SYSTEMATIC LAYOUT PLANNING
• Systematic Layout Planning (SLP) is a technique developed by Richard Muther and Associates. Associates. The 3 fundamental areas of the technique; Relationships; Space and Adjustment, include 10 sub-headings within the process:
• Relationships 1. Collection of Input Data 2. Flow of Materials 3. Activity Relationships 4. Relationship Diagrams
• Space 1. Space Requirements 2. Space Available 3. Space Relationship Diagrams
• Adjustments 1. Modifying Considerations 2. Practical Limitations 3. Evaluation & Final Selection
• This technique combines quantitative measurement of materials movement with non-flow considerations such as noise, fumes, temperature, supervision, communications, personnel comfort and movement. It’s major advantage being that it clearly documents the logic of the layout and easily allows input from all levels of staff.
PLANT LAYOUT • A FLOOR PLAN FOR DETERMINING AND ARRANGING THE DESIRED MACHINERY AND EQUIPMENT OF A PLANT • IT PERMITS – THE THE QUICKEST FLOW OF MATERIALS IN PROCESSING THE PRODUCT •FROM THE RECEIPT OF THE RAW MATERIALS TO THE SHIPMENT OF THE FINISHED PRODUCT – AT AT THE LOWEST COST, AND – WITH WITH THE LEAST AMOUNT OF HANDLING
OBJECTIVES • PROVIDE ENOUGH PRODUCTION CAPACITY • REDUCE MATERIAL HANDLING COST • REDUCE CONGESTION IMPEDING MOVEMENT OF MEN AND MATERIAL • REDUCE HAZARDS TO WORKING PERSONNEL • UTILISE LABOUR EFFICIENTLY • INCREASE EMPLOYEE MORALE • UTILISE AVAILABLE FLOOR SPACE EFFICIENTLY AND EFFECTIVELY
OBJECTIVES • REDUCE ACCIDENTS • PROVIDE FOR VOLUME AND PRODUCT FLEXIBILITY • PROVIDE EASE OF SUPERVISION AND MAINTENANCE • FACILITATE CO-ORDINATION AND FACE-TOFACE COMMUNICATION • PROVIDE FOR EMPLOYEE SAFETY AND HEALTH • ALLOW HIGH MACHINE UTILISATION • IMPROVE PRODUCTIVITY
CRITICAL FACTORS • MATERIALS – TYPE, AVAILABILITY, PROVISION FOR STORAGE AND MOVEMENT
• PRODUCT – TYPE I.E. HEAVY,LIGHT, WET OPERARTION (CEMENT), MARKET DEMAND (DECISION ON MACHINERY TYPE)
• WORKERS – MALE, FEMALE (SPECIAL NEEDS), FACILITIES
• MACHINERY – FIXED OR MOBILE POSITION OF MEN, MACHINERY, JOB TO DECIDE MACHINERY LAYOUT-DEPENDING LAYOUT-DEPEND ING ON TYPE, VOLUME OF PRODUCTION
CRITICAL FACTORS • TYPE OF INDUSTRY – SYNTHETIC • CONSTITUENT ELEMENTS COMBINING TO MAKE THE FINAL PRODUCT E.G. CHEMICAL INDUSTRY
– ANALYTICAL • CONVERSION OF RAW MATERIALS INTO VARIOUS ELEMENTS E.G. PETROLEUM INDUSTRY
– CONDITIONING • CHANGING IN SHAPE / FORM OR PHYSICAL PROPERTIES E.G. FOUNDARY, METAL WORKING INDUSTRY
– EXTRACTIVE • INVOLVING SEPARATION OF ONE ELEMENT FROM THE OTHER E.G. METAL FROM IRON ORE
– EACH OF ABOVE FURTHER CLASSIFIED INTO • INTERMITTENT INDUSTRIES • CONTINUOUS INDUSTRIES
CRITICAL FACTORS • LOCATION – SIZE AND TERRAIN DECIDES TYPE OF BUILDING – LOCATION DECIDES MODE OF TRANSPORTATION OF RAW MATERIAL AND FINISHED PRODUCTS – FUEL REQUIREMENT FOR THE PLANT – FUTURE EXPANSION PROVISION
• MANAGERIAL POLICIES – – – – – –
VOLUME OF PRODUCTION AND EXPANSION EXTENT OF AUTOMATION MAKING OR BUYING DECISION RAPID DELIVERY TO CUSTOMERS PURCHASING POLICY PERSONNEL POLICIES
PRINCIPLES OF LAYOUT • PRINCIPAL OF MINIMUM TRAVEL • PRINCIPLE OF SEQUENCE • PRINCIPLE OF USAGE • PRINCIPLE OF COMPACTNESS • PRINCIPLE OF SAFETY AND SATISFACTION • PRINCIPLE OF FLEXIBILITY • PRINCIPLE OF MINIMUM INVESTMENT
