FINAL REPORT PLANT LAYOUT
FINAL REPORT PLANT LAYOUT
FINAL REPORT PLANT LAYOUT
INDEX
1. INTRODUCTION ................................................................................................1
5. PROPOSED MODEL........................................................................................16
6. CONCLUSION...................................................................................................17
8. REFERENCES ...................................................................................................18
9. ANNEXURE ......................................................................................................19
LIST OF FIGURES
1. INTRODUCTION
Plant layout is a critical aspect of manufacturing and production planning, focusing on the physical
arrangement of machinery, equipment, and resources within a facility to optimize efficiency,
workflow, and productivity. A well-designed layout ensures smooth and logical flows of materials,
people, and information, minimizing delays, congestion, and bottlenecks.
Plant layout strategies vary depending on the industry, production processes, and the specific needs
of the operation, such as job shops, production lines, or fixed-position layouts. By organizing
production areas effectively, companies can achieve higher productivity and quality control,
reduce operational costs, and improve employee safety and morale. Factors influencing plant
layout decisions include the size and shape of the available space, production volume, product
type, process requirements, and future expansion possibilities. Efficient layouts are also designed
to accommodate easy maintenance and promote flexibility, allowing companies to quickly adapt
to changes in product demand or technological advancements. For example, a process-oriented
layout is commonly used for custom production, while a product-oriented layout is preferred for
mass production. Furthermore, as industries adopt lean manufacturing and just-in-time production,
plant layouts increasingly emphasize minimizing waste and enhancing responsiveness to customer
demands.
In today’s competitive market, companies continuously refine their layouts to maintain an edge in
productivity, quality, and cost-efficiency, making plant layout a dynamic and evolving field that
directly impacts overall operational success.
The layout and design optimization of Bhoruka Aluminum’s plant focuses on creating a
streamlined, efficient, and adaptable production environment to enhance operational efficiency,
minimize waste, and meet growing market demands. By carefully planning the arrangement of
machinery, equipment, and workstations, the plant aims to minimize material handling costs,
reduce production time, and optimize the flow of materials and personnel. This includes
strategically placing equipment to reduce bottlenecks, improving the accessibility of high-use
areas, and enhancing safety standards for all employees. With an emphasis on lean manufacturing
principles, the layout is designed to accommodate scalability for future expansions while ensuring
compliance with environmental standards. By optimizing plant layout, Bhoruka Aluminium
positions itself to achieve higher productivity, lower operational costs, and a more sustainable
production process, allowing the company to maintain a competitive edge in the aluminium
industry.
2. LITERATURE SURVEY
A significant amount of work has been done on analysing and optimising the existing layout of
various scale of plant and most of the existing research focuses on the influence lean tool on
enhancing productivity. A brief review of some of the literature related to our proposed work is
given below.
1. Priyanka Sonawane, Rahul Deore provides an overview of the importance of facility layout
in manufacturing management, highlighting its impact on operational efficiency andproduction
cost reduction. Their research paper discussed on various models and approaches for solving
facility layout problems, and touches upon important related issues. Additionally, it emphasizes
the significance of plant layout for productivity improvement in small-scale industries
2. Jikadra Milan, Bhutaiya Adharmesh, Rathod Bharat bhai, Shah Aagam analyzed the
current plant layout and manufacturing practices using industrial engineering tools. Their project
aimed to propose a new plant layout and develop improved manufacturing practices with a focus
on lean and kaizen philosophies. These proposed practices will be implemented, and productivity
will be evaluated. They also mentioned the use of Value Stream Mapping (VSM) analysis to
identify and reduce waste in the production process, ultimately increasing productivity.
Additionally, the application of the 5S technique of lean manufacturing is expected to reduce waste
and enhance overall productivity.
3. Gourav Goyal, Devendra S Verma proposed to develop a new plant layout using Systematic
Layout Planning Technique (SLP) to reduce meter movement, search times, and increase
productivity. The proposed model based on SLP demonstrates significant improvements in
inventory turnover, labour productivity, and a reduction in material movement. It addresses issues
of inefficiency in existing layouts, such as long travel distances between departments, hindering
material flow and increasing costs. The proposed layout, based on activity relationship charts,
shows promise in improving production performance and offers a solution for small industries
seeking to enhance their efficiency. The optimized layout and material handling systemare well-
received for their positive impact on cost reduction, throughput time, storage space, quality, and
safety, highlighting the practical benefits of this research.
