What is a plant layout

what is a plant layout

Plant Layout | Objectives | Steps involved in designing

In the words of Mallick and Gandreau, “Plant layout is a floor plan for determining and arranging the designed machinery and equipment of a plant, whether established or contemplated, in the best place, to permit the quickest flow of material, at the lowest cost and with the minimum handling in processing the product, from the receipt of raw material to the shipment of finished product.”Estimated Reading Time: 8 mins. Plant layout is a plan for effective utilisation of facilities for the manufacture of products; involving a most efficient and economical arrangement of machines, materials, personnel, storage space and all supporting services, within available floor educationcupcake.usted Reading Time: 6 mins.

Once a suitable location of the plant has been decided upon, the next important issue is the design of the layout. Plant layout is the plan for arranging the physical facilities and manpower required to manufacture a product with the objective of utilizing them in an effective manner. Plant Layout — Objectives, Steps in Designing. Plant Layout is also known as facilities design. Plant layout constitutes planning of the amount of space required for all kind of activities in an industry, i.

The primary objective of layoutt layout is to what is a plant layout the movement of men and materials in the plant. Designing a proper layout is important because it has a direct relationship with efficiency of operations and cost of production.

A poorly designed layout will result in inefficiencies and losses throughout the existence of the plant. As Decisions regarding plant layout cannot pkant taken once and for all. Changes in process and techniques of production necessitate changes in plant layout. It is therefore important to design the layout in such a way that it is flexible to change. The primary objective of plant layout is to maximize production at minimum cost. The layout should be designed in such a way that it is flexible to change according to new processes and production techniques.

The layout should be able to satisfy the needs of all those who are associated with the production system such as workers, supervisors whxt, managers etc. Ensuring optimum utilization of men, materials, equipment and available space. Ensuring safety of workmen by minimizing and eliminating the chances of accidents. Flexibility in design how to add custom items to private server adapt to the changing future requirements.

Since decisions regarding layout design have considerable impact in the efficiency and profitability of a firm how can robots be useful to humans requires careful consideration.

The following are the steps involved in designing a layout:. Data about the size of the what is a plant layout, type of products to be produced, method of production to be adopted, extent of space available, extent of mechanization etc are to be collected. Based on the data gathered, a blue print has to be prepared for the floor plan. Care should be taken to ensure,that the layout provides wgat unhindered movement of men iw materials with minimum possible effort and time. The process chart and flow diagram depicting the various activities to be performed and the wnat between them has to be prepared.

A draft layout needs to be prepared clearly depicting the positioning of men and materials and the process flow. The draft layout should be circulated and discussions held with employees inviting suggestions for improvement.

Flaws pointed out need to be lxyout and suggestions received incorporated after due discussions. A test run is important to understand the wht of the layout in a real time work environment. Problems not noticed in the earlier stages can layoit at this stage. The initial problems noticed need to be modified and test runs should be continued for at-least a few times to ensure that olant layout is able to facilitate maximum production at minimum cost.

Plant Layout Objectives Steps involved in designing. Table of Contents What is a Plant Layout? Importance of a plant layout Objectives of plant layout Steps involved in designing a plant layout 1.

Collection of required data 2. Preparation of blueprint for the floor plnt 3. Preparation of process chart and flow diagram 4. Layoht of draft layout 5. Test run. Related Posts. Tags: businessbusiness management.

One Response Dr. Yerriswamy Wooluru. It is a good material for basics of plant layout for undergraduate students.

Dec 22,  · Plant layout is the plan for arranging the physical facilities and manpower required to manufacture a product with the objective of utilizing them in an effective manner. Plant Layout – Objectives, Steps in Designing Plant Layout is also known as facilities educationcupcake.usted Reading Time: 3 mins. Having an effective plant layout is one of the keys to success in factory management. It will not only have a direct effect on the efficiency of your operations but also affect the total operation of your company, including the production processes, inventory, dispatch, and educationcupcake.usted Reading Time: 8 mins.

