Zis layout
- 2. What is a Plant layout? In simple words, plant layout means allocation of space and arrangement of equipments in such a manner that overall operating costs are minimized.
- 3. Objectives of Plant layout: Minimize material handling cost. Effective utilization of men, equipment and space. Make effective utilization of cubic space. Provide for employee convenience- safety & comfort. Minimize investment in equipment. Minimize overall production time.
- 4. Principles of Plant layout: 1. Principle of minimum movement. 2. Principle of space utilization. 3. Principle of flexibility. 4. Principle of interdependence. 5. Principle of safety 6. Principle of smooth flow 7. Principle of supervision 8. Principle of satisfaction
- 5. Factors affecting Plant layout: 1. Policies of management 2. Plant location 3. Nature of product 4. Availability of floor space 5. Volume of production
- 6. Types of Plant layout: 1. Product layout 2. Fixed layout 3. Process layout 4. Combination layout
- 7. Product or Line layout: Machines & equipments are arranged in one line depending upon the sequence of operations required for the products. The materials move from one work station to another sequentially without any back-tracking. Under this, machines are grouped in one sequence therefore materials are fed into the first machine & finished goods travel automatically from machine to machine. The output of one machine becomes the input of the next. For example, in a paper mill, bamboos are fed into the paper mill at one end & paper comes out from the other end.
- 8. Required general principles: 1. All the machine tools or other items of equipment must be placed at the point demanded by the sequence of operations. 2. There should be no point where one line crosses another line. 3. Materials maybe fed where they are required for assembly but not necessarily at one point. 4. All the operations including assembly, testing, packing must be included in the line.
- 9. Juice processing flow-chart (with respect to FIL industry): Raw material Blending Homogenization De-aeration Sterilization Rinsing Storage
- 11. Advantages of Product Layout: Low cost of material handling Smooth operations Continuous flow of work Optimum use of floor space Shorter processing time
- 12. Disadvantages of Product layout: High initial capital investment in special purpose machine. Breakdown of one machine will hamper the whole production process. Heavy overhead charges.
- 13. Fixed layout: In this type of layout, the major product being produced is fixed at one location. Equipments, labor and material are moved to that location. All facilities are brought and arranged around one work center. This type of layout is not relevant for small scale entrepreneurs. Material Labou r Equipment Finished product Rambagh flyover
- 14. Advantages of fixed layout: It saves time and cost. The layout is flexible. It is economical.
- 15. Disadvantages of fixed layout: Production period being very long, capital investment is very heavy. Very large spaces required. There's a possibility of confusion and conflicts among different work groups.
- 16. Process layout: In this type of layout machines of a similar type and performing similar operations are arranged together at one place. In this type of layout the work has to be allocated to each area in such a way that no machines are chosen to do as many different jobs as possible, i.e. Emphasis is on the general purpose machine.
- 17. Advantages of Process layout: 1. Lower initial capital investment. 2. Lower overhead costs. 3. Change in output design can be adopted to the output of variety of products. 4. Breakdown of one machine doesn’t lead to complete stoppage. 5. Effective supervision. 6. Great flexibility. Disadvantages: 1. Higher material handling costs. 2. More skilled labour is required which further increases the cost. 3. Time gap in production is higher. 4. Work in progress inventory is high, leading to greater storage space.
- 18. Combined layout: Certain manufacturing units may require all three processes, namely intermittent processes (job shops), the continuous process ( mass production shops), and the representative process combined process ( miscellaneous shops). In most of industries, only a product layout or process layout or fixed location layout does not exist. Thus in manufacturing concerns where several products are produced in repeated number with no likelihood of continuous production, combined layout is followed. Generally a combination or product & process layout or other combination is followed in practice.
- 19. Plant layout and production layout of DANONE: DANONE is a French food product multinational corporation that produces fermented dairy products like yoghurt & curd. Quality check of milk tanker Weighing of milk tanker Milk in Mix Tank (according to plan) Quality check & release of recipe
- 20. Weighing Of recipe from warehouse Mixing of ingredient & Hydration for 30min Pasteurization (95°C for 5 mins) & Homogenization at 300 bar Inoculation Tank {2.5kl, 6KL &Tote (700ltr)} Hot culturing: for stirred products at 38-400 C Cold culturing: for set products at 4-60 C Reheater (40-42°C) Packaging (Hassia, Zhongia Pouch filling machine)
- 21. Printing & Weighing Incubation (42°C till it achieves desired pH) Cold Storage (4-6°C) Dispatch to Market (in refrigerated trucks)
- 22. Production involves mainly 6 processes & equipments: Tri blender Pasteurizer Sterilizer Homogenizer Reheater