PRESENTED BY SWAPNIL KSHIRSAGAR(116) RASIK SAWANT(97) RISHIKESH DIXIT(67) VENKATESH(93) AKSHAY MANKAPURE(80) SANDEEP NARVADE() VAIBHAV PATANSHETTY() MAHENDRA

MANE()

WHAT IS LAYOUT?
A layout is an arrangement of the space and facilities according to:
The type and size of activities to be carried out, Convenience of operations, Efficiency, Productivity, Economy, and Safety of the facilities and the users of the facilities.

There can be various options for the layout with in the same space, each one having certain merits or demerits. A good layout is a combination of cultural, social, operational, location, climatic and safety factors. Layout is greatly influenced by the availability of the space, laws governing the activities, standards applicable and future plans of the organization.

NEED FOR PLANNING LAYOUT

Helps in proper arrangement of the departments, sections and machines for smooth operations. Improves safety of men & machines. Economy of operations. Poor layout may require too much movement of men and materials. Sometimes, additional facilities may have to be arranged for carrying out such movements. Additional facilities would need additional space and additional cost of operation and maintenance, thus increasing the production cost.

NEED FOR PLANNING LAYOUT

Difficult to make any change at a later stage. Even a minor modification would be very costly and would involve lots of efforts including disruption of activities. A good layout optimizes the operation costs and increases the profits. Improvement in line balancing and arranging work stations. Optimization on the machines in the plant.

FACTORS INFLUENCING PLANT LAYOUT

Operation requirements Size of operations Safety aspects Technology aspects Systems design System arrangement Location aspects Governmental regulations

LAYOUT AND ASPECTS OF SYSTEM DESIGN

Types of materials handled (Powder, Liquid, Gases) Types of plant and machinery (Small or big). Climatic conditions (Cold, hot, rains, windy) Availability of power (coal/ gas/ oil based ) Movement of materials and men Future plans

LAYOUT AND GOVERNMENT REGULATIONS

Legislations for protection from safety hazards:
Every plant is supposed to have a clinic for treatment

Direction to take care of basic needs of the workmen:

Every plant has to provide shades, washrooms, toilets and canteen for the workers. (OH&S Act, ESIC)

Compliance to these governmental regulations requires the plant layout to be such that these facilities are available in required measures and at convenient places. Similarly, governments have brought out regulations about environmental protection which influence the layout of the plant.(Environment protection Act)

TYPES OF LAYOUT

Process Layout

Product Layout

Fixed Position Layout

Objective of Layout Design

1. Facilitate attainment of product or service quality 2. Use workers and space efficiently 3. Avoid bottlenecks 4. Minimize unnecessary material handling costs 5. Eliminate unnecessary movement of workers or materials 6. Minimize production time or customer service time 7. Design for safety
6-9

Importance of Layout Decisions

Requires substantial investments of money and effort Involves long-term commitments Has significant impact on cost and efficiency of short-term operations

6-10

Product Layout
Figure 6.4

Raw materials or customer

Material and/or labor

Station 1 Material and/or labor

Station 2
Material and/or labor

Station 3
Material and/or labor

Station 4

Finished item

Used for Repetitive or Continuous Processing

6-11

Advantages of Product Layout

High rate of output Low unit cost Labor specialization Low material handling cost High utilization of labor and equipment Established routing and scheduling Routing accounting and purchasing

6-12

Disadvantages of Product Layout

Creates dull, repetitive jobs Poorly skilled workers may not maintain equipment or quality of output Fairly inflexible to changes in volume Highly susceptible to shutdowns Needs preventive maintenance Individual incentive plans are impractical

6-13

PRODUCT LAYOUT OF LAUNDRY

Classification and marking of clothes

Washing Machine

Dryer

Steam press

Storage Area for Pressed clothes

Delivery Counter

To produce one standard product in large volumes.

Each unit produced undergoes same sequence of operations and uses same flow of work. The work centers and equipments are arranged in a line for continuous operation.

