FACTORY LAYOUT

ABSTRACT
The efficiency of production depends on how well the various machines; production facilities and employees amenities are located in a factory. Only the properly laid out factory can ensure the smooth and rapid movement of material, from the raw material stage to the end product stage. Factory layout encompasses new layout as well as improvement in the existing layout.An ideal factory layout should provide the optimum relationship among the output, floor area and manufacturing process. An efficent factory layout is one that aims at achieving various objectives like efficient utilization of available floor space, minimizes cost, allows flexibility of operation, provides for employees convenience, improves productivity etc.The entrepreneurs must possess the expertise to lay down a proper layout for new or existing plants. It differs from one factory to another. But basic principles to be followed are more or less same. From the point of view of factory layout, we can classify small business into three catagories i.e.(a) manufacturing units (b) trades (c) services establishments. Designing of layout is different in all above three categories e.g. manufacturing unit may follow one of product,process and fixed position or combined layout,as the case may be. Traders might go either for self-service or full service or special layouts whereas service establisments such as motels, hotels, and restaurants must give due attention to customer convenience, quality of service, efficiency in delivering the service etc. While deciding for layout for factory or unit or store, a small entrepreneur has to consider the factors like the nature of the product, production process,size factory building, human needs etc

KEYWORDS
Efficiency, amenity, enccompasses, utilization, trader

1. DEFINITION
A factory layout can be defined as follows; Factory layout refers to the arrangement of physical facilities such as machinery, equipment, furniture etc. with in the factory building in such a manner so as to have quickest flow of material at the lowest cost and with the least amount of the finished product. According to Ringgs, the overall objective of factory layout is to design a physical arrangement that most economically meets the required output-quantity and quality. According to J.L.Zundi, Factory layout ideally involves alloction of space and arrangement of equipment in such a manner that overall operating costs are minimized.

2. IMPORTANCE
Factory layout is an important decision as it represents

long-term commitment. An ideal factory layout should provide the optimum relationship among output, floor area and manufacturing process.It facilitates the production process, minimizes material handling, time and cost, and allows flexibility of operations, easy production flow, makes economic use of the building, promotes effective utilization of manpower, and provides for employees convenience safety, comfort at work, maximum exposure to natural light and ventilation. It is also important because it affects the flow of material and processes, labour efficiency, supervision and control, use of space and expansion possibilities etc.

3. ESSENTIALS
An efficient factory layout is one that can be instrumental in achieving the following objectives; a) Proper and efficient utilization of available floor space b) To esure that work proceeds from one point to another point without any delay c) Provide enough production capacity d) Reduce material handling cost e) Reduce hazards to personnel f) Utilise labor efficiently g) Increase employee morale h) Reduce accidents i) Provide for volume and product flexibility j) Provide ease of supervision and control
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k) Provide for employee safety and health l) Allow ease of maintenance m) Allow high machine or equipment utilization n) Improve productivity

4. TYPES OF LAYOUT
An discussed so for the factory layout facilitates the arrangement of machines, equipment and other physical facilities in a planned manner within the factory premises. An entrepreneur must possess an expertise to lay down a proper layout for new or existing plants. It differs from plant to plant, from location to location and from industry to industry. But the basic principles govering factory layout are more and less more. As far as small business is concerned, it requires a smaller area or space and can be located in any kind of building as long as the space is available and it is convenient. Factory layout for small scale business is closely linked with the factory building and built up area. From the point of view of factory layout , we can classify small business or unit into three categories: 1) Manufacturing units 2) Traders 3) Service Establishment

4.1. Manufacturing units

In case of manufacturing units, factory layout may be of four types:

1) Product or line layout 2) Process or functional layout 3) Fixed position or location layout 4) Combined or line layout

4.1.1. Product or line layout:

Under this, machines and equipments are arranged in one line depending upon the sequence of operation required for the product . The materials move form one workstation to another sequentially without any backtracking or deviation. Under this, machines are grouped in one sequence. Therefore matereals are fed into the first machine and fineshed goods travel automatically from machine to machine, the output of one machine becoming input of the next, e.g. in a paper mill, bamboos are fed into the machine at one end and paper comes out at the other end. The raw material moves very fast from one workstation to other station with a minimum work in progress storage and material handling. The grouping of machines should be done keeping in mind the following general principles: a) All the machine tools or other items of equipments must be placed at the point demanded by sequence of operations. b) There should no points where one line crossed another line. c) Materials may be fed where they are required for assembly but not necessarily at one point. d) All the operations including assembly, testing packing must be included in the line.

