Plant layout and its brief note about its process

Plant layout refers to the overall arrangement of production processes, storage areas, tool rooms, material handling equipment, aisles, racks, and employee services within a factory. It’s like the master blueprint that coordinates all operations performed inside the factory. The goal? To achieve the most effective utilization of resources—men, materials, and machines

1. Plant layout meaning and definition MODULE 02

2. Plant layout is a plan for effective utilisation of facilities for the manufacture of products; involving a most efficient and economical arrangement of machines, materials, personnel, storage space and all supporting services, within available floor space. Meaning

3. According to George R Terry “Arrangement of machines, work areas and service within a factory”. Definition

4. Importance of plant layout Optimal space utilization Enhanced productivity Cost efficiency Communication and supervision Quality and lead time reduction

5. PRINCIPLES OF PLANT LOCATION 1.Integration 2.Minimum Distance 3.Minimum space utilization 4.Process Flow 5.Maximum Flexibility 6.Minimum material handling 7.Safely,security and satisfaction

6. PRODUCT LAYOUT MEANING: Product layout is a group or line layout, uses an assembly line where workers and equipment are arranged in order of production sequence.

7. MERITS OF PRODUCT LAYOUT Lower material handling cost Optimum space utilization Effective utilization of resources Production control

8. DEMERITS OF PRODUCT LAYOUT Rigidity Expansion is difficult Complete stoppage during breakdown High labour cost

9. Process layout The process facility layout, also known as functional layout, involves arranging employees, tasks, and machine, According to the nature or type of operations. The process layout is best for a company that has low production volume facilities and non-respective tasks. The workflow revolves around the production process and follows a logical sequence of production activities. For example in welding facilities, grinding is completed in one area, assembling in another and inspection in a different location.

10. Advantages Ideal for small production volumes Suitable for non-respective activities Ensure efficient utilization of equipment Reduces initial equipment purchase costs Disadvantage Requires extensive floor space Its ineffective for the production of standardized products Longer total production cycle time

11. Fixed position layout The process facility layout, also known as functional layout, involves arranging employees, tasks, and machine, According to the nature or type of operations. The process layout is best for a company that has low production volume facilities and non-respective tasks. The workflow revolves around the production process and follows a logical sequence of production activities. For example in welding facilities, grinding is completed in one area, assembling in another and inspection in a different location.

12. Advantages: The investment in the layout is very small
The layout is flexible as if any rearrangement of men and material required it can be done easily
The project takes long time to finish the job so if there is any shortage of material or men it can be met later

13. Disadvantage As the production period is very long so the capital investment is very high
Very large space is required for the storage of material and equipments near the product
As several operations carried out simultaneously so there is a possibilities of conflict and confusions

14. Cellular Manufacturing(CM)Layouts Cellular manufacturing refers to a manufacturing strategy used to arrange different machines functionally in specific geometric layouts and larger functional units known as manufacturing cells to optimize the production process.

15. Advantages: 1. Enhanced production environment and quality control.
2. Improved capacity to produce high-volume, high-variety products at a fast pace.
3. Substantial reduction in manufacturing lead time and wastes .
4. Smaller work-in-progress (WIP) inventory.
5.Develop a highly versatile and efficient workforce.

16. Disadvantages: Prone to production bottlenecks in case of machinery breakdown
Errors in the setup can lead to a loss of efficiency instead of the promised improvements
The setup time can be long since moving machinery and training take time

17. Cellular Manufacturing layout

18. Facility of plant building Plant Facility means a specific establishment where the production or assembling of components takes place.

19. Types of buildings Single storey buildings High bay and monitor types Multi storey buildings Special types

20. PLANT LIGHTING Plant lighting refers to the design, installation, and maintenance of lighting systems within a manufacturing or industrial facility.

21. Importance of plant lighting Ease of seeing Reduced eye-strain Improved quality Increased output Better utilisation of floor space Good housekeeping Fewer accidents Better supervision

22. Sources of lighting 1. Day-light Day-lighting is that light which (natural lighting) is received from the sun through apertures in in the paragraphs that follow the building. It is the main, and sometimes the only lighting used during the greater part of the working period a) It is available in abundance, particularly in tropical regions. b) It is available free of cost, and has all the attributes of good lighting. c) It requires no maintenance. d) It is free from problems like load-shedding, power failure, etc.

23. 2.Artificial lighting Artificial (Illumination) Lighting As the term itself implies, artificial lighting refers to the illumination secured artificial mean such as the use of bulbs and tubes. The term illumination, strictly speaking, involves the use artificial sources of light . a) The illumination provided is constant. There are no variations in the illumination during the day or night. b) The intensity of the illumination can be controlled to suit the requirements of specific operations. c) It is the only method of lighting available during night shifts and for overtime work. d) It is well suited to provide supplementary lighting.

24. SANITIZATION The process of keeping places free from dirt, infections, disease, etc.., by removing waste, trash and garbage by cleaning surrounding and street, etc.

25. INDUSTRIAL SANITIZATION Industrial sanitization is the science of safeguarding health of industrial workers. It involves the provision to safeguard and promote the health of workers in an industry. It focuses upon the implementation of workplace safety and hygiene.

26. Elements of Industrial sanitization Supply of water Disposal of waste Supply of healthy food Good industrial housekeeping Avoidance and control of insects Providing facilities for personnel services

27. What is industrial safety? The term “Industrial safety” is a set of safety protocols, policies and regulations to protect the workers, workplace, work equipment and environment from hazards

28. Education Consultancy Treatment Medical Examination Importance

29. Material handling safety Industrial safety program Industrial safety activities Measures

30. Facility of Air conditioning Meaning Air conditioning refers to the process of controlling the temperature, humidity, and air quality within an indoor space to create a comfortable environment. It typically involves the use of an air conditioning system or unit that cools the air, removes excess moisture, and can also filter and purify the air.

31. Definition According to A fuller definition of air- conditioning is: “Industrial air-conditioning, in its broadest sense, requires control over temperature, humidity, dust, motion, purity, and odours”.

32. OBJECTIVES OF AIR-CONDITIONING To protect workers health. To raise workers comfort level. To secure specified temperature conditions . To improve the quality of products. Product preservation. To reduce maintenance charges. To improve employer – employee relations.

33. TYPES OF AIR-CONDITIONING Winter air-conditioning. Summer air-conditioning.