Transcript Chapter 02 - Facility layout and materials handling

Facility layout can be defined as the process by which the
placement of departments, workgroups within departments,
workstations, machines, and stock-holding points within a
facility are determined
This process requires the following inputs:
◦ Specification of objectives of the system in terms of output and
flexibility
◦ Estimation of product or service demand on the system
◦ Processing requirements in terms of number of operations and
amount of flow between departments and work centers
◦ Space requirements for the elements in the layout
◦ Space availability within the facility itself
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Provide enough production capacity
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Reduce material handling cost
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Reduce congestion impeding movement of men and
material
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Reduce hazards to working personnel
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Utilize labour efficiently
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Increase employee morale
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Utilize available floor space efficiently and effectively
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Ensure a smooth work flow or a desired traffic
pattern with minimum backtracking
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Reduce accidents
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Provide for volume and product flexibility
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Provide ease of supervision and maintenance
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Facilitate co-ordination and face-to-face
communication
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Provide for employee safety and health
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Allow high machine utilisation
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Improve productivity
-Material handling costs.
-Movement of people and material
-Hazards to personnel
-Accidents
- Production capacity
- Labour efficiency
- Employee morale
- Space utilization
- Ease of Supervision and Maintenance
Material
Managerial
Policies
Product
Factors
Influence
Location
Manpower
Type of
Industry
Machinery
Principles For Ideal Layout
Minimum
Travel
Compactness
and Minimum
investment
Safety and
Satisfaction
Ideal
Layout
Sequence
Usage and
Flexibility
Economies in handling
Effective use of available area
Minimization of production delays
Improved quality control
Avoidance of bottlenecks
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Continued…
Better production control
Better supervision
Improved utilization of labour
Improved employee morale
Avoidance of unnecessary and costly
changes
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Layout decisions are concerned with the arrangement of
production, support, customer service and other facilities.
Layout can be costly investments, but they effect material
(non production cost) handling, capital equipment
utilization, inventory storage levels, worker productivity,
and even group communications and employee morale. A
good layout will enable materials, people, and information
to flow in a safe and efficient manner.
For this reason two of the major criteria for selecting and
designing a layout are;
1. Materials-handling cost
2. Worker effectiveness.
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Material- handing cost
 often been considered the most important criteria
 Cost minimized by using belts and conveyors to
automate product flows belts
 keeping the flow distances as short as possible
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Workers effectiveness
 an increasingly important criterion in facilities today
 Good layouts provide workers with a satisfying job
and permit them to work effectively at the highest
skill level for which they are being paid
 Good communications systems and well-placed
supporting activity locations are critical to the
success of any facility
Changes in
environmental
or other legal
requirements
Changes in volume of
output or mix of
products
Morale problems
Changes in methods
and equipment
Basic types of layouts are
 Process (functional) layouts
 Product (line) layouts
 Fixed position layouts
 Cellular Layout
There are many combinations of these. Flexible production systems are line
layouts that use micro processor and robots to gain some of the advantages
of functional layouts.
The type of layout is generally determined by the following:
 Type of product: This concerns whether the product is a good or a service,
the product design and quality standards and whether the product is
produced for stock or for order.
 Type of production process: This relates to the technology used, the type of
materials, handled, and for the means of providing the services.
 Volume of production: Volume affects the present facility design and
capacity utilization, plus provisions for expansion or change.
High
Fixed
position layout
VARIETY
Process layout
Cell layout
Low
Product layout
Low
VOLUME
High
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Facility layout are influenced by the level of
automation and cost of manufacturing equipment.
Many numerically controlled (CNC) machines and
industrial robots perform simple tasks such as drilling
hales or welding joints. However, as the number of
task performed by automated machinery increases,
the machines can become quite large and expensive.
In these situations the equipment and configuration
significantly influence the layout and product floor.
The more advanced systems gaining acceptance in
U.S. firms today cellular manufacturing which is
building-block step toward flexible manufacturing
system.
Manufacturing cells also enable a firm to operate with
less work-in-process inventory.
Materials handling is
the art and science of moving,
packing and storing of
substances in any form.
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Defined as the art and science of moving, packing
and storing of substances in any form.
Creation of time and place utility
Movement and storage of material at the lowest
possible cost through the use of proper methods
and equipment
Lifting, shifting and placing of materials which
effect a saving in money, time and place
Art and science of conveying, elevating,
positioning, transporting, packaging and storing of
materials
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Efficient material handling is important to
manufacturing operations. Materials sent by
vendors must be unloaded, moved through
inspections and production operations to
stores and finally to the shipping department.
These movements do not add value to the
product but they do add value to the cost
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Material handling analysis is a subset of plant
layout. Method study, plant layout and material
handling are all part of the design of a production
facility
Material handling system and plant layout enhance
effectiveness of each other.
Efficient operation of appropriate material handling
methods reduces costs and enables maximum
capabilities to be derived from a given production
facility
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Function of production control
Concerned with scheduling of production control
Material Handling adds value to product cost
Material Handling increases effectiveness of in
plant layout by reducing the cost
In a typical manufacturing facility:
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25% of the work-force is used in material handling
55% of the factory floor is reserved for it
87% of the production time!
It may represent 15% to 70% of the total cost generated in
the company
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To Lower unit materials handling cost
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To reduce manufacturing cycle time
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To provide better control of the flow of materials
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To provide better working conditions
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To provide contribution for better quality by avoiding
damages to products
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To Increase storage capacity
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To provide higher productivity at lower manufacturing
costs
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Material should be moved as little as possible
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Reduction in time by using shortest routers and
mechanical material handling equipment
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The material movement should be in lots rather than in
individual units
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Design of material handling equipment should be such
that it can increase the effectiveness
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Gravity should be used
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Rehandling and back tracking of materials should be
avoided
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Periodically repairing, maintenance & checkup of
existing material handling equipments
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Materials + Moves + Methods = Preferred system
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Mechanized
Semi-automated
Automated
Information-directed
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The structure varies with industry, type of
manufacturing process, the product manufactured,
its bulk and its value
In small firms, it may be one of the functions
assigned to the plant engineer, purchasing
manager or production manager.
Big firms , a separate dept. itself is developed to
study procedures and devise better handling
techniques. When thus organised, they form part of
industrial engineering division.
Factors affecting the
Selection of
Materials Handling
Equipment
Production
problem
Human element
involved
Capabilities of the
handling
equipment
available
Volume of
Production to be
maintained
Production
Problem
Layout of plant &
building facilities
Class of materials
to be handled
Adaptability
Flexibility
Speed
Load
capacity
Space
requirements
Equipments
Factors
Power
Supervision
required
Ease of
Maintaince
Cost
Environment
Human Factors
Capabilities of
manpower
Safety of Personnel
1. Equipments oriented systems :-
a)
Conveyor Systems
b)
Tractor transfer system
c)
Fork lift truck
d)
Industrial truck system
e)
Underground system
2. Material Oriented Systems
a)
Unit handling system
b)
Bulk handling system
c)
Liquid handling system
3. Methods oriented system
a)
Manual systems
b)
Automated systems
c)
Job shop handling system
d)
Mass production system
4. Function oriented system
a)
Transportation systems
b)
Conveying systems
c)
Transferring systems
d)
Elevating systems
1.
2.
3.
4.
Conveyers
Cranes, Elevators and Hoists
Industrial Trucks
Auxiliary Equipments
1. Conveyors Gravity or powered devices
 Used for moving loads from one point to point
over fixed paths.
These are overhead devices used for moving
varying loads intermittently between points
within an area.