TYPES • PROCESS LAYOUT, FUNCTIONAL LAYOUT OR JOB SHOP LAYOUT • PRODUCT / LINE PROCESSING OR FLOW LINE LAYOUT • FIXED POSITION / STATIC LAYOUT • CELLULAR MANUFACTURING (CM) OR GROUP TECHNOLOGY (GT) LAYOUT • COMBINATION / HYBRID LAYOUT
PROCESS LAYOUT • GROUPING TOGETHER OF SIMILAR MACHINES IN ONE DEPARTMENT • MATERIAL MOVES FROM ONE GROUP OF MACHINES TO THE OTHER • MOVEMENT OVER LONGER DISTANCE AND ALONG CRISS-CROSS PATHS • MAY ALSO INVOLVE PART FINISHED INVENTORY WAITING BEST SUITED FOR INTERMITTENT TYPE OF PRODUCTION/LIGHT AND HEAVY INDUSTRIES
PRODUCTION SUB-SYSTEM RAW MATERIALS RECEIVING OPERATION A WIP
MATERIAL FLOW
STORAGE FINISHED GOODS
EDP CONTROL SYSTEMS WIP
OPERATION D SHIPPING FINISHED GOODS
OPERATION B WIP
WIP OPERATION C INFORMATION FLOWS
INTERMITTENT FLOW PRODUCTION SYSTEM (JOB SHOP )
PROCESS LAYOUT • IMPORTANT CONSIDERATIONS – DISTANCE BETWEEN DEPARTMENTS AS SMALL AS POSSIBLE – DEPARTMENTS TO BE LOCATED AS PER SEQUENCE OF OPERATION – CONVENIENCE FOR INSPECTION AS WELL AS SUPERVISION
PROCESS LAYOUT • ADVANTAGES – REDUCED INVESTMENT ON MACHINES, BEING GENERAL PURPOSE MACHINES – GREATER FLEXIBILITY IN PRODUCTION – BETTER AND MORE EFFICIENT SUPERVISION – GREATER SCOPE OF EXPANSION – BETTER UTILISATION OF RESOURCES – HADLING BREAKDOWN OF EQUIPMENT EASIER-JOBS CAN BE TRANSFERRED TO OTHER MACHINES – FULL UTILISATION OF MACHINERY
PROCESS LAYOUT • LIMITATIONS – DIFFICULTY IN MOVEMENT OF MATERIALS – LAYOUT REQUIRES MORE SPACE – DIFFICULTY IN PRODCUTION CONTROL – PRODUCTION TIME INCREASED BECAUSE OF EXTRA TRAVEL – ACCUMULAT ACCUMULATION ION OF WORK-IN-PROCESS AT DIFFERENT MACHINES
PRODUCT LAYOUT • MACHINES ARRANGED IN A LINE DEPENDING UPON SEQUENCE OF OPERATIONS • MATERIAL MOVES IN A LINE FROM THE FIRST MACHINE TO THE FINISHED PRODUCT ON THE LAST MACHINE. • INVESTMENT HIGHER AS COMPARED TO PROCESS LAYOUT
BETTER SUITED FOR STANDARDIS S TANDARDISED ED PRODUCTS ON A MASS SCALE PRODUCTION. EX CHEMICALS,PAPER
PRODUCTION SUB-SYSTEM RAW MATERIALS RECEIVING
OPERATION B STORAGE OPERATION A MATERIAL FLOW
EDP CONTROL SYSTEMS
OPERATION D
OPERATION C SHIPPING FINISHED GOODS
INFORMATION FLOWS
CONTINUOUS FLOW PRODUCTION SYSTEM (FLOW SHOP)
PRODUCT LAYOUT • IMPORTANT CONSIDERATIONS – ALL MACHINES PLACED AT POINTS DEMANDED BY SEQUENCE OF OPERATION – NO CROSSING OVER OF ONE LINE WITH THE OTHER – MATERIALS MAY BE FED WHERE THEY ARE REQUIRED FOR ASSEMBLY BUT NOT NECESSARILY ALL AT ONE POINT – ALL OPERATIONS INCLUDING ASSEMBLY, TESTING AND PACKING INCLUDED IN THE LINE
PRODUCT LAYOUT • ADVANTAGES – REDUCTION IN MATERIAL HANDLING COST DUE TO MECHANISATION – LAYOUT AVOIDS PRODUCTION BOTTLENECKS – ECONOMY IN MANUFACTURING TIME – BETTER PRODUCTION CONTROL – REQUIRES LESS FLOOR AREA PER UNIT OF PRODUCTION – WORK-IN-PROGR WORK-IN-PROGRESS ESS IN REDUCED – EARLY DETECTION OF MISTAKES
PRODUCT LAYOUT • LIMITATIONS – LAYOUT INFLEXIBLE – LAYOUT EXPENSIVE – DIFFICULTY IN SUPERVISION – EXPANSION IS DIFFICULT – ANY BREAKDOWN ALONG THE LINE CAN DISRUPT TOTAL PRODUCTION
FIXED POSITION LAYOUT • MOVEMENT OF MEN & MACHINERY TO THE PRODUCT • PRODUCT REMAINS STATIONARY – COST OF MOVING PRODUCT IS HIGH,BEING BULKY
BEST SUITED FOR BULKY & HEAVY PRODUCTS EX.SHIPS, AEROPLANES ETC.
