Q.5 Write the objectives of plant layout? (AKTU. 2010 - 11)
Related Questions -
Q. Discuss the objectives and advantages of plant layout. (AKTU. 2012 - 13)
Ans. Objectives of Plant Layout: -
Whatever may be the mode of plant layout, the endeavor always is to arrange the buildings, men and materials, in such way that the following objectives are efficiently served:
(i) The material has to move a minimum distance.
(ii) There is a smooth flow of the product in the plant.
(iii) The entire space of the plant is fully utilized.
(iv) The layout provides adequate safety and satisfaction to the plant workers.
(v) It provides for enough flexibility in the arrangement of the above factors so as to suit the minor future changes, if any.
(vi) It facilitates an effective supervision.
(vii) Over and above all, it integrates all the above factors in such a way that the best compromise and coordination is achieved among them.
Advantages of Good Layout: -
Advantages and benefits are offered by a good plant layout, of which a few prominent ones are given below:
(i) The floor area is effectively and economically utilized.
(ii) The rate of production is increased and less men and machine hours are used per unit of production.
(iii) The material handling time is minimized.
(iv) The usual production delays are avoided.
(v) The men, machinery and factory services are more effectively utilized.
(vi) The overall production time is reduced.
(vii) A fairly large amount of paper work is eliminated.
(viii) The indirect expenses are considerably reduced.
(ix) A better utilisation of labour is provided.
(x) The inventory work for material is cut down considerably.
(xi) A better supervision is facilitated and confusion reduced.
(xii) Any congestion due to men, machines or material is avoided.
(xiii) An adequate flexibility in arrangement is provided to suit the future changes, if any.
(xiv) It promotes better planning and effective control.
(xv) It facilitates a better and easier maintenance of plant and machinery.
(xvi) It provides safer and healthier working conditions, thereby improving the morale of the workmen.
(xvii) It provides the material as well as psychological satisfaction to the workers.
(xviii) It result in better wages to the workers and enhanced overall efficiency of the plant.
Q.6 Give a brief classification of plant layout. (AKTU. 2010 - 11)
Related Questions -
Q. Discuss the product layout and process layout with suitable examples. (AKTU. 2011 - 12)
Ans. Plant Layout Can be Classified as :
(a) Process (or functional) layout
(b) Product (or line) layout
(c) Fixed position layout
(d) Combination layout
(a) Process Layout: -
It is also known as functional layout and is characterized by installing similar machines or similar operations at one location (place). For example, all lathe machines kept in one section called lathe sections all milling machines in one section called milling section and so on. Machines are arranged according to their functions. Process layout is generally recommended for job order production and non-repetitive kind of works.
Advantages: -
(i) Cheaper in comparison of others.
(ii) Shops can run independently.
(iii) It has flexibility. i.e. with change in production volume and product design, it can be changed.
(iv) Ratio of fixed cost to total cost is low.
(v) It promotes expertise in working and supervising one type of work because of similar operations being performed in one shop.
Disadvantages: -
(i) More material handling as compared to others. Automatic material handling is not easy.
(ii) For same volume of production, it needs more space.
(iii) Work-in-process inventory is large.
(iv) Production planning and control is relatively difficult.
(v) It requires more inspections and efficient co-ordination.
(b) Product Layout: -
It is also called line (type) layout. In this type of layout, the machines are arranged in the sequence in which the raw material will be operated upon. Product layout is recommended for continuous production which involves a continuous flow of in-process materials towards finished product stage.
Advantages: -
(i) Less space is required for same production volume.
(ii) Automatic material handling is easier, lesser material handling movements, time and low costs.
(iii) Work-in-process inventory is lesser.
(iv) Completion of same product takes less time.
(v) Production planning and control is simple.
(vi) Smooth and continuous work.
(vii) Semi-skilled workers can serve the purpose.
Disadvantages: -
(i) Layout flexibility is reduced.
(ii) Higher initial investment is required to set up production lines.
(iii) Break down of a single work station in the production line stops the entire production, leaving other work stations idle.
(iv) It involves less inspection as compared to process layout, but sometimes inspection becomes difficult when one inspector has to inspect many machines in two or more than two production lines.
(c) Fixed Position Layout: -
In a fixed position layout, the work piece remains fixed at one work place and manufacturing facilities are made to move towards it to work upon. Fixed layout is used to manufacture or repair a very big product like building, aircrafts, ships, road, etc.
Advantages: -
(i) It involves least or negligible movement of materials.
(ii) It is suitable for intermittent production.
(iii) It is possible to assign one or more skilled workers to a project from a start to a finish in order to ensure the continuity of work.
(iv) A number of different projects can be taken with same layout.
(v) Change in the sequence of operations and in product design can be easily accommodated.
Disadvantages: -
(i) It generally involves a low content of work-in-progress.
(ii) There appears to be under utilization of labour and equipments.
(iii) Higher material handling cost is associated with it.
(d) Combination Layout: -
It is a combination of both process and product layout, thus incorporating in itself the advantages of both types of layouts. Now-a-days, pure product or process layouts are rarely used. A combination layout is recommended where an item is being made is of different type and size. In this kind of layout, a set of similar manufacturing facilities are installed in one section to perform similar types of operations. Different sections of different manufacturing facilities are installed in the plant in the same sequence of operations in which these are required to produce the product.
Advantages: -
(i) Material handling is minimum, because the raw material moves along a line. Back tracking and zigzag movements are eliminated.
(ii) In this layout, failure of one machine does not stop the entire production line because other similar manufacturing facilities are unaffected.
(iii) It possesses all advantages of process and product layout besides the above advantages.
Disadvantages: -
(i) It involves a higher capital cost.