4. Viswajit Talluru; Rani Teja, Prajna Deepthi studied the printing industry that focuses on
enhancing the plant layout of an existing facility to reduce travel time. The relocation of
machinery, guided by systematic layout planning (SLP), led to a 25% reduction in travel time.
Their study provides a comprehensive 3-D flow diagram depicting the entire production process,
along with detailed floor-specific explanations using flow process charts. They contributed to the
literature by demonstrating practical improvements in plant layout for efficiency gains.
6. Dr. Tiamiyu I. Muhammed, Gbenga A. Odesanmi talks about how the software’s are helpful
in reducing the facility arrangement cost, Demolition of existing facilities, and give roomfor future
expansion. The publishers of this paper have developed their own software called FLEXPLAYS
and also have explained all the required information for data input. The procedure for using the
software is explained in detail. This paper concludes that the software approach is very efficient
in solving future expansion problems.
8. Ravikumar, Suryaprakash Singh gives idea about the cellular plant layout, which comprise
of both process and product layout. They have studied the activities of Tower manufacturing
industries which had process layout and analysis of SCFLP, DCFLP and RSCFL was made to
draw the tables and results were considered to modify the existing plant layout. The RSCFL
method was chosen and implemented for modification and optimization of the plant layout.
9. Phong Nhu Nguyen designed a Lean Layout, which involves applying the concepts and
principles of Lean to something larger than one process. It focuses on reducing changeover time,
eliminate waste at my workspace. Lean Layout gives idea about how to organize a whole facility,
where is the waste, reorganize the whole organization so that it fits with the concepts offlow and
Just-In-Time. Lean Layout can be a real game changer in terms of saving money and freeing up
labour.
10. Deepan Selvan, S Santosh Raj, T S Ponselvan, R Praveen Kumar discusses about theNon
– value added activities and its effects like it always pulls down the efficiency, effectiveness and
profit of the industry which will lets to devastating future. Here a project has been carried outon a
casting industry in which non-value-added activities such as unnecessary transportation, motion,
and waiting and high space conception are identified using current state mapping and current state
layout. It is highly complicated to implement all the lean tools in a manufacturing system. So, to
prioritize only few lean tools which are essential to eliminate those wastes and an integrated model
(combine fuzzy and FMEA environment) was used. Fuzzy is to avoid ambiguityin observation and
FMEA is to prioritize the cause.
I. Work stations are randomly placed in this organization, this is leading to various efficiency and
coordination
II. The lack of proper storage for raw materials, are leading to several inefficiencies like
a. Material Delays: Without dedicated storage, there is a risk of delays in production due tothe
unavailability of required materials when needed.
b. Disorganization: Random storage of steel sheets can result in a disorganized workspace,making
it difficult for workers to locate and access the necessary materials efficiently.
c. Space Constraints: Inadequate storage space can lead to cluttered work areas, limiting theplant's
capacity for efficient material handling and production flow.
d. Quality Issues: Improperly stored materials may be susceptible to damage, affecting the
quality of the final product.
III. In this industry the placement of frequently used machines in corners and rarely used machines
in easily accessible areas. This arrangement of machines can lead to inefficiencies in the plant
layout.
Here are some problems associated with this arrangement:
a. Increased Man Movement: Placing frequently used machines in remote corners necessitates more
worker movement, leading to increased travel time and decreasedproductivity.
b. Waste of Time: Workers spend more time walking between workstations, which can be a significant
source of non-value-added time and contribute to overall operational inefficiency.
IV. In this plant the finished goods are stored somewhere in the middle of manufacturing line and
its distance from the dispatching location is far this can introduce several inefficiencies and challenges:
a. Workflow Disruption: Placing finished goods in the middle disrupts the natural flow of
manufacturing processes, leading to congestion and potential delays in production.
b. Increased Handling Time: Workers may spend more time transporting finished goods from the
Interior to the dispatch area, leading to increased handling time and reduced overall efficiency.
c. Congestion in Dispatch Area: The dispatch area may experience congestion and inefficiencies
when trying to move finished goods from an interior location to the exit point.
d. Longer Dispatch Distance: Placing finished goods deep within the facility requires a longer
distance for dispatch, resulting in increased transportation time and potential delays in order
fulfilment.
V. The office of this plant is placed at a location that requires visitors to navigate through the entireplant
layout which is resulting in inefficiencies and disruptions such as:
a. Worker Disturbance: Visitors passing through the plant layout to reach the office can disrupt the
concentration of workers, leading to decreased productivity and potential safety hazards.
b. Increased Foot Traffic: Higher foot traffic in the production area may impede the flowof materials
and workers, causing congestion and delays in manufacturing processes.
c. Confidentiality Concerns: Workers may feel uncomfortable with visitors having accessto sensitive
areas of the plant, potentially compromising confidentiality and security.
d. Distraction and Noise: Visitors walking through the production area can create noise and
distractions, negatively impacting the working environment and focus of employees.
