BY: AKANKSHA ARORA SUMIT ROHIWAL SHASHANK ARORA MANISH CHAUHAN

Layout is a Fundamental of every organization and enterprise. Plant layout involves the development of physical relationships among building equipment and production operations which will enable the manufacturing process to be carried on efficiently Morris Plant Layout - placement of departments, placement of workgroups within departments, placement of workstations, placement of machines, placement of stock-holding points All within a facility

Proper and efficient utilization of cubic (i.e. length, width and height) of available floor space. Reduce material handling costs. Increase employee morale. Eliminate conjugation and bottle neck at work. Provide ease of supervision and control. Allow ease of maintenance. Improve productivity.

4 Factors Influencing Layout :

Nature of product & Production process. Type of machinery. Material Handling Equipments. Auxiliary Services.

6 Types of Layout Manufacturing units :

Product or line layout Process or functional layout Fixed position or location layout Combined layout Fixed Layout Cellular (or) Group Technology Layout

Machinery and Materials are placed following the product path. This type of plant layout is useful when the production process is organized in a continuous or repetitive way. Continuous flow: The correct operations flow is reached through the layout design and the equipment and machinery specifications. Repetitive flow (assembly line): The correct operations flow will be based in a line balancing exercise, in order to avoid problems generated by bottle necks.

Economy material handling activities. Mechanization of material handling equipments. Work In Process almost eliminated. Minimum manufacturing time. Simplification of the production planning and control systems. Tasks simplification. Greater incentive for group. Disadvantages: No flexibility in the production process Low flexibility in the manufacturing times. High capital investment. Difficulty of supervising, since the person is expert in only one function. Every workstation is critical to the process.- The lack of personnel or shut down of a machine stops the whole process. Monotonous work. Difficulty in expansion.

This type of plant layout is useful when the production process is organized in batches. Personnel and equipment to perform the same function are allocated in the same area. The different items have to move from one area to another one, according to the sequence of operations previously established. The variety of products to produce will lead to a diversity of flows through the facility. The variations in the production volumes from one period to the next one (short periods of time) may lead to modifications in the manufactured quantities as well as the types of products to be produced.

Flexibility in the production process. Better control of manufacturing cost. No Duplication. Easy to handle the problems. Better Supervising. [Experts will be there in each department] Higher Individual incentive. Disadvantages: Manufacturing time increases. Controlling will be costly and complex. Material handling cost will be higher. More workspace required. Accumulation of work-in process.

In Fixed product layout, the products generally circulate within the production facilities (machines, workers, etc.); in this particular type of layout, the product does not move, the different resources are moved to perform the operations on the product. This type of layout is commonly found in industries that manufacture large size products, such as ships or aircrafts. The equipment is brought to the object being processed, and the object does not move. Example: Air craft manufacturing. Arranging materials and equipment concentrically around the production point in their order of use.

Layout is fully flexible and is capable of absorbing any sort of change in product and process. Lower labor cost [People are drawn from functional departments] Saving in time Less floor space because machines and equipment are in moving position. Most suitable way of assembling large and heavy products. Disadvantages Of Stationery Layout: Higher capital investment Unsuitability for manufacturing or assembling small products in large quantities. It is suitable only in case where the product is big or the assembling process is complex.

Combined Layout or Mixed Layout Manufacturing concerns where several products are produced in repeated numbers with no likelihood of continuous production , combined layout is followed. Generally, a combination of the product and process layout or other combination are found, in practice, e.g. for industries involving the fabrication of parts and assembly, fabrication tends to employ the process layout, while the assembly areas often employ the product layout.

In a cellular layout the design is not according to the functional characteristics of equipment, but rather by self-contained groups of equipment (called cells), needed for producing a particular set of goods or services. Group technology, or cellular manufacturing, classifies parts into families so that efficient mass-production-type layouts can be designed for the families of goods or services.