I.E

1. I.E GHARIA PRADIP SINH.G 096470319100 • PLANE LAYOUT GUIDED: V.H.M

2. PLANT LAYOUT • Layout: the configuration of departments, work centers, and equipment, with particular emphasis on movement of work (customers or materials) through the system • Product layouts • Process layouts

3. Basic Layout Types • Product layout • Layout that uses standardized processing operations to achieve smooth, rapid, high-volume flow • Process layout • Layout that can handle varied processing requirements

4. Objective of Layout Design • Facilitate attainment of product or service quality • Use workers and space efficiently • Minimize unnecessary material handling costs • Eliminate unnecessary movement of workers or materials • Minimize production time or customer service time • Design for safety

5. 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. Process Layouts • All similar equipment or functions are grouped together • Production of unique products is done in small batches • Product follows a serpentine path, usually in batches • High inventory levels • Products might travel for several miles within a factory during the production process

7. Milling Assembly& Test Grinding Plating Drilling Process Layout - work travels to dedicated process centers Process Layout

8. Advantages of Process Layouts • Can handle a variety of processing requirements • Not particularly vulnerable to equipment failures • Equipment used is less costly • Possible to use individual incentive plans

9. Disadvantages of Process Layouts • In-process inventory costs can be high • Challenging routing and scheduling • Equipment utilization rates are low • Material handling slow and inefficient • Complexities often reduce span of supervision • Special attention for each product or customer • Accounting and purchasing are more involved

10. Product Layouts • In a product layout, equipment is organized to accommodate the production of a specific product • Product layouts exist primarily in companies with high-volume production • The product moves along an assembly line beside which the parts to be added to it have been stored • Placement of equipment or processing units is made to reduce the distance that products must travel

11. Product Layout Figure 6.4 Raw materials or customer Station 2 Station 3 Station 4 Finished item Station 1 Material and/or labor Material and/or labor Material and/or labor Material and/or labor Used for Repetitive or Continuous Processing

12. 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

13. 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

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