4.1.2. Process layout:

In this type of layout machines of similar type are arranged together at one place. E.g. Machines performing drilling operations are arranged in the drilling department, machines performing casting operations be grouped in the casting department. Therefore the machines are installed in the plants, which follow the process layout. Hence, such layouts typically have drilling department, milling department welding department, heating department and painting department etc. The process or functional layout is followed from historical period. It evolved from the handicraft method of production. The work has to be allocated to each department in such a way that no machines are chosen to do as many different job as possible i.e. the emphasis is on general purpose machines. The grouping of machines according to the process has to be done keeping in wind the following principles: a) The distance between departments should be as short as possible for avoiding long distance movement of materials b) The departments should be in sequence of operations c) The arrangement should be convenient for inspection and supervision.

4.1.3. Fixed Position or Location Layout:

In this type of layout, the major product being produced is fixed at one location. Equipment labour and components are moved to that location. All facilities are brought and arranged around one work center. This type of layout is not relevant for small scale entrepreneur.

4.1.4. Combined layout:

Certain manufacturing units may require all three processes namely intermittent process the continuous process and the representative process combined
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process. In most of industries, only a product layout or process layout process or fixed location layout does not exist. Thus, in 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 combinaion 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 soap, manufacturing, plant, the machinery manufacturing soap is arranged on the product line principle, but ancillary services such as heating, the manufacturing of glycerin, the power house, the water treatment plant etc. are arranged on a functional basis.

4.2. Traders
When two outlets carry almost same merchandise, customers usually buy in the one that is more appealing to them. Thus, customers are attracted and kept by good layout i.e. good lighting, attractive colours, good ventilation, air conditioning, modern design and arrangement and even music. All of these things mean customer convenience, customer appeal and greater business volume. The customer is always impressed by service, efficiency and quality. Hence, the layout is essential for handling merchandise, which is arranged as per the space available and the type and magnitude of goods to be sold keeping in mind the convenience of customers. There are three kinds of layouts in retail operations today. 1)Self service or modified self service layout 2) Full service layout 3) Special layuots The self-service layouts, cuts down on sales clerks time and allow customers to select merchandise for themselves. Customers should be led through the store in a way that will expose them to as much display area as possible, e.g. Grocery Stores and department time and allow customers to select merchandise for stores. In those stores, necessities or convenience goods should be placed at the rear of the store. The use of color and lighting is very important to direct attention to interior

displays and to make the most of the stores layouts. All operations are not self-service. Certain specialty enterprises sell to fewer numbers of customers or higher priced product, e.g. Apparel, office machines, sporting goods, fashion items, hardware, good quality shoes, jewelry, luggage and accessories, furniture and appliances are all examples of products that require time and personel attention to be sold. These full service layouts provide area and equipment necessary in such cases. Some layouts depend strictly on the type of special store to be set up, e.g. TV repair shop, soft ice cream store, and drive-in soft drink store are all examples of business requiring special design. Thus, good retail layout should be the one, which saves rent, time and labour.

4.3. Services centers and establisment

Services establisments such as motels, hotels, restaurants, must give due attention to client convenience, quality of service, efficiency in delivering services and pleasing office ambience. In todays environment, the clients look for ease in approaching different departments of a service organization and hence the layout should be designed in a fashion, which allows client quick and convenient access to the facilities offered by a service establisment.

5. FACTORS INFLUENCING LAYOUT

While deciding his factory or unit or establishment or store, a small-scale businessman should keep the following factors in mind: a) Factory building: The nature and size of the building determines the floor space available for layout. While designing the special requirments, e.g. air conditioning, dust control, humidity control etc. must be kept in mind. b) Nature of product: Product layout is suitable for uniform products whereas process layout is more appropriate for custom-made products. c) Production process: In assembly line industries, product layout is better. In job order or intermittent manufacturing on the other hand, process layout is desirable. d) Type of machinery: General purpose machines are often arranged as per process layout while special purpose machines are arranged according to product layout. e) Repairs and maintenance: Machines should be so arranged that adequate space is avaible between them for movement of equipment and people required for repairing the machines. f) Human needs: Adequate arrangement should be made for cloakroom, washroom, lockers, drinking water, toilets and other employee facilities, proper provision should be made for disposal of effluents, if any.

g) Plant environment: Heat, light, noise, ventilation and other aspects should be duly considered, e.g. paint shops and plating section should be located be in another hall so that dangerous fumes can be removed through proper ventilation etc. Adequate safety arrangement should also be made. Thus, the layout should be conducive to health and safety of employees. It should ensure free and efficient flow of men and materials. Future expansion and diversification may also be considered while planing factory layout.

6. DYNAMICS OF PLANT LAYOUT

Plant layout is a dynamic rather than a static concept meaning thereby if once done if is not permanent in nature rather improvement or revision in the existing plant layout must be made by keeping a track with development of new machines or equipment, improvements in manufacturing process, changes in materials handling devices etc. But any revision in layout must be made only when the savings resulting from revision exceed the costs involved in such revision. Revision in plant layout may become necessary on account of the following reasons: a) Increase in the output of the existing product b) Introduction of a new product and diversification c) Technological advancements in machinery, material, processes, product design, fuel etc. d) Deficiencies in the layout unnoticed by the layout engineer in the beginning.