1. Factory layout
Facility layout design has major
influence on plant productivity.
Eng. Mohammed S. Alghamdi
Presentation By: Ayman Aljahdali
2. Definition of Factory layout
It is concerned with planning the space available for all activities
and facilities associated with manufacturing with the aim of
enabling the factory to operate effectively.
Factory layout can be defined as a technique of locating machines, processes and plant services
within the factory so as to achieve the greatest possible output of high quality at the lowest
possible total cost of manufacturing.
The most important factors for any new industrial enterprise, after
determining the location of the plant.
3. Types Of Layout
Product or
line layout.
Process or
functional layout.
Fixed position or
location layout.
Combined or
group layout
4. Objectives of Factory Layout
An efficient plant layout is one that can be instrumental in achieving the following objectives:
Proper and efficient utilization of
available floor space.
Allow high machine or equipment
utilization.
Reduce material handling
costs.
Provide enough production
capacity.
To ensure that work proceeds from one point
to another point without any delay.
Increase employee morale.
Utilize laborers efficiently.
Reduce accidents.
Provide for employee safety
and health.
Reduce hazards to personnel.
Provide for volume and product
flexibility.
Provide ease of supervision
and control.
Allow ease of maintenance.
Improve productivity.
Provide proper lighting, ventilation
of the work stations.
Provide space for future expansion
of the plant.
5. Principles of Factory Layout
Provides integration of production facilities like men,
machinery, raw materials, supporting activities and any
other such factors which result in the best compromise.
The movements of men and materials
should be minimized.
Arranges the work station for each operate
process in same order or sequence that
forms treat or assembles the materials.
Principle of Overall Integration
Principle of Minimum Distance
Principle of Cubic Space Utilization
Principle of Flow
Principle of Satisfaction and Safety
Principle of Flexibility
According to Muther (Mr. Systematic) there are six basic principles of “best layout”.
According to this, the best layout utilizes cubic space
i.e. space available both in vertical and horizontal
directions is most economically and effectively utilized.
Provides satisfaction and safety to
all workers.
In automotive industries where models of products
change after sometime, the principle of flexibility
provides adoption and rearrangements at a
minimum cost and least inconvenience.
6. and general items &mechanical
components.
Switch Gear
manufacturing facility
Occupies 87.891 × 60.627 m2.
The facilityhas:
-Main store: receives the parts
-Kitting Area: store raw material
-Assembly line & Wiring shop.
-Customer area.
Needto improve productivityby modify the
existinglayout.
This done by performing:
-PQRST* analysis.
Existing layout of switchgear facility.
-Activity relationships analysis.
-Material flow analysis.
-Relationship diagram.
-Space requirements/available analysis.
*The key – PQRST – to unlocking layout problems.
Case Study
7. Systematic layout planning (SLP)
By using of SLP as a simplified
approach for layout design.
Since the facility manufactures a customize product.
The layout alternatives are evaluated on basis of
better integration of facility.
8. Functional areas
From-to chart
Flow diagram Relationship diagram
Production Departments areas
Space relationship diagram.
Analysis of manufacturing facility
9. Space relationship diagram Evaluation table.
After applying the constraints on mileage chart, new layout alternatives are developed as shown
Layout alternatives-Practical constraints
Converttherelationshipchartinto
blocklayout.
10. Evaluation & Results
New plant layout of switchgear facility.
Projection of material flow on productivity
Evaluated
layout
Material
Flow
(m/panel)
Lead
Time
(h/panel)
Product- ion
Rate
(panel/yr.)
Transport
Cost
per panel ($)
Cost
Reduction
per panel ($)
Cost
Savings
per yr. ($)
Existing 125 22 218 40 0 0
Alternative i 115 20.24 237 34 6 1,460
Alternative ii 92 16.19 296 22 18 5,437
Alternative iii 84 14.78 325 18 22 7,125
Alternative iv 76 13.38 359 15 25 9,050
The new layout successfully increased the overall
productivity of the facility.
Results prove improvement in distance which ultimately
reduces lead time and increases value addition.
The proposed layout also emphasize on better integration
of production departments of the facility.