VI. The unwanted items were left scattered on the floor in this plant layout which leads to various
inefficiencies and challenges:
a. Safety Hazards: Unwanted items on the floor pose safety risks, increasing the likelihood of trips,
falls, and other accidents, jeopardizing the well-being of workers.
b. Clutter and Congestion: Accumulation of unwanted stuff creates clutter, hindering the smooth flow
of workers and materials, and contributing to congestion in the workspace.
c. Reduced Workspace Efficiency: Valuable floor space is compromised when clutter is left
unaddressed, reducing the overall efficiency of the workspace and potentially limiting production
capacity.
d. Difficulty in Navigation: Navigating through a cluttered workspace becomes challenging,impacting
the speed at which workers can move between workstations and causing delaysin production.
In the proposed idea we are trying to implement U layout in the plant which will significantly
optimize the workstations that were initially randomly placed. In this new layout,the product
follows a U-shaped flow, effectively reducing unnecessary movement of both manpower and
materials, consequently minimizing motion waste. The total traveling distance,initially was 'x
meters,' will now be successfully reduced to 'y meters' after the layout improvement.
These advantages collectively highlight the positive impact of transitioning from a random
layout to a U layout, emphasizing efficiency, cost-effectiveness, and overall operational
improvement.
Incorporating dedicated workstations into the layout is a strategic move towards optimizing
the workflow, improving efficiency, and creating a workspace that prioritizes bothproductivity
and employee well-being.
The introduction of 5S management in the storage rack is a strategic step towards optimizing
the workspace, promoting efficiency, and cultivating a culture of cleanliness and orderliness.
4.5 Relocation of the office area for the benefit of both workers and visitors
a. Enhanced Visitor Experience: Placing the office at the entrance streamlines the
visitor experience, allowing them to efficiently conduct their business without navigating
through the entire plant, reducing disruptions and saving time.
b. Improved Work Efficiency: By separating visitor pathways from the operational
areas, the proposed layout minimizes work disturbance and prevents unnecessary
interruptionsto ongoing tasks, leading to improved overall work efficiency.
c. Reduced Foot Traffic in Production Zones: Locating the office at the entrance
minimizesfoot traffic within critical production zones, mitigating the risk of accidents and
promoting a safer working environment.
d. Streamlined Communication: Placing the office at the entrance enhances
communication flow by ensuring that essential messages and information reach the right
personnel without unnecessary detours, fostering a more responsive work environment.
e. Optimal Space Utilization: The rearrangement optimizes the use of available space,
ensuring that operational areas are dedicated solely to production and not encumbered.
In the proposed plant layout, with the office positioned at the entrance, brings about a
multitude of advantages ranging from improved efficiency and safety to enhanced visitor
experience and employee satisfaction. This strategic rearrangement reflects a holistic
approach to plant design, addressing both operational and visitor-related considerations.
4.6 Relocating the Finished Goods Storage Area for Easy Dispatching
a. Efficient Workflow Distribution: Relocating finished goods near the entrance
optimizes workflow distribution, minimizing the distance travelled during the
manufacturing process and reducing bottlenecks in the production line.
b. Seamless Dispatch Operations: Proximity to the entrance facilitates smooth dispatch
operations, ensuring quicker and more efficient loading of products onto delivery
vehicles, reducing turnaround times, and enhancing overall logistics performance.
c. Enhanced Customer Interaction: Placing finished goods near the entrance allows
customers to easily engage with office personnel, inquire about products, and inspect
items firsthand, fostering a more customer-centric experience and potentially leading to
increased satisfaction and sales.
d. Reduced Congestion in Dispatch Area: The new layout minimizes congestion in
the dispatch area by shortening the distance between finished goods storage and dispatch
points, preventing potential bottlenecks and delays during the shipping process.
e. Real-time Product Information: The adjacency of finished goods to the office
facilitates real-time communication between customers and office personnel, allowing
for immediate access to product information, specifications, and any necessary
documentation.
