Plant Layout Design - DOC by kvp14729

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									Plant Layout Design
What is Plant Layout?
The organization of a company’s physical facilities to promote the efficient use of
equipment, material, people and energy.

What are the Goals of Plant Layout Design?
      Minimize unit costs
      Optimize quality
      Promote effective use of people, equipment, space and energy
      Provide for employee convenience, safety and comfort
      Control project costs
      Achieve production deadlines

What Procedure is Followed in Plant Layout Design?
Plant Layout Procedure - Phase 1 Information Gathering

      Determine what will be produced
      Determine how many will be produced
      Determine what components will be made or purchased
      Determine required operations
      Determine sequence of operations
      Set time standards for each operation

Plant Layout Procedure - Phase 2 Production and Flow Analysis

      Determine the plant rate, R
      Determine the number of machines
      Balance production lines
      Study the flow requirement
      Determine activity relationships
      Layout each workstation

Plant Layout Procedure - Phase 3 Support Services

      Identify needs for personal and plant services
      Identify office needs
      Develop total space requirements
      Select material handling equipment
      Allocated area
      Develop plot plan and building shape

Plant Layout Procedure - Phase 4 Implementation and Evaluation

      Construct master plan
      Seek input and adjust
      Seek approvals
      Install
      Start up
      Follow up

What is Flow Analysis?
Considers the operations, transportations, inspections, delays, and storages required as a
part moves from receiving to shipping in a plant.

What are the goals of Flow Analysis?
      to minimize distance traveled
      to minimize backtracking
      to minimize cross-traffic
      to eliminate unnecessary steps in the process
      to combine steps in the process
      to minimize production costs

What plant flow analysis techniques are used?
      Process charts
      Flow diagrams
      Operations charts
      Process Charts
          o operations
          o transportations
          o storages
          o inspections
          o delays

Process Chart Example

Analysis of Process Charts
      Can I eliminate this step?
      Can I automate this step?
      Can I combine this step with another?
      Can I change the routing to reduce distances traveled?
      Can I move workstations closer together?
      Can I justify production aids to increase effectiveness?
      How much does this part cost to produce?

Flow Diagram
Graphical diagram which shows the path traveled by each part from receiving to stores to
fabrication of each part to final assembly to packout to warehousing to shipping. Flow
Diagram Example

Analysis of Flow Diagrams
Is there cross-traffic?

      results in congestion and safety hazards
      eliminated through proper placement of equipment, services and departments

Is there backtracking?

      costs three times as much as correct flow
      eliminated through proper location of operations

Are transport distances excessive?

      distance traveled costs money
      excessive material handling can degrade quality

Operations Charts
Graphically show the raw material, the buyouts, the fabrication sequence, the assembly
sequence, the equipment needs, the time standards, and a glimpse of plant layout.

The flow process chart combines the operations chart with the process chart. Effective
tools for summarizing plant activities.

Operations Chart Example

Summary of Flow Analysis
Provides critical information to layout designer including operation requirements,
material handling needs, storage needs, inspection requirements, delay reasons.
With this information, the designer is challenged to eliminate as many steps as possible,
combine steps, eliminate backtracking and cross-traffic, reduce distance traveled, reduce
production costs, improve quality and increase safety

On to Ergonomics and Job Design

								
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