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Introduction
Layout planning is determining the best
physical arrangement of resources within
a facility.
t may be defined as a technique of
locating machines, processes and plant
services within the factory so as to achieve
the right quantity and quality of output at
the lowest possible cost of manufacturing.
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Objective of a good Layout
!rovide enough production capacity.
#educe 2aterial handling costs.
#educe congestion that impedes the
movement of people or material.
#educe hazards to personnel.
ncrease e2ployee 2orale.
#educe accidents.
&tilize available space effectively & efficiently.
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!rovide for volu2e & product flexibility.
!rovide ease of supervision.
acilitate co-ordination and face-to-face
co22unication where appropriate.
!rovide for e2ployee safety and health.
llow ease of 2aintenance.
llow high 2achine/equip2ent utilisation.
mprove productivity.
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actor infIuencing Layout
MateriaIs
Product
Worker
Machinery
Location
Type of industry
- $ynthetic assembling industries. E.g. watch
making or paper making industry
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- nalytical- converts raw material into
various elements. E.g. Oil refinery yields
gasoline, tar, kerosene, paraffin etc
- Conditioning-change in form or physical
properties. E.g. metal working industries
- tractive- separation of one element
from another. E.g. Metal from ore
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ManageriaI PoIicies
- The volume of production & provision of
expansion.
- The extent of automation.
- Making or buying a particular component.
- Desire for rapid delivery of goods to consumers
- !urchasing policy
- !ersonnel policies.
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PrincipIes of Layout
!rinciple of Minimum Travel
!rinciple of Sequence
!rinciple of Usage
!rinciple of Compactness
!rinciple of Safety & Satisfaction
!rinciple of lexibility
!rinciple of Minimum nvestment
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Types of Layout
!rocess Layout, unctional Layout or Job shop
Layout.
!roduct Layout, Line processing layout or low
Line Layout.
ixed !osition Layout or Static Layout.
Cellular manufacturing Layout or Group
Technology Layouts.
Combination Layout or Hybrid Layout
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Process Layout
Group similar resources together.
or job lot manufacturer or batch production.
nvolves grouping together of like machines in
one department.
E.g. machines performing drilling operations
installed in the drilling department.
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PrincipIes
a) The distance between departments should be
as short as possible for avoiding long distance
movement of materials
b) The departments should be in sequence of
operations
c) The arrangement should be convenient for
inspection and supervision
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dvantages:
a) ower initial capital investment in machines and equipments. There is high
degree of machine utilization, as a machine is not blocked for a single product
b) The overhead costs are relatively low
c) Change in output design and volume can be more easily adapted to the
output of variety of products
d) Breakdown of one machine does not result in complete work stoppage
e) Supervision can be more effective and specialized
f) There is a greater flexibility of scope for expansion.
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isadvantages:
a. Material handling costs are high due to backtracking
b. More skilled labour is required resulting in higher cost.
c. Time gap or lag in production is higher
d. Work in progress inventory is high needing greater
storage space
e. More frequent inspection is needed which results in
costly supervision
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$uitabiIity:
. !roducts are not standardized
2. Quantity produced is small
3. There are frequent changes in design and
style of product
4. Job shop type of work is done
5. Machines are very expensive
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Product Layout
nvolves the arrangement of machines in
one line, depending upon the sequence of
operations.
Materials are fed into the first machines
and finished products come out of the last
machine.
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PrincipIes
a) ll the machine tools or other items of equipments must
be placed at the point demanded by the sequence of
operations
b) There should no points where one line crossed another
line.
c) Materials may be fed where they are required for
assembly but not necessarily at one point.
d) ll the operations including assembly, testing packing
must be included in the line.
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dvantages:
a) Low cost of material handling, due to straight and short route and
absence of backtracking
b) Smooth and uninterrupted operations
c) Continuous flow of work
d) Lesser investment in inventory and work in progress
e) Optimum use of floor space
f) Shorter processing time or quicker output
g) Less congestion of work in the process
h) Simple and effective inspection of work and simplified production
control
i) Lower cost of manufacturing per unit
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isadvantages:
a. High initial capital investment in special purpose
machine
b. Heavy overhead charges
c. Breakdown of one machine will hamper the
whole production process
d. Lesser flexibility as specially laid out for
particular product.
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$uitabiIity:
) Mass production of standardized products
2) Simple and repetitive manufacturing process
3) Operation time for different process is more or
less equal
4) #easonably stable demand for the product
5) Continuous supply of materials
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Circumstances when !roduct &
!rocess Layout can be used.
One or few standard
products.
Large volume of
production of each item
over a considerable
period of time.
Minimum inspection
required during the
sequence of operation.
Many types or kinds of
products or emphasis on
special orders.
#elatively low volume of
production of individual
items
Many inspections
required during a
sequence of operations.
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Materials & products
permit bulk or continuous
handling by mechanical
means.
Little or no occasion to
use the same machine or
work station for more
than one operation.
Materials or products too
bulky to permits bulk or
continuous handling by
mechanical means.
requent need for using
the same machine or
work station for two or
more different operations.
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Comparison of !roduct & !rocess
Layout
Mechanisation of Material Handling
voidance of botttlenecks
Economy in manufacturing time
Minimisation of investment in work in process
Better production control
Early detection of bad workmanship.
Greater incentive to a group of workers to raise
the level of their performance.
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#educed investment on machines
lexibility in production
Scope of expansion
Handling of breakdowns is easy.
Greater incentive to individual workers to
raise the level of their performance.
Better utilisation of workers and equipment
Specialisation in supervision
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Comparison of !roduct vs. !roduct Layouts
Process Layouts Product Layouts
Products: Iarge , different smaII , efficientIy
Resources: generaI purpose speciaIized
aciIities: more Iabor intensive more capitaI intensive
IeibiIity: greater reIative to market Iower reIative to market
Processing sIower faster
Rates:
HandIing costs: high Iow
$pace requirements: higher Iower
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ixed !osition Layout
nvolves the movement of men and
machines to the product which remains
stationary.
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dvantages:
a) t saves time and cost involved on the movement of work
from one workstation to another.
b) The layout is flexible as change in job design and
operation sequence can be easily incorporated.
c) t is more economical when several orders in different
stages of progress are being executed simultaneously.
d) djustments can be made to meet shortage of materials
or absence of workers by changing the sequence of
operations.
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isadvantages:
a. !roduction period being very long, capital
investment is very heavy
b. Very large space is required for storage of
material and equipment near the product.
c. s several operations are often carried out
simultaneously, there is possibility of confusion
and conflicts among different workgroups.
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$uitabiIity:
. Manufacture of bulky and heavy products such
as locomotives, ships, boilers, generators,
wagon building, aircraft manufacturing, etc.
2. Construction of building, flyovers, dams.
3. Hospital, the medicines, doctors and nurses are
taken to the patient (product).
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eIIuIar Manufacturing Layout
n this machines are grouped into cells
and the cells function somewhat like
product layout within a larger shop or
process layout.
product layout is visible inside each cell.
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Machine
1
Machine
2
Machine
3
Machine
4
Machine
5
MateriaIs in
inished
goods out
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dvantages
#educed material handling and transit time
#educed setup time
#educed work-in-process inventory
Better use of human
resources
Easier to control
Easier to automate
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isadvantages
nadequate part families
!oorly balanced cells
Expanded training and scheduling of
workers
ncreased capital investment
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Combination Layout
Combination of three pure types:
!roduct , !rocess, and ixed !osition
Layout
Example:
Hospital: process and fixed position.
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