Meaning of plant layout Plant layout is a

Meaning of plant layout • • Plant layout is a physical arrangement of everything needed for production of goods and delivery of services. It is arrangement of materials, equipment, other utilities , machines etc. A well designed plant layout is concerned with maximum and effective utilisation of available resources at minimum operating cost. Primary objective is minimise movement of men.

Definition of plant layout “plant layout involves the development of physical relationship among building, equipment and prodiction operations, which will enable the manufacturing process to be carried on efficiently”. -Morris E. Hurley

Objectives of plant layout 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. To minimise production delay. To ensure less spoilege and scrap. To promote efficent production planning and control. To minimise accident. To ensure better quality product. To provide better customer services. To employ efficent work methods. To reduce maintenance costs. To improve morale of employees. To promote specilisation.

Principles of plant layout • • Principles of minimum movement Principles of flow Principle of space Principle of safety Principle of flexibility Principle of interdependence Principle of overall integration Principle of minimum investment

Principle of minimum movement As far as possible materials and labour should be moved over minimum distances.

Principle of flow • • The work areas should be arranged according to the sequence of operation so that there is continuous flow of material without congestion. The layout should allow for easy movement of materials without interruption of delay.

Principle of space All available cubic space should be effectively both vertically and horizontally.

Principle of safety There should be consideration for safety and convenience of workers. There should be built in provision for the safety and comfort.

Principle of flexibility �Layout should be designed in the manner that production facilities can easily be arranged when it become necessary in future on account of expansion and technological advancement.

Principle of interdependence Interdependent operations and process should be located in close proximity to each other.

Principle of overall integration All the plant facilities should be integrated into a single operating unit so as to maximize efficiency and minimize costs of production

Principle of minimum investment The layout should yield savings in fixed capital investment through optimum utilization of available facilities.

Advantages of good layout From the standpoint of worker ü ü ü Reduce their efforts; Reduce the number of handling; Reduce the no. of accidents from the stand point of cost of labour ü ü ü Increase the output per man-hour Reduce the length of hauls Minimise lost motions between operations

From the standpoint of manufacturing costs üSave the power load üReduce the spoilage and scrap üEnsure better cost control From the standpoint of production control üIncrease the pace of production üFacilitate receipts, shipment and delivery From the standpoint of supervision üHelp in easing the burden of supervision üReduce the cost of supervision üDecrease the degree of insepction

Factors influencing plant layout 1. Factor building: -the nature and size of building determines the floor space available for layout. 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 arranges accordingly to product layout. 5. Repair and maintenance : - machine 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, and other employees facilities , proper provision should be made for disposal of effluents, if any.

Types of plant layout 1. 2. 3. Product or line layout Process or functional layout A combination of product and process layout

Product or line layout refers to the arrangement of machines or equipment in a line or sequence of operations. advantages of plant layout 1. Economic in material handling 2. Reduction of inventory 3. Optimal use of floor space disadvantages of plant layout 1. Inflexible 2. Difficult to expand

Process or functional layout refers to an arrangement whereby similar machines are placed in one department for one distinct operation advantages of process layout 1. Flexible 2. Specialisation 3. Effective supervision disadvantages of process layout 1. Require more floor area 2. Difficult in control

A combination of line and process layout Under this type of layout , some of the machines may be grouped in accordance with process layout, to be integrated into the line later on. “it is possible to have both type of layouts in an efficiently combined form if the products manufactured are somewhat similar and not too complex. ”