EXAMPLES OF PRODUCT LAYOUT

Assembly line for air-conditioner, Car manufacturing unit, Car washes and Canteen facilities

Process Layout
The process layout is followed from historical period. It evolved from the handicraft method of production. In this layout, the major plan is to fix up or collect machinery or equipments of the similar role keen on one group or division. In this type of layout machines of a similar type are arranged together at one place. It is most efficient when making products with different requirements

Advantages
Flexibility. The firm has the ability to handle a variety of processing requirements. Cost. Sometimes, the general-purpose equipment utilized may be less costly to purchase and less costly and easier to maintain than specialized equipment. Motivation. Employees in this type of layout will probably be able to perform a variety of tasks on multiple machines, as opposed to the boredom of performing a repetitive task on an assembly line. A process layout also allows the employer to use some type of individual incentive system. System protection. Since there are multiple machines available, process layouts are not particularly vulnerable to equipment failures.

Disadvantages
Orders take more time to move through the system because of difficult scheduling. High labour skill needs also increase the required level of training and experience and high work in process levels increase capital investment. The span of supervision is small due to job complexities (routing, setups, etc.), so supervisory costs are higher. Additionally, in this type of layout Work in progress inventory is high needing greater storage space .

Example
An example is machining parts for aircraft engines. Some processes (such as heat treatment) need specialist support (e.g. fume extraction), while other processes (e.g. machining centres) need technical support from machine setters/operators. So the factory will be arranged with heat treatment together in one location and machining centres in another. Different products will follow different routes around the factory.

What is a fixed position layout?

In this type of layout, the major product being produced is fixed at one location. Equipment labor 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.

Advantages:

Investment is very less. saves time and cost. The layout is flexible. Economical when orders are executed simultaneously.

Disadvantages
High capital investments.
Confusion and conflicts among groups.

Suitability:
Manufacture of bulky and heavy products such as locomotives, ships, boilers, generators, wagon building, aircraft manufacturing, etc. Construction of building, flyovers, dams. Hospital, the medicines, doctors and nurses are taken to the patient (product).

FIXED POSITION LAYOUT

 1.Easy for products which are difficult to move. 2. Flexibility for change in design, operation sequence, labor availability, etc., exists in this layout.

3. This layout is very cost effective when many orders of similar type are existing in different stages of progress. 4. Large project type of jobs such as construction are suited in this layout.

TYPES OF PRODUCTION SYSTEM

JOB PRODUCTION What is a job production? Advantages Disadvantages Suitability Examples

TYPES OF PRODUCTION SYSTEM

BATCH PRODUCTION What is a batch production? Advantages Disadvantages Suitability Examples

Mass Production
Mass production (also flow production, repetitive flow production, series production, or serial production) is the production of large amounts of standardized products, including and especially on assembly lines. Mass Production involves making many copies of products, very quickly, using assembly line techniques. Mass production is capital intensive and energy intensive process. One of the descriptions of mass production is that "the skill is built into the tool.

Advantages of Mass Production

Reduction of non-productive effort of all types. Time required is shorter than traditional methods. The probability of human error and variation is also reduced A reduction in labour costs, as well as an increased rate of production

Disadvantages of Mass Production

Mass production is inflexible. Any mistake in design or formula or command can result in large losses. All products produced on one production line will be identical. Thus, Less variety.

Uses of Mass Production

Production of standard products such as:
Manufacturing of cars, weapons, consumer durables, TV plants etc. Products of mass consumption such as Coalgate toothpaste, Lux soap, soft drinks etc.

GODREJ SECURITY SOLUTIONS(PL-17)

PRODUCT RANGE SAFES STRONG DOORS SAFE DEPOSIT LOCKER UNITS RECORD PROTECTING EQUIPMENT MARINE DOORS

LAYOUT OF PLANT 17
OFFICE Press Shop Safety

EngineePRESS SHOP PRE-TREATMENT SDLC Assembly -ring Cell

SAFE ASSEMBLY

STRONG DOOR Assembly

ATM SAFE ASSEMBLY

Maintenance Dept. PROTO SHOP.

BSR (FG)

OFFICE Safe Assembly

PAINT SHOP

OFFICE Paint shop

BONDED STORE ROOM (FG) AND PACKING. RM

FINAL FITTING AND PACKING STORES

FORKLIFT Maintenance VDC MACHINE SHOP MARINE DOORS

*
OFFICE Personnel

RPE ASSEMBLY

SERVICE

SAFE ASSEMBLY LAYOUT

GRIEVENCES
MATERIAL HANDLING CEMENT FILLING HOUSEKEEPING LACK OF SKILLED LABOUR M/C DOWNTIME