Plant Layouts Prepared by Bhakti Joshi June 20, 2013
Examples Chemist shop Tailor Shop Kiraana Restaurant College Grocery store in a mall Movie Theatres
Organisation’s context… There are plant layouts “…floor plan for determining arranging the desired machinery and equipment of a plant to permit the quickest flow of material at the lowest cost and with the least amount of handling in processing the product from the receipt of the raw materials to the shipment of the finished products.”
Why Layouts? Efficiency in use of workers and space Minimisation of material handling costs Elimination of unnecessary movements of workers and materials Minimisation of production and customer time Elimination in delays Safety and improved working conditions Attainment of product/service quality
Types of Plant Layouts PROCESSPRODUCT FIXED POSITION CELLULAR COMBINATION
Process Layout: Example 1 Embroidery StitchingSewing Output
Process Layout: Example 2 (Metal) Source: Google Images, Transtutors.com * * Lathe is a machine in which work is rotated about a horizontal axis and shaped by a fixed tool # Milling machine creates corrugated edges like in a coin #
Process Layout Also known as functional layout Evolved from handicraft production Grouping the same kinds of machines in one department
Process Layout – Key Principles Minimum distance between departments Departments in a sequence of operations Convenience for inspection and supervision
Process Layout: Advantages and Disadvantages Advantages FlexibilityCostSystem Protection Economies of Scale Incentives for Workers Disadvantages Utilisation Excess material handling Difficulties in operations control Is this layout meant for bulk orders or small orders?
Product Layout: Example Making a boat …? How was it made…? What were it’s input…? Could be taught…? Could it be replicated …?
Product Layout Also known as straight- line layout Sequence of workstations interconnected in one line Work done in small amounts
Product Layout – Key Principles Specific volume to be manufactured/serviced Stable product demand Product Standardisation Continuous material supply
Product Layout: Advantages and Disadvantages Advantages SimplicitySmall Space Optimum cost of materials Time efficiencyLimited skill sets Disadvantages Dull and repetitive Product variety is limited Fault in one can affect all Is this layout cost-effective? High capital investments Inelastic capacities
Fixed Position Layout: Example Paper boat versus the real one? Operations in hospitals? Manufacturing a plane
Fixed Position Layout: Example (Contd…)
Fixed Position Layout Job done at a fixed position The main equipment/s, heavy materials, sub- assemblies, etc., remain fixed Completion done by movement of machines, workers and tools
Fixed Position Layout: Advantages and Disadvantages Advantages Easy for immobile products Flexibility Possibly cost- effective Feasible for large projects Disadvantages High capital investments Large storage spaces Careful planning Can such layouts be discouraged completely?
Cellular Layout: Example 1 Source:
Cellular Layout: Example 2 Source: manufacturing manufacturing
Cellular Layout Also known as functional layout Suitable for large variety of products in small volumes Based on Group Technology (GT) principle – Parts with similar product design characteristics – Parts with similar process characteristics
Cellular Layout: Advantages and Disadvantages Advantages Flexibility Small batches of production Higher machine utilisation Workers’ empowerment Disadvantages Requirement of skills Possibility of imbalances Disadvantages of process and product layouts What kind of businesses will require cellular layouts? Low cost of production
Combination Layout Hybrid Layout Mixture of three main layouts
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