1. Session-17-23
Pooja patnaik

2. Facility Layout
Facility layout can be defined as the process by which the placement of departments, workgroups within departments, workstations, machines, and stock-holding points within a facility are determined
This process requires the following inputs:
Specification of objectives of the system in terms of output and flexibility
Estimation of product or service demand on the system
Processing requirements in terms of number of operations and amount of flow between departments and work centers
Space requirements for the elements in the layout
Space availability within the facility itself

3. Need of layout decision and redesign
Need for layout decisions :
Need for Redesign:
It helps to determine long term efficiency
in-efficient operation
Accidents, health hazards and low safety.
It establishes company’s competitive priorities in regard to capacity, processes flexibility.
changes in product design/service design
Introduction to new products/services.
It helps the organization to achieve strategic advantage that supports differentiation, low cost, fast response
Changes in volume of output or product mix changes
Changes in method, processes or equipment
Low employee morale.

4. Objective Of layout: Higher space utilization
Improved flow of material, information and people
Improved employee morale and working conditions
Improved production capacity.
Reduce material handling cost.
Reduce health hazards
To allow ease of maintenance
Improve productivity.
Higher flexibility

5. Factors influencing layout
Material
Worker
Machinery
Product
Types of industry
Location
Managerial Policies

6. Principles of Layout The Principle of Minimum Travel
Principle of Sequence
Principle of Usage
Principle of Compactness
Principle of Safety and Satisfaction
Principle of Flexibility
Principle of Minimum Investment

7. Types of layout- a) Process Layout
Process layout or functional layout or job shop layout-Machines grouped by process they perform. These machines include lathe, drilling, milling etc.
Eg: Maruti Service Station.
Process layout is commonly found in service set ups like bank, hospitals, post offices

8. Advantages and Disadvantages-Process Layout
Sl.No
Advantages
Disadvantages 1.
Maintenance cost is low because of low cost general purpose machines
Material handling is time consuming as there is no fixed route 2.
This system is more flexible to design changes in products or processes compared to product layout
WIP is high in batch processing 3.
Breakdown in a machine do not lead to halt in production as substitute machines are there
Low output rate , thus high cost per unit. 4.
The system promotes creativity of workers due to variety of tasks performed by them.
Routing and scheduling is tedious and time consuming for different products. 5. -
High cost of supervision because of special treatment to every products being processed.

9. Types of layout- b) Product Layout
Product layout or line processing layout or flow-line layout- Linear arrangement of workstations to produce a specific product
The production line is often called the assembly line. The assembly line has a mechanized moving platform which moves at regular intervals.

10. Advantages and Disadvantages-Product Layout
Sl.No.
Advantages
Disadvantages 1.
Easier material handling and less inventory cost
Maintenance cost is slightly high to ensure smooth running of line 2.
Less supervision and labor training costs
Inflexible to design changes in products or processes 3.
A high output rate thus low cost of item per unit
Breakdown in machines or absenteeism of workers leads to halt in production 4.
High efficiency of labor and equipment
Monotonous and repetitive works lead to frustration of workers 5.
No need of routing and scheduling once the line is already done -

11. Types of layout c) Fixed Position Layout
Fixed position layout or static layout-Used in projects where the product cannot be moved thus equipment ,labor, resources are brought to the site basically skilled people are required.

12. Comparison between product layout and process layout
Sequential arrangement of machines
Functional grouping of machines
Intermittent, job shop, batch production, mainly fabrication.
Continuous, mass production basically assembly
product is varied and made to order
Product is Standardized made to stock
demand is fluctuating and volume is low
Demand is stable and volume is high
Inventory high in process and low finished goods
Inventory low in process and high finished goods
greater flexibility in production
Avoidance of bottleneck
Full utilization of the plant
Early detection of badly produced items.

13. Cellular Layout and FMS
Machines are grouped into cells where the cells performs like a product layout or process layout.
Each cell in CM layout is formed to produce single part family
Advantage: low WIP inventories, reduced material handling cost, simplified production planning, improved visual control, increased operator responsibility.
Disadvantages: Reduced utilization of the machines, Duplicate pieces of equipment may be needed

14. CM

15. Service Layout
Goal--maximize net profit per square foot of floor space
Services capes
Ambient Conditions
Spatial Layout and Functionality
Signs, Symbols

16. Layout Tools and Techniques
Plant layout template is a scaled representation of a physical object in a layout.
Templates
Operations Sequence Analysis
Operations sequence analysis helps arrange departments graphically analyzing the layout problem.
Line balancing is the study that nearly equally divides the work to be done among the workers and minimizes the number of employees required to complete a project.

17. Criteria for Selection and Design of Layouts
Material handling cost and worker effectiveness are the two criteria used for selecting layout design.
The various methods used for selecting the best layout among several alternatives layouts are
Travel Chart Method
Load-Distance Analysis Method
Systematic Layout Planning

18. Block diagramming Create load summary chart
Calculate composite (two way) movements
Develop trial layouts minimizing number of nonadjacent loads

19. Project Assignments
Make the layout of a floor of the main CUTM building. Identify and label various rooms and halls in order to improve the efficiency in terms of walking distance. Brainstorm the various modifications suggested in class and prepare an action plan for implementation.