RAW MATERIALS
MACHINE & EQUIPMENT
AIRCRAFT ASSEMBLY
LABOUR
FIXED POSITION OR STATIC LAYOUT
FINISHED PRODUCT (AIRCRAFT)
FIXED POSITION LAYOUT ADVANTAGES • MEN/MACHINERY CAN BE MOVED FOR A WIDE VARIETY OF OPERATIONS PRODUCING DEFFERENT PRODUCTS • WORKER IDENTIFIES HIMSELF WITH THE PRODUCT & TAKES PRIDE WHEN THE WORK IS COMPLETED • INVESTMENT ON LAYOUT IS SMALL • HIGH COST & DIFFICULTY IN TRANSPORTING A BULKY JOB AVOIDED
CELLULAR MANUFACTURING (CM) LAYOUT • GROUPING OF MACHINES INTO CELLS • CELLS FUNCTION SOMEWHAT LIKE PRODUCT LAYOUT WITHIN A LARGER SHOP OR PROCESS LAYOUT • EACH CELL IN THE CM FORMED TO PRODUCE A SINGLE PART / A FEW PARTS – ALL WITH COMMON CHARACTERISTICS WHICH USUALLY REQUIRES SIMILAR MACHINES AND SETTINGS
• FLOW OF PARTS WITHIN THE CELL CAN TAKE MANY FORMS
CELLULAR MANUFACTURING LAYOUT
CELL # 2
CELL # 1
1
2 1
2
3
PART D
3 PART X
5
4 PART Y
1 PART A
PART B
1
2 4
PRODUCTION OPERATION
2
CELL # 4
3 3
CELL # 3
PRODUCT OR MATERIAL FLOW
CM LAYOUT ADVANTAGES • LOWER WORK-IN-PROCESS INVENTORIES – REDUCED MATERIAL HANDLING COSTS – SHORTER FLOW TIMES IN PRODUCTION – SIMPLIFIED PRODUCTION PLANNING (MEN, MATERIAL ETC.) – OVERALL PERFORMANCE OFTEN INCREASES BY LOWERING PRODUCTION COSTS & IMPROVING ON-TIME DELIVERY – IMPROVED QUALITY
CM LAYOUT LIMITATIONS • REDUCED MANUFACTURING MANUFACTURING FLEXIBILITY & POTENTIALLY INCREASED MACHINE DOWNTIME • DUPLICATE PIECES OF MACHINERY MAY BE NEEDED SO AS TO AVOID MOVEMENT OF PARTS BETWEEN CELLS
COMBINED LAYOUT • COMBINATION OF PRODUCT & PROCESS LAYOUT WITH AN EMPHASIS ON EITHER • GENERALLY ADOPTED IN INDUSTRY • IN FABRICATION PLANTS INCLUDING ASSEMBLY, FABRICATION TENDS TO EMPLOY PROCESS LAYOUT WHILE ASSEMBLY AREAS EMPLOY PRODUCT LAYOUT – SOAP MANUFACTURING INDUSTRY EMPLOYS PRODUCT LINE FOR MANUFACTURING OF SOAP, BUT ANCILLARIES SUCH AS HEATING, MANUFACTURING OF GLEYCERINE, POWER HOUSE ETC. ARE ARRANGED ON FUNCTIONAL BASIS.
PR ODU ODUCT LAY AYO OUT
RAW MATERIAL
F.P.
G.C.
H.T.
G.G. FINISHED PRODUCTS (GEARS)
RAW MATERIAL T U O Y A L S S E C O R P
F.P.
G.C.
H.T.
G.G.
G.C.
F.P. = FORGING PRESS
G.C. = GEAR CUTTING
H.T. = HEAT TREATMENT FURNACE
G.G. = GEAR GRINDING MACHINE
COMBINATION LAYOUT OR HYBRID LAYOUT FOR GEAR MANUFACTURING
SERVICE FACILITY LAYOUT • MAIN DIFFERENCE BETWEEN SERVICE AND MANUFACTURING MANUFACTUR ING FACILITY IS TO BRING TOGETHER CUSTOMERS & SERVICES IN MANY SERVICE FACILITIES • FACILITIES TO PROVIDE FOR – EASY ENTRANCE FROM THE FREEWAYS AND BUSY THOROUGHFARES – LARGE WELL ORGANISED AND AMPLY ILLUMINATED PARKING AREAS ETC.
