Advantages of good layout

Advantages of good plant layout are discussed along with its different types.

1. Government College of Engineering, Aurangabad Advantages of Good Plant Layout 1

2. ADVANTAGES OF GOOD PLANT LAYOUT 2

3. “ A good layout results in comfort, convenience, appearance, safety and profit. A poor layout results in congestion, waste, frustration and inefficiency .” - MoNaughton Wayne 3

4. What is plant layout? Basically plant layout is physical arrangement of industrial facilities Orderly and proper arrangement with the use of available resources i.e., Men, Money, Machines, Materials and Method of production J. Lundy defines plant layout as follows : “Plant layout ideally involves the allocation of space and arrangement of equipment in such a manner that overall operation cost can be minimized” 4

5. Over crowding of men, material, machine and equipment . Scrap or wastage of material is more . Difficult to supervise . More frequent accidents . When to think about planning a layout? 5

6. Mental or Physical stress in the workers . Long transportation lines . Poor utilization of space . 6

7. Product Layout ( Line Layout ) Process Layout ( Functional Layout ) Fixed Position Layout Types of Plant Layout 7

8. All the equipments and machines are arranged according the sequence of operations on product. Here, the layout is dictated by the ‘product’. Only one type of product is produced in operating area in large number of quantities (Mass Production). Generally, all assembly lines in different industries follow the ‘Product Layout’. 1 . Product Layout 8

9. Example : 9

10. Here, the layout is dictated by the ‘Process’ and not by the ‘Product’. In this type of layout, the machines and not arranged according to the sequence of operations but are arranged according to the nature or type of the operations . The process layout is particularly useful where low volume of production is needed with a greater variety of products 2. Process Layout 10

11. Example 1 : Example 2 : 11

12. Comparison of two layouts Product Layout Process Layout 12

13. In this type, material or major component remains stationary because it is too heavy or too big As product remains fixed at one location other materials, parts, tools, machinery, man power and other supporting equipment’s are brought to this location . This type of layout is used in the manufacture of boilers, Huge aircrafts, hydraulic and steam turbines and ships etc. Fixed Position Layout 13

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15. Economies in material handling Direct channels for the flow of materials Cost of material handling is considerably reduced Lesser manufacturing time As no involvement of backward handling of materials, considerable saving of time in manufacturing Advantages of Product Layout 15

16. Lesser work in progress Lesser accumulation of work in progress of semi finished goods Proper use of floor space Optimum use of available floor space is possible Due to non-accumulation of work in progress Economy in inspection Need for inspection under this method is much less and can be confined at some crucial points only 16

17. Lesser manufacturing cost Due to less material handling, inspection cost, and good utilization of available space there is less manufacturing cost Lesser labour cost Less skills required Routine task is to be carried out under this method 17

18. Lesser flexibility Difficult to adopt any changes Large investment Unavoidable machinery duplication Results in idle capacity and large capital investments Disadvantages of Product Layout 18

19. Interruption due to breakdown Stoppages of work due to interdependency on previous machines Reasons may be breakdown of machine, irregular supply of material, poor production scheduling and employee absenteeism Lack of specialization in supervision Due to large variety and large quantity of machines available in the section, one cannot be expert of all the machines Hence only general supervision is possible and not the specialized one 19

20. Maximum utilization of machines Greater flexibility Change in the sequence of operations and machines can be made without much difficulty Scope for expansion By installing additional machines without much difficulty Advantages of Process Layout 20

21. Specialization in supervision Less variety in machines hence possible Effective utilization of workers Skilled operators are appointed Leads to effective and efficient use of their talent and capabilities Less work stoppages Production schedule is not seriously affected due to breakdown of any machine Work can be transferred to the other machines 21

22. Coverage of more floor area Material handling is more expensive Higher labor cost due to the requirement of higher grades of skills Longer total production time Large in-process inventories Increased inspection cost Disadvantages of Process Layout 22

23. Economies of transportation Work is not carried from one place to another but fixed at one position Saving in transportation cost Different jobs with same layout Different projects Advantages of Fixed Position Layout 23

24. Production in accordance with specifications Jobs can be performed in accordance with the specification given by the customer Scope for flexibility Flexibility for various changes in production processes and designs of the products 24

25. Large investments Unsuitable for small products Not suitable for producing and assembling small products in large quantities Production process is time consuming Machines and tools etc. take more time to reach the work place Highly skilled workers are required Disadvantages of Fixed Position Layout 25

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27. Questions are welcomed… 27