Plant layout &

Material handling-
MS60301(c 03 credits)

ENG. INOKA KIRINDEGEDARA

B.SC. ENG.(PERADENIYA), MBA IN MOT

(MORATUWA)
Manufacturing Systems-Continue..
Plant Layout -Lecture 2 &3
Introduction
Classification of Layout,
Advantages and Limitations of different layouts,
Layout design procedures
Classification of Layout,

1. Product or Line Layout

2. Process or Functional Layout.
3. Fixed Position Layout.
4. Combination type of Layout.

Keeping in view the type of industry and volume of

production, the type of layout to be selected is to
be decided
 Classification of manufacturing systems,
which uses the material flow type as its
basis:

1. Product based:
❖These are manufacturing systems that are designed specifically
for a fixed product (or product type).
❖The underlying principles are those of interchangeability, and
division of labour.
❖These systems may be highly automated, or human-labour
intensive.
❖In every case, they must operate at relatively high throughput
rates.
 1. Product or Line Layout:

If all the processing equipment and machines are arranged according to the
sequence of operations of the product, the layout is called product type of layout.

There, only one product of one type of products is produced in an operating area.

Standardized and produced in large quantities in order to justify the product

layout.
The raw material is supplied at one end of the line and goes from one operation
to the next quite rapidly with a minimum work in process, storage and material
handling. Fig. 8.3 shows product layout for two types of products A and B.
 Product based conti..

Further divided into:

1. Continuous production (e.g. chemicals, food processing etc.)

2. Discrete part production.

❖Further divided into:

❖ Assembly lines

❖ Transfer Lines
Advantages offered by Product
Layout:
(i) Lowers total material handling cost.
(ii) There is less work in processes.
(iii) Better utilization of men and machines,
(iv) Less floor area is occupied by material in transit and for temporary
storages
(v) Greater simplicity of production control.
(vi) Total production time is also minimized.
Limitations of Product Layout

(i) No flexibility which is generally required is obtained in this layout.

(ii) The manufacturing cost increases with a fall in volume of production.
(iii) If one or two lines are running light, there is a considerable machine idleness.
(iv) A single machine break down may shut down the whole production line.
(v) Specialized and strict supervision is essential.
2. Process-based:

these are facilities where machines of the same type are

grouped together physically.

Examples: job shops, workshops, prototype makers, tool

makers.
Flexible Manufacturing systems may loosely be categorized as
highly automated versions of process-based systems.
 2. Process or Functional Layout:

The process layout is particularly useful where low volume of production is needed.
If the products are not standardized, the process layout is more low desirable, because it
has creator process flexibility than other.
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.
This layout is commonly suitable for non repetitive jobs.
Same type of operation facilities are grouped together such as lathes will be
placed at one place, all the drill machines are at another place and so on
 2.Process layouts conti..

Group resources based on similar processes or functions.

This type of layout is seen in companies with intermittent processing systems.
You would see a process layout in environments in which a large variety of items are produced in a
low volume.
Since many different items are produced, each with unique processing requirements, it is not possible
to dedicate an entire facility to each item.
It is more efficient to group resources based on their function.
The products are then moved from one resource to another, based on their unique needs.
The challenge in process layouts is to arrange resources to maximize efficiency and minimize waste
of movement.
If not appropriate design, many products will have to be moved long distances, often on a daily basis.
This type of movement adds nothing to the value of the product and contributes ...
 2.Process functional layout
Advantages of Process Layout:

(i) There will be less duplication of machines. Thus, total investment in equipment
purchase will be reduced.
(ii) It offers better and more efficient supervision through specialization at various
levels.
(iii) There is a greater flexibility in equipment and man power thus load distribution
is easily controlled.
(iv) Better utilization of equipment available is possible.
(v) Break down of equipment can be easily handled by transferring work to another
machine/work station.
(vi) There will be better control of complicated or precision processes, especially
where much inspection is required.
Limitations of Process Layout:

(i) There are long material flow lines and hence the expensive handling is required.
(ii) Total production cycle time is more owing to long distances and waiting at
various points.
(iii) Since more work is in queue and waiting for further operation hence bottle
necks occur.
(iv) Generally, more floor area is required.
(v) Since work does not flow through definite lines, counting and scheduling is more
tedious.
(vi) Specialization creates monotony and there will be difficult for the laid workers
to find job in other industries.
3. Fixed position:

For single units of a large item (e.g. construction project, ship building etc.)
 3. Fixed Position Layout:

This type of layout is the least important for today’s manufacturing industries.

In this type of layout the major component remain in a fixed location, other materials, parts, tools,
machinery, man power and other supporting equipment’s are brought to this location.

The major component or body of the product remain in a fixed position because it is too heavy or too
big and as such it is economical and convenient to bring the necessary tools and equipment’s to work
place along with the man power.

Used in the manufacture of boilers, hydraulic and steam turbines and ships etc.
 Advantages Offered by Fixed
Position Layout:

(i) Material movement is reduced

(ii) Capital investment is minimized.
(iii) The task is usually done by gang of operators, hence continuity of operations is
ensured
(iv) Production centers are independent of each other. Hence, effective planning
and loading can be made. Thus total production cost will be reduced.
(v) It offers greater flexibility and allows change in product design, product mix
and production volume.
 Limitations of Fixed Position
Layout:

(i) Highly skilled man power is required.

(ii) Movement of machines equipment’s to production centre may be time consuming.

(iii) Complicated fixtures may be required for positioning of jobs and tools. This may
increase the cost of production.
 4. Combination Type of Layout:

Now a days in pure state any one form of layouts discussed above is rarely
found.
Generally the layouts used in industries are the compromise of the above
mentioned layouts.
Every layout has got certain advantages and limitations.
Therefore, industries would to like use any type of layout as such.
Flexibility is a very important facter, so layout should be such which can be
molded according to the requirements of industry, without much investment.
If the good features of all types of layouts are connected, a compromise
solution can be obtained which will be more economical and flexible.
Example for combination ; Cellular

Typical cells are small clusters of a mixed bunch of machines that can handle a
particular family of products.

Such layouts are used when the batch sizes of orders are not large, but
throughput times required are lower.
Thank you