Learn the fundamentals of plant layout, the different types of plant layouts and how it contributes to success in factory management. Lean Thinking has evolved over the years and while the latest buzzword is Industry 4. Having an effective plant layout is one of the keys to success in factory management. It will not only have a direct effect on the efficiency of your operations but also affect the total operation of your company, including the production processes, inventory, dispatch, and administration.

These views will change depending on the type of layout you wish to achieve. Here at TXM, we call a good plant layout, one that applies Lean principles to create a Lean plant layout. As you may know, Lean eliminates wastes, and deliver values to your customers with lower costs, high quality, shorter lead time, safer and high morale.

Lean facilities create a seamless flow for material and information, minimising handling time and effort, saves on floor space, shortens lead times to customers, increases productivity and quality. If you are designing or redeveloping your operations a Lean plant layout will help you create a more flexible and efficient use of your space. There are a variety of factors that differentiate a Lean plant layout from a Traditional plant layout. Traditional plant layout focuses more on process-based departments.

Similar machines are grouped into functional work centers or workshops. A typical traditional machinery factory might be separated into workshops of cutting, fabrication, machining, and assembly. Usually, there are walls between these different workshops, and materials are transported between department by forklifts.

To make production more economical, work is often done in batches in the name of economic batch quantity. This leads to high levels of work-in-process inventory and long lead times. Lean plant layout focuses on value streams, all value-added steps from raw materials until the delivery to your customer.

Lean layouts are more likely to combine processes horizontally across the factory, compared to vertical process departments like silos in a traditional facility layout. With a Lean layout, different machines tend to be grouped by product families a group of products that passes through common processes or equipment and they have similar work content. As the processes are connected in a Lean layout, much less material handling is required. The Lean layout reduced material handling dramatically, forklifts were not required anymore, batch sizes were reduced, this led to less work-in-process inventory and shorter lead times.

Most manufacturers have several large machines that are key to the quality and cost of the product. The traditional mass production requires larger equipment to make larger batches within less time and lower cost. The large equipment might be efficient on a per-unit basis, but actually, impede material flow through the facility. Traditional plant layout developers place these large machines in layouts but impede materials flows and cause stoppages and blockages.

They proudly show us how much capacity they have, how fast they can run, and how low the cost-per-unit can be. However, they usually forget to mention that the large machinery is usually expensive, brings higher work-in-process inventory before and after, and is inflexible when demand changes, which happens regularly.

Instead of the too-large-to-be-easily-moved machinery in traditional plant layout, Lean Layouts try to use smaller equipment dedicated to each product family. Right-sized equipment is selected to suit the demand of the value streams, with quick changeover to enable smaller batch size. Some manufacturing cells even have equipment on casters for easy movement to align with takt time from the customers.

Lean Layouts use small and precisely sized equipment to make the flow to the customers faster and more flexible, which helps manufacturers be more agile to demand. Factories are meant to be functional. Sometimes aesthetic considerations are allowed to over-ride common sense. We have seen factories that are spectacularly beautiful on the inside, with large spaces between lines or machines or even with fountains, trees, tables, and chairs between machines.

Usually, the excess space is quickly occupied with excess work-in-process inventory. The wide spaces also lock in excessive movement and transportation waste. So, when designing a factory layout, forget aesthetic beauty and focus on function. At TXM we believe a well-designed Lean production cell operating smoothly to takt time is actually a thing of beauty in itself!

Factories have to organise everything efficiently on tiny space as the land is precious there, which drove Japanese factories towards Lean plant layouts. Lean plant layouts usually have very little room between machines thus preventing inventory from building up, as well as reducing motion and transportation. Less waste will be generated, excessive inventory will reduce, as will over-production, motion, and transportation.

Moreover, when there is a waste, it becomes visible. Lean facility layout makes the flows of people, material, and information more streamlined, and use visual controls to make obstacles and stops of flows visible.

Lean plant layouts use visual controls for better communication and set visual standards. Adhesive floor markings are used instead of area painting applied on the shop floor, which makes the communication of layout changes easier and cheaper.

