This is best for plant layout required for any firm and industry where material handling is one of founding pillar of plant layout
Here each type is explained in simple and effective manner with principles.
Material handling is also listed with principles and types of material handling
3. OUTLINE
FACTORY LAYOUT
1. Types of Layouts
2. Merits, demerits and applications
3. Principles of designing Plant Layout
MATERIAL HANDLING
1. Principles of Material Handling
2. Material Handling equipments and applications
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Factory Layout and Material Handling By A. N. Deshpande
4. FACTORY LAYOUT
Plant layout is “an arrangement of machines within a factory
so that each operation is performed at point of greatest
convenience.
It is technique of locating different machines , plant services
so that greatest possible output of high quality at lowest
possible total cost can be available.
Proper factory layout is key to success. It can be
numerous for same product, but best is which costs
less. These may vary with size and type of plant. 4
Factory Layout and Material Handling By A. N. Deshpande
5. FACTORS AFFECTING TYPES OF LAYOUTS
1. Location of various departments
2. Location of production departments in building
3. Position of service departments
4. Premises
5. Size and locational conditions of factory
6. Type of construction
7. Ventilation and air conditioning
8. Lighting
9. Appearance
10. Plant protection
11. Provision for future expansion
12. Sanitary convenience 5
Factory Layout and Material Handling By A. N. Deshpande
6. OBJECTIVES OF FACTORY LAYOUT
1. To produce better quality product
2. Max. utilization of floor area
3. To reduce internal transportation of goods from one
place to another
4. Lower cost of scrap and waste
5. Fewer accidents
6. Minimizing production delays
7. Safety- personnel and machines
8. Savings of costs
9. Easy supervision
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Factory Layout and Material Handling By A. N. Deshpande
7. PRINCIPLES OF DESIGNING PLANT LAYOUT
1. Principle of overall integration
2. Principle of Minimum distance
3. Principle of Flow
4. Principle of Cubic space
5. Principle of Satisfaction and safety
6. Principle of Flexibility
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Factory Layout and Material Handling By A. N. Deshpande
8. TYPES OF PLANT LAYOUTS
1. Line or Product Layout
2. Functional or Process Layout
3. Combination Layout
4. Fixed Position Layout
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Factory Layout and Material Handling By A. N. Deshpande
9. 1. LINE OR PRODUCT LAYOUT
Famous in Mass Production
Only one type of product is operating area which is
standardized and produced in huge quantity
M/C – arranged in order of their use performing
operations in sequence
All parts, sub-assemblies are started at right time to be
ready at required time and kept moving until finished
product is available at end of assembling line.
Also called –Synthetic System
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Factory Layout and Material Handling By A. N. Deshpande
10. Advantages:
1. Less space requirement
2. Minimum handling or transportation
3. Less work in process
4. Better utilization of machines and labour
5. Production control- gets simplified.
Disadvantages:
1. Mfg. cost rises due to fall in production
2. When model changes, layout requires change
3. All m/c are not used for max. capacity
4. Only for one special product, no flexibility
5. If any machine fails, others have to idle till it gets
repaired.
6. Worker performs single job again & again, no skill of
other m/c
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Factory Layout and Material Handling By A. N. Deshpande
11. Suitability:
For continuous process industries like car or automobile
and chemical industries
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Factory Layout and Material Handling By A. N. Deshpande
12. 2.FUNCTIONAL OR PROCESS LAYOUT
Machines are arranged according to their functions i.e.
similar machines are arranged at one location.
Each department carries particular process and not a
product as in line type.
Also called- Analytical Layout
Suitability:
1. This is very useful when low volume of production
is required
2. Where non repetitive activities are done.
3. For job production type.
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Factory Layout and Material Handling By A. N. Deshpande
13. Advantages:
1. Requires less machines
2. Similar jobs produced on similar machines. Supervision is
simple.
3. Flexibility is more than line type.
4. Any breakdown of m/c doesn’t affect production
5. Workers are all rounder knowing all m/c
6. Better control on precision and quality
Disadvantages:
1. Total production cycle time is more
2. Routing and scheduling is difficult
3. More training for workers
4. Handling and back-tracking of material is too much
5. More floor area requirement
6. Inspection is more so more inspection time and cost causing
delays.
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Factory Layout and Material Handling By A. N. Deshpande
14. 3. COMBINATION LAYOUT
Combination of Line and Process Layout
most modern type of layout
Possible when item is made in different types and
sizes where m/c arranged as in functional type
but group of m/c are arranged in sequence like
product type.
Suitability:
Files, hacksaws, wood saws, gear manufacturing,
etc.
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Factory Layout and Material Handling By A. N. Deshpande
15. 4. FIXED POSITION LAYOUT
Men, machines are moved to material which is at
one place and product is complete at same
constant place.
Suitable for aircraft, ship vessel, pressure vessels
Also called static product layout
Suitability:
For large items made singly or in very small lots
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Factory Layout and Material Handling By A. N. Deshpande
16. Advantages:
1. Less movement of materials
2. Maximum flexibility
3. Capital is minimum
4. Less total production cost
5. Different no. of projects can be done in same layout
Disadvantages:
1. Low utilization of m/c and equipment
2. High m/c handling costs
3. Low work content in process
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Factory Layout and Material Handling By A. N. Deshpande
17. It involves movements of materials manually or
mechanically in batches or one item at a time in plant.
Movement may horizontal, vertical or combination of
both.
It is so important that about 20-50% cost of total
production is of material handling cost.
Cost of product can lower considerably by proper
material handling equipments.
MATERIAL HANDLING
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Factory Layout and Material Handling By A. N. Deshpande
18. PRINCIPLES OF MATERIAL HANDLING
1. To choose production m/c to eliminate need of material
handling as can as.
2. Reduce movements in production
3. Reduce distance moved by choosing shortest routes
4. Employ mechanical aids in manual case to speed up
production
5. Change sequence of operation if required
6. Utilize gravity whenever possible
7. Chose most suitable handling equipment which is safe
at minimum cost.
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Factory Layout and Material Handling By A. N. Deshpande
