Plant Lay Out 2994
Plant Lay Out 2994
Plant Lay Out 2994
College of Engineering
Mechanical Engineering Department
Lecture Notes of MANUFACTURING PROCESSES (ME337), 3rd Year (2015-2016)
Lecturer: Dr. Hassanein Ibraheem Khalaf
2.1. Introduction
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University of Basrah
College of Engineering
Mechanical Engineering Department
Lecture Notes of MANUFACTURING PROCESSES (ME337), 3rd Year (2015-2016)
Lecturer: Dr. Hassanein Ibraheem Khalaf
necessarily mean planning a new enterprise only. However, it also involves minor
improvements, here and there, in the existing layout, expansion of the existing plant,
re-layout of the existing plant and layout of a new proposed plant. In a best possible
plant layout, material handling and transportation is minimized and efficiently
controlled. Bottlenecks and points of congestions are eliminated so that the raw
material and semi-finished goods move fast from one work station to another. Work
stations are designed suitably to facilitate the smooth processing of the proposed or
undertaken product in the most effective, most efficient and most economical manner
in the minimum possible time. Optimal spaces are allocated to production centers and
service centers. The primary goal of plant layout is to maximize profits by setting up
the best possible arrangements of all plant facilities to the maximum advantage of
reducing the cost of production of the proposed product.
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University of Basrah
College of Engineering
Mechanical Engineering Department
Lecture Notes of MANUFACTURING PROCESSES (ME337), 3rd Year (2015-2016)
Lecturer: Dr. Hassanein Ibraheem Khalaf
minimum. Working conditions as far as possible should be safer and better for the
satisfaction of the workers. There should be an increased flexibility for changes in
product design and for future expansion. There should be full utilization of whole
space of the shop and plant layout. The work methods and reduced production cycle
times should be improved and the plant maintenance must be simpler. There should
be increased productivity and better product quality with reduced capital cost. A good
layout facilitates materials to move through the plant at the desired speed with the
minimum possible cost.
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University of Basrah
College of Engineering
Mechanical Engineering Department
Lecture Notes of MANUFACTURING PROCESSES (ME337), 3rd Year (2015-2016)
Lecturer: Dr. Hassanein Ibraheem Khalaf
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University of Basrah
College of Engineering
Mechanical Engineering Department
Lecture Notes of MANUFACTURING PROCESSES (ME337), 3rd Year (2015-2016)
Lecturer: Dr. Hassanein Ibraheem Khalaf
Advantages
Its main Advantages are:
1. Layout is highly flexible for varieties of products having intermittent demand
as the type of product and the related processes can be easily altered without
any change in the layout.
2. There is a minimum movement of men, material, and tooling during
manufacturing process.
3. The material is drastically reduced.
4. Highly skilled operators are required to complete the work at one point and
responsibility for quality is fixed on one person or the assembly crew.
5. Every personnel of manufacturing team is responsible for quality work for
manufacturing the product.
Disadvantages
The major disadvantages of this layout are:
1. The cost of equipment handling is very high.
2. Labors and equipments are difficult to utilize fully.
3. It is limited to large items only.
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University of Basrah
College of Engineering
Mechanical Engineering Department
Lecture Notes of MANUFACTURING PROCESSES (ME337), 3rd Year (2015-2016)
Lecturer: Dr. Hassanein Ibraheem Khalaf
Applications
This type of layout is mostly adopted for extremely large items manufactured in
very small quantity such as ships, aero planes, aircraft, locomotive, ship assembly
shops, shipyards, boilers, reactors etc.
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University of Basrah
College of Engineering
Mechanical Engineering Department
Lecture Notes of MANUFACTURING PROCESSES (ME337), 3rd Year (2015-2016)
Lecturer: Dr. Hassanein Ibraheem Khalaf
Advantages
The major advantages of this layout are :
1. There exists a wide flexibility regarding allotment of work to equipment and
workers.
2. There is a better utilization of the available equipment.
3. Comparatively less numbers of machines are needed in this layout and hence
thus reducing capital investment.
4. There is an improved product quality, because the supervisors and workers
attend to one type of machines and operations.
5. Varieties of jobs coming as different job orders thus make the work more
interesting for the workers.
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University of Basrah
College of Engineering
Mechanical Engineering Department
Lecture Notes of MANUFACTURING PROCESSES (ME337), 3rd Year (2015-2016)
Lecturer: Dr. Hassanein Ibraheem Khalaf
6. Workers in one section are not affected by the nature of the operations carried
out in another section. For example, a lathe operator is not affected by the rays
of the welding as the two sections are quite separate.
Disadvantages
The major disadvantages of this layout are :
1. This layout requires more space in comparison to line or product layout for the
same amount of production.
2. Production control becomes relatively difficult in this layout.
3. Raw material has to travel more which increases material handling and the
associated costs.
4. This layout requires more efficient co-ordination and inspections.
5. Increased material handling cost due to more movement of process raw
material to various paths
6. More material in process remains in queue for further operations.
7. Requires large in-process inventory.
8. Completion of same product takes more time.
Application
1. This layout is used for batch or moderate production.
2. It specify path for group technology.
operated upon. In this type of layout all the machines are placed in a line according to
the sequence of operations, i.e., each following machine or section is arranged to
perform the next operation to that performed by its preceding machine or section. In
this layout raw material starts from one end of production lines and moves from one
machine to next along a sequential path. Line layout is advantages in the continuous-
production system where the number of end products is small and the parts are highly
standardized and interchangeable. It is suitable for products having steady demand.
This layout may have operational sequence