Facility layout

The presentation content Introduction
Objective, Factors affecting layout, Scope of facility of layout, Type of facility of layout and Process designing
Prerequisites for Developing a Facility Layout
Level of plants, Technique for designing a facility layout, Case study with example

1. A Presentation By: AMOL GORGILE (PM/2018/411) NIPER HYDERABAD MBA PHARM Facility LAYOUT

2. Contents- Introduction Objective Factors affecting layout Scope of facility of layout Type of facility of layout Process designing Prerequisites for Developing a Facility Layout Level of plants Technique for designing a facility layout Case study

3. Introduction The layout facility is the physical location of the various department/units of the facility within premises of the facility The department may be located based on the considerations such as: Less walking distance Logical sequence of the processing requirement of the product Emergency services, etc. Factors affecting layout Material, Product, Machinery, Labor, Location, Managerial, Type of industry, Policies.

4. Objectives of an Effective Facility Layout include: Scope of layout Related to material Less material handling and minimum transportation cost Less waiting time for in-process inventory. Related to work place Safe working condition from the point of ventilation, lighting etc Minimum movement of worker Least chances of accident fire etc Proper space for machines, worker, tool, etc.

5. Type of layouts Process layout- suitable when product having standard features is to be produced in large volumes. Process layout, also called functional layout or batch production layout, is characterized by the grouping together of similar machines, based upon their operational characteristics. Product layout: In Product layout, also called straight line layout, machinery is arranged in one line as per the sequence of production operations. Materials are fed into the first machine and finished products come out of the last machine.

6. Fixed position layout: This type of facility layout is used to assemble products that are too large, heavy or fragile to move to a location for completion. In the fixed position layout, machinery, men, as well as other pieces of material, are brought to the location where the product is to be assembled. Grouping technology layout: it is a cellular manufacturing layout is made for a single part family i.e. parts with common characteristic. In this layout dissimilar machines are grouped into cells and each cell function like product layout

7. Combination or hybrid layout: It is difficult to use the principles of product layout, process layout, or fixed location layout in facilities that involve fabrication of parts and assembly. In such cases, hybrid layout is sought. A hybrid layout attempts to combine efficiency of a product layout with flexibility of a process layout. Fabrication tends to employ the process layout, while assembly areas often employ the product layout.

8. Prerequisites for Developing a Facility Layout Developing process charts: A process chart is the graphical representation of production activities performed by an organization. These charts facilitate a systematic analysis and demonstration of the entire production process. They are further classified into two categories, namely operation process chart and flow process chart. Making process flow diagrams: A process flow diagram represents the movement of materials on a floor layout. These diagrams help an organization in avoiding needless material movement and rearranging facility operations. Developing machine data cards: A machine data card helps in developing equipment layout by providing information related to power and materials handling requirements along with capacity and dimensions of different machines. Visualizing the layout: This technique involves creating duplication of machines and equipment and arranging them in two- or three-dimensional plans for determining the effectiveness of a layout.

9. Process of Facility Layout Designing Implementation & Evaluation

10. Levels of Plant Layout Design There are four levels of detail in plant layout design

11. Techniques for Designing a Facility Layout Two main techniques of designing a facility layout are Block Diagramming & Richard Muther’s Systematic Layout Planning (SLP) Block diagramming: The block diagram can be prepared by using the following steps: Analyze the unit load summary that provides information about the average number of unit loads moved between different departments of an organization. Calculate the composite movements (back-and-forth movement) of the unit load between the departments and rank them from the highest movement to the lowest movement. Place the trial layouts, which are designed using the ranking between departments, on a grid. This grid represents the relative distance between the departments.

12. SLP is a technique developed by Richard Muther & associates. The 3 fundamental areas of the technique are Relationships, Space and Adjustment. This technique combines quantitative measurement of materials movement with non-flow considerations such as noise, fumes, temperature, supervision, communications, personnel comfort and movement. In this technique, a grid displays the ratings of the relative importance of the distance between different departments of an organization. This grid is also called ‘closeness rating chart’. In this chart, the rating for department A relative to department B is similar to the rating of department B to department A. Closeness ratings are given to departments in the form of codes, which depict the desired closeness of the departments according to the relative strength of their closeness. Advantage: This technique clearly documents the logic of the layout and easily allows input from all levels of staff. Richard Muther’s systematic layout planning (SLP):