHEREKAR PM-2014-408 1
- 2. In the words of James Lundy, 'Plant layout identically involves the allocation of space and the arrangement of equipments in such a manner that overall operating cost are minimized.’’ The disposition of the various parts of a plant along with all the equipments used is known as Plant Layout. It should be designed that the plant functions most effectively. 2
- 3. Objectives of a good Layout Provide enough production capacity. Reduces handling costs. Reduces congestion. Reduces hazards to personnel. Utilizes labour efficiently. Increase employee morale. Reduce accidents. Utilizes available space efficiently and effectively. Provide for volume and product facility. Provide ease for supervision. Facilitate co-ordination communication. Provide safety and health. Allow ease of maintenance. Allow high machine/equipment utilization. Improve productivity. 3
- 4. FACTORS INFLUENCING FACILITY LAYOUT MATERIALS (Type of raw materials and availability) PRODUCT (Type of product and its position) WORKER (Type , position and requirements) MACHINERY(Product, volume and process) INDUSTRY (Type of industry: Synthetic, Analytical, Conditioning and Extractive) LOCATION (Factor of production) MANAGERIAL POLICIES ( volume, provision for expansion, automation, making or buying decisions, desire for rapid delivery, purchasing policy and personnel policies) 4
- 5. Principles of Layout Principle of minimum travel Principle of sequences Principle of usage Principle of compactness Principle of safety and satisfaction Principle of flexibility Principle of minimum investment. 5
- 6. Types of layout Process layout or functional or job shop layout. Product layout or line processing layout. Fixed position layout or static layout. Cellular manufacturing layout or Group Technology layout . Combination layout or Hybrid layout. 6
- 7. Process layout The distance between departments should be as short as possible. Machines should be grouped in accordance with the principle of sequence of operation. Convenience for inspection. Convenience for supervision. 7
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- 9. Advantages of Process layout Reduced investment of machine. Greater flexibility. Better and efficient supervision. Scope for expansion as the capacity can be easily increased. Better utilisation of men and machine. Easier to handle breakdown of equipment. Full utilisation of equipments. Investment of equipment would be comparatively lower. Greater incentive to individual worker . 9
- 10. Disadvantages of Process Layout. Difficulty in the movement of material. Requires more space. Difficult in production control. More production time as work in progress has to travel from place to place. Accumulation of work in progress at different places. 10
- 11. Product Layout (Straight Line) All the machine tool and equipment must be placed at the point demanded by the sequences of operations. There should be no points where one line crosses another line. Materials may be fed where they are required for assembly but not necessarily all at one point. All the operations , including assembly, testing and packing should be included in the line. 11
- 12. Recei ving Raw Materials stores Fabrication line for part C Fabrication for part B Packing and shipping Raw Material Fabrication line for Part A Finishing t goods store WC-1 WC-2 WC-3 TEST Assembly line for the product Finishedgoods Line Layout or Product Layout 12
- 13. Product Layout (advantages) Reduction in material handling cost due to mechanization. Avoid production bottleneck. Economy in manufacturing time. Better production control. Require less floor area per unit of production. Work-in-progress is reduced and so on investment. Early detection of mistakes. Greater incentive to a group of workers to raise their level of performance. 13
- 14. Product Layout (disadvantages) Product layout is known for its inflexibility. This is an expensive layout Difficulty in supervision. Expansion is also difficult. Breakdown can disrupt the whole system. 14
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- 16. Fifth major innovation Sandwiches assembled in order Elimination of some steps, shortening of others No food prepared ahead except patty New bun toasting machine and new bun formulation Repositioning condiment containers Savings of $100,000,000 per year in food costs Mc Donald’s new kitchen layout 16
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