What is a Good Lean Plant Layout? So how can you tell your plant layout is a suitable Lean plant layout? Here are five criterions you can apply to see if your layout is really a Lean plant layout. Lean plants aim at delivering products to customers on time in full and defect-free. The entire value stream is either continuous flow to customers or pulled by real consumption from customers.

Lean plant layout not only allows the entire value stream to be connected with external customers but also connects processes with internal customers. Instead of process silos in the traditional batch production, Lean Plant Layout brings machines closer, makes production with smaller batches or even in one-piece flow.

It physically brings your internal customers next to you, which allows defects to be communicated from the next process with short response time and with fewer defect products produced. Connecting supplier processes, customer processes, and communication makes the process of continuous improvement much easier. They are raw material flows, work-in-process, finished goods, consumables flow, people movement, waste flow, and information flow.

Long-distance, long setup times, big batch-oriented machines, poor maintenance, and process bottlenecks, are typical obstacles to Lean flows. A good Lean Plant Layout will make these flows run efficiently through all processes. We want to see these processes running smoothly and not blocking the flow of materials, information or people. The blocked flows in the plant should be avoided in the Lean Plant Layout Development.

If there are any blocked flows, they can be easily detected and removed. One example is easily set up and easily maintained machines being placed together under the same value stream with balanced cycle time which streamlines the process as much as possible.

A poor plant layout will have the effect of increasing wastes. As discussed earlier, traditional mass production creates long changeover times. Over-production of large batch size products will fill the empty space with excessive work-in-process inventory. Excessive inventory will subsequently create more transportation and over-processing. Large batch size makes other products or processes wait.

Large batches also amplify the effect of defects, because they are often found only after a large batch has been created. Lean Layouts should have fewer wastes and promote continuous improvement. Continuous flow or one-piece flow makes just in time production possible, with less inventory and waiting time. Smaller spaces between machines not only reduces motion for operators but also makes it hard to overproduce.

There simply is not enough space for excess work in progress so you are forced to fix the causes of this work in progress. After the new layout is implemented, there could be a variety of changes: expansion due to demand increase, new product launches, changes in methods or equipment, or safety and environmental requirements.

Saving space for future expansion or new products is also worthwhile, rather than giving up space to excessive inventory. A Lean layout should not be developed by just one group of stakeholders, it needs to be a collaborative effort from a range of stakeholders in the business after a future state map has been created. However, emphasis on user-experience is usually not sufficient for developing a successful plant layout. It might just lead to a new plant layout similar to the current one with comparable wastes.

A good Lean plant layout should set a new standard for everyone. A key step to prepare for a successful Lean plant layout is to train all involved people in core Lean skills required at the new Lean layout. Some basic Lean tools, such as standardised work, 5S, continuous flow and quick changeover are relevant. Without these skills, operators tend to complain about the new layout, instead of solving problems.

It might be painful while you are developing a Lean plant layout, but you will get rewarded by getting less pain afterward. Compared to traditional plant layout, a well-designed Lean plant layout can bring a variety of benefits:. Remember — there is no perfect Lean plant layout; there will always be room for further continuous improvement. Back to Top. Privacy policy and cookies This site uses cookies.

By continuing to browse the site you are agreeing to our use of cookies. Read our Privacy Policy. Many plant managers today experience the same pain points that were common years ago: At capacity with bottlenecks in production. Too much fire fighting and fixing problems. Long production and lead times. An unpleasant work environment with too much finger-pointing, blame, and excuses.

What are the differences between a Traditional and Lean Plant Layout? What is a good Lean Plant Layout? What is a Lean Plant Layout? Process-Based vs Value Stream-Focused Traditional plant layout focuses more on process-based departments. The traditional process-based layout grey vs Lean Value Stream-Focused Layout green Cost-Per-Unit vs Flexible Most manufacturers have several large machines that are key to the quality and cost of the product.

Beautiful vs. Visual Controls Factories are meant to be functional. Example of a factory with fountains, trees, tables and chairs between machines What is a Good Lean Plant Layout?

5 Replies to “What is a plant layout”

Add a comment

Your email will not be published. Required fields are marked*