• HOTELS, CINEMA HALLS ETC HAVE DIFFERENT AREAS TO CATER TO THE COMFORT & CONVENIENCE OF CUSTOMERS
EXIT
PARKING AREA
ENTRANCE
CASUALTY DEPT DE PT / INPATIENT DE PT
PARKING AREA
HOSPITAL WARDS SURGERY, RADIOLOGY, I.C.U., TECH SERVICES
S S Y Y A A W W G G N N A A G G / / S S E E L L SI IS A A
HOSPITAL WARDS
HOSPITAL WARDS
DOCTORS LOUNGE / OFFICES
NURSES LOUNGE
CAFETERIA
ADMIN. OFFICE
PARKING AREA
CASUALTY DEPT / INPATIENT DEPT
ENTRANCE
PARKING AREA
EXIT
SERVICE FACILITY LAYOUT ( HOSPITAL LAYOUT )
A A E E R R A A G G IN I N K K R R A A P P
A A E E R R A A G G IN I N K K R R A A P P
SERVICE FACILITY LAYOUT • LAYOUT IMPORTANT TO ACHIEVE CLIENTCUSTOMER GOAL OF FAST SERVICE – FAST SERVICE SUPPORTED BY POINT OF SALE SYSTEM, SCANNERS, SELF SERVICE TO PROVIDE SPEED AS WELL AS REDUCE COST, ATMs BY BANKS ETC.
• FLOW LINE APPROACH FOLLOWED IN FAST FOOD SERVICE • PROCESS LINE LAYOUT OCCURS IN MANY SERVICES LIKE MEDICAL CLINICS, OFFICES ETC.
SERVICE FACILITY LAYOUT • GENERALLY, AS IN MANUFACTURING – LINE LAYOUT PREFERRED IN HIGH VOLUME, STANDARDISED PRODUCTS • FAST FOOD SERVICE
– PROCESS LAYOUT PREFERRED IN SERVICE OPERATIONS ALSO • GENERAL OFFICES, BANKS, GENERAL HOSPITALS, MUNICIPAL OFFICES ETC.
SERVICE WAITING LINE MODULES
WAITING LINE
SERVICE FACILITY
SINGLE CHANNEL, SINGLE PHASE MODULE
WAITING LINE
SERVICE FACILITY
MULTIPLE CHANNEL, SINGLE PHASE MODULE
WAITING LINE
SERVICE FACILITY
SINGLE CHANNEL, MULTIPLE PHASE MODULE
WAITING LINE
SERVICE FACILITY
MULTIPLE CHANNEL, MULTIPLE PHASE MODULE
LAYOUT PLANNING • NEED FOR FUTURE REVISIONS CAUSED DUE TO EXPANSIONS, TECHNOLOGICA TECHNOLOGICAL L ADVANCES, IMPROVED LAYOUTS ETC • MAJOR CRITERIA FOR SELECTING AND DESIGNING LAYOUTS – MATERIAL HANDLING COST • MATERIAL HANDLING COSTS MINIMISED BY USING MECHANISED MATERIAL HANDLING EQUIPMENTS
– WORKER EFFECTIVENESS • GOOD LAYOUT PROVIDES WORKERS WITH A SATISFYING JOB AND PERMITS THEM TO WORK MORE EFFECTIVELY AT THE HIGHEST SKILL LEVEL • GOOD COMMUNICATION SYSTEM AND WELL PLACED SUPPORTING ACTIVITY LOCATIONS IMPORTANT
LAYOUT PLANNING METHODOLOGY • TRAVEL CHART METHOD • LOAD-DISTANCE ANALYSIS METHOD • SYSTEMATIC LAYOUT PLANNING METHOD • ANALYSING LAYOUTS WITH COMPUTERS – ALDEP (AUTOMATED LAYOUT DESIGNING PROGRAMME) – CORELAP (COMPUTERISED RELATIONSHIP LAYOUT PLANNING) – CRAFT (COMPUTERISED RELATIVE ALLOCATION OF FACILITIES TECHNIQUE)
THANK YOU
REFERENCES • PRODUCTION & OPERATIONS MANAGEMEN MANAGEMENT: T: ASWATHAPPA / BHAT • MODERN PRODUCTION / OPERATIONS MANAGEMENT: BUFFA / SARIN • PRODUCTION OPERATIONS MANAGEMENT: LEVIN / MCLAUGHLIN et al
