The presentation content Introduction Objective, Factors affecting layout, Scope of facility of layout, Type of facility of layout and Process designing Prerequisites for Developing a Facility Layout Level of plants, Technique for designing a facility layout, Case study with example

1. A Presentation By:
AMOL GORGILE (PM/2018/411)
NIPER HYDERABAD
MBA PHARM

2. Introduction
Objective
Factors affecting layout
Scope of facility of layout
Type of facility of layout
Process designing
Prerequisites for Developing a Facility Layout
Level of plants
Technique for designing a facility layout
Case study

3. The layout facility is the physical location of the various department/units
of the facility within premises of the facility
 The department may be located based on the considerations such as:
Less walking distance
Logical sequence of the processing requirement of the product
Emergency services, etc.
Material,
Product,
Machinery,
Labor,
Location,
Managerial,
Type of industry,
Policies.

4. Objectives of an
Effective Facility
Layout include:
Improved
quality
control
Shorter
production
cycles
Elimination
of
bottlenecks
Efficient
utilization of
labor
Minimum
material
handling
Reduction in
production
delays
Related to material
•Less material handling and minimum
transportation cost
•Less waiting time for in-process
inventory.
Related to work place
•Safe working condition from the
point of ventilation, lighting etc
•Minimum movement of worker
•Least chances of accident fire etc
•Proper space for machines, worker,
tool, etc.

5. Process layout-
 suitable when product having
standard features is to be
produced in large volumes.
 Process layout, also called
functional layout or batch
production layout, is
characterized by the grouping
together of similar machines,
based upon their operational
characteristics.
Product layout: In Product layout, also called straight line layout,
machinery is arranged in one line as per the sequence of production
operations. Materials are fed into the first machine and finished products
come out of the last machine.

6. Fixed position layout: This type of facility layout is used to assemble
products that are too large, heavy or fragile to move to a location for
completion. In the fixed position layout, machinery, men, as well as other
pieces of material, are brought to the location where the product is to be
assembled.
Grouping technology layout: it is a cellular manufacturing layout is made
for a single part family i.e. parts with common characteristic. In this layout
dissimilar machines are grouped into cells and each cell function like product
layout

7. Combination or hybrid layout: It is difficult to use the principles of
product layout, process layout, or fixed location layout in facilities that
involve fabrication of parts and assembly. In such cases, hybrid layout is
sought. A hybrid layout attempts to combine efficiency of a product layout
with flexibility of a process layout. Fabrication tends to employ the
process layout, while assembly areas often employ the product layout.

8. Developing process charts: A process chart is the graphical representation
of production activities performed by an organization. These charts
facilitate a systematic analysis and demonstration of the entire production
process. They are further classified into two categories, namely operation
process chart and flow process chart.
Making process flow diagrams: A process flow diagram represents the
movement of materials on a floor layout. These diagrams help an
organization in avoiding needless material movement and rearranging
facility operations.
Developing machine data cards: A machine data card helps in developing
equipment layout by providing information related to power and materials
handling requirements along with capacity and dimensions of different
machines.
Visualizing the layout: This technique involves creating duplication of
machines and equipment and arranging them in two- or three-dimensional
plans for determining the effectiveness of a layout.

9. IV
III
Support Services
II
Production & Material Flow Analysis
I
Information Gathering
Implementation & Evaluation

10. Levels of Plant Layout Design
There are four levels of detail in plant layout design
Site Layout
• shows
how
• the
building
• should be
• located
in a
• proper
way
Block
Layout
• shows
the
• sizes of
• the dept
• in the
• buildings
Detailed
Layout
• shows
• arrangeme
nt
• of
equipment
and
• workstatio
n
• in the dept
Workstatio
n Layout
•shows the
•locations
•of every
•part of
the
•workstatio
n

11. Two main techniques of designing a facility layout are Block
Diagramming & Richard Muther’s Systematic Layout Planning (SLP)
Block diagramming: The block diagram can be prepared by using
the following steps:
• Analyze the unit load summary that provides information about
the average number of unit loads moved between different
departments of an organization.
• Calculate the composite movements (back-and-forth movement)
of the unit load between the departments and rank them from
the highest movement to the lowest movement.
• Place the trial layouts, which are designed using the ranking
between departments, on a grid. This grid represents the relative
distance between the departments.

12. SLP is a technique developed by Richard Muther & associates. The 3
fundamental areas of the technique are Relationships, Space and
Adjustment.
This technique combines quantitative measurement of materials
movement with non-flow considerations such as noise, fumes,
temperature, supervision, communications, personnel comfort and
movement.
In this technique, a grid displays the ratings of the relative
importance of the distance between different departments of an
organization. This grid is also called ‘closeness rating chart’. In this
chart, the rating for department A relative to department B is
similar to the rating of department B to department A. Closeness
ratings are given to departments in the form of codes, which depict
the desired closeness of the departments according to the relative
strength of their closeness.
Advantage: This technique clearly documents the logic of the layout
and easily allows input from all levels of staff.