Flow
Pattern in Plant Layout
One of the
most important phases of plant layout is to achieve an optimum effective flow
of materials (raw materials, and in-process materials) through the plant.
Naturally the principle of minimum movements (i.e., number of movements and
distance travelled in one move) forms the basis for optimum effective flow.
The
principle of minimum movements reduces material handling costs, in- process
inventory and space for processing. The supervision and control become simpler.
While designing a new plant layout, generally the flow patterns are decided
earlier and then a system of facilities (machinery, material and building,
etc.,) is designed and built around the flow pattern.
As far as
possible a flow pattern should be simple in order to have easy supervision and
control.
Steps in planning the layout for a new enterprise
Following is a brief
analysis of the procedure for laying out the plant of a new undertaking:
1. Objectives:
Every
entrepreneur is guided by basic objectives around which the business activities
are to planned and executed.
The
usual basic objectives are:
(a) Large
volume of output,
(b)
variety of output,
(c)
quality of the output, and
(d) low
cost per unit of output.
The
management should outline the layout goals touching upon the capacity,
production rate, plans for future expansion etc. Production of the specified
product at the required rate of output at economical cost is obviously the
objective of new plant arrangement.
2. Accumulation of the Layout Data:
After the
formulation of broad objectives, the layout engineer should collect the data
relating to operational processes and physical equipment necessary for
manufacturing a given product. The process analysis is the critical step in
layout procedure.
The nature
of the operations and their sequence have to be studied and then it will be
possible to indicate the location of machines, deployment of personnel and
arrangement of equipment.
The
process analysis yields the following information:
(i) Bill
of materials and list of parts required
(ii)
Equipment and machine requisition
(iii) Personnel-skilled
and trained-necessary for operating the machines
(iv)
Sequence and schedule of operations
3. Preparation of Charts, Templates, Model and Drawings:
On the
basis of data collected, the operation process charts, flow process diagrams,
templates and model relating to the operations and machines are to be prepared
for visualising the perspective of layout. They portray in detail the process
of work in all its facets.
4. Compilation of an Overall Plan:
An overall
plan embracing the flow of production with allied arrangement should be
compiled.
Floor
arrangement and flow plan for machinery and processes should be thought of.
Depending on the type and scale of industrial operations, the system of layout
should be decided upon. Either product layout, or process layout or their
combination would be adapted in manner as to fulfil the management policies
consistent with the technical aspects of the processes analysed.
The
building plan suited to the needs of the layout should be drawn.
A model
plot-plan indicating the site, building and its utilisation should be prepared.
Plans which permit economical processing, easy materials handling, production
flexibility and provision for expansion with minimum investment should be
compiled after careful survey and analysis.
5. Relationship:
The
relationship between various departments is to be charted and space
requirements of all the activities are to be calculated.
6. Layout Templates:
Layout
templates and models of machines are to be fixed as per flow plan of operations
to achieve balanced capacity.
7. Finalised Layout:
Finalised
layout drawings and plant plans are to be submitted to specialists for review
and suggestions. Modifications whenever advisable should be made as per their
opinions.
8. Layout Alteration:
The
building suited to the layout should be bought or constructed or alterations in
the existing building may be made as required for installing the layout.
Total
floor space, floor load, ceiling heights, doors, windows specifications,
elevator size, staircases, passage areas, storage areas-details of these
aspects are to be noted and appropriate adjustments in the building have to be
made for achieving the layout objectives.
9. Arrangement of Service Activities:
Auxiliary
activities are to be provided for in the layout to facilitate smooth working of
the plant and assist the personnel in carrying out their assignments properly
and promptly.
Service
activities include:
(a)
Materials handling system through hand, trucks, conveyors, rollers, etc. should
be introduced.
(b)
Storage, receiving and transporting areas are to be located in contiguity for
quick movement of work-in-process and dispatch of finished goods.
(c)
Inspection cribs or stations are to be located at each stage of operations as
per the production plan.
(d)
Provision for maintenance, repairs and servicing of machinery should be made.
(e)
Officers or departments doing allied work are to be positioned adjacent to one
another.
(f)
Employee facilities like locker rooms, toilets, first-aid clinics, dispensary,
canteens, parking space, recreation as well as safety devices are to be
provided for.
10. Installation and Test-Run:
(a) As per
the overall plan supported by charts, diagrams, models, plot plans, the
machines, equipment, service stations etc. should be actually installed in the
building selected.
(b) When
the building is ready and the installations are completed, the new plant should
be “turned over to process
engineers for trying out of pilot lots.” Test operation of
the new plant should be conducted.
The
test or trial operation of the new plant would reveal the product results with
reference to the design, processing methods, materials handling, quality
inspection and safety of the machines. Any hitches in the new plant discovered during
the trial- run shall have to be corrected. Thereafter, the plant and its
physical facilities are to be handed over for actual production under the
guidance of production engineers and administrators.
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