The proposed relocation of finished goods near the entrance and adjacent to the office not only
addresses logistical challenges but also enhances customer interaction and overall plant
aesthetics. This strategic improvement aligns with the goal of creating an efficient, customer-
friendly, and visually appealing manufacturing environment
5. PROPOSED MODEL
6. CONCLUSION
In conclusion, the plant layout and design optimization for the Bhoruka Aluminium plant can
significantly enhance both efficiency and productivity by streamlining the flow of materials
and reducing bottlenecks. Through strategic positioning of machinery and workstations,
coupled with the adoption of lean manufacturing principles, the plant can achieve a more
systematic arrangement that minimizes handling time and resource waste. This optimized
layout also enables smoother operational processes, which reduces downtime and promotes
safety by minimizing congestion and improving workspace organization. Moreover, aligning
the layout with the plant's production goals allows for easier scalability and adaptability to
future expansions or technological upgrades, thus ensuring the plant's long-term operational
success and competitive advantage in the aluminium industry.
7. FUTURE WORKS
[1]. Automated Puff Filling Process: Introduce a dedicated machine for puff filling to
automate the mixing and pouring processes. This not only reduces manual labour but also
significantly decreases the time required for puff filling, contributing to overall process
efficiency and faster production cycles.
[2]. Machinery Rationalization: Identify and eliminate redundant machines, streamlining the
production line for improved efficiency. This optimization can lead to space savings, reduced
maintenance costs, and enhanced overall productivity.
8. REFERENCES
[1] Priyanka Sonawane, Rahul Deore. 2020. “Productivity Improvement in Small Scale
Industry Through Plant Layout.” International Journal of Research in Engineering, Science
and Management, Volume -3, Issue -4.
[2] Jikadra Milan, Bhutaiya Adharmesh, Rathodbharatbhai, Shah Aagam. 2020. “Development
and Implementation of Lean and Kaizen Practices in Small Scale Manufacturing Industry”.
This Study Was Conducted in Plastic Rope Making Machine Manufacturing Industry.
[3] Gourav Goyal, Devendra S Verma. 2019. “Optimization of Plant Layout Manufacturing
Industry”. International Journal of Recent Technology and Engineering (IJRTE). ISSN:
2277-3878 (Online), Volume-8 Issue -2.
[4] Viswajit Talluru, Rani Teja, Prajna Deepthi. 2017. “A Case Study of Printing Industry Plant
Layout for Effective Production”. Design And Development of Progressive Tool for
Manufacturing Washer. AIP Conference Proceedings 1859.
[5] Wilson R Nyemba, Charles Mbohwa, Lloyd E N Nyemba. 2016. “Optimization of Plant
Layout and Material Handling Systems for A Furniture Manufacturing Company”.
Proceedings Of the World Congress on Engineering 2016 Vol Ll, WCE 2016, June 29-
July1, 2016, London, U.K.
[6] Dr. Tiamiyu I. Muhammed, Gbenga A. Odesanmi. 2014. “Development of A Flexible Plant
Layout System for Small and Medium Scale Industries in Nigeria”. The Pacific Journal of
Science and Technology.
[7] Okpala, Charles Chikwendu, Okechukwu. 2016. “Plant Layout Analysis and Design”.
International Journal of Advanced Engineering Technology. E-ISSN 0976-3945.
[8] Ravikumar, Suryaprakash Singh. 2018. “Cellular Facility Layout Problem: A Case Study
of Tower Manufacturing Industry”. An International Journal of Research Paper in
Management of Environmental Quality, MEQ -04-2018 -0076.R1.
[9] Phong Nhu Nguyen .2010. “Lean Production”. A Conference Paper of HCMC University
of Technology VNU HCM.
[10] Deepan Selvan, S Santosh Raj, T S Ponselvan, R Praveen Kumar. 2022. “Integration of
Lean Principles with Fuzzy FMEA In a Small-Scale Casting Industry”. Journal Of Physics
Conference Series 2272(1):012029.
[11] Pawar, A., Gaikwad. T. “Inventory Reduction and Improvement In Material Storage &
Handling With The Use Of Lean Practices”.
[12] Wu, H., Tang, D., Zhao, A. M., & Zhu, H. B. 2016. “Study Of the Microstructure and
Property of FH460 Grade Ship Steel Plate with High Strength and Toughness [J]. Metal
World, 5.
[13] Chien-Wen Chen and D. Y. Sha, “A Literature Review and Analysis to The Facility Layout
Problem,” Journal of The Chinese Institute of Industrial Engineers, Feb. 2010
[15] Devashri D. Thakre, Uday A. Dabade, “Case Study on Improvement in Plant Layout
Design,” Journal of Advances in Science and Technology, Vol. 13, No. 1, March 2017.
9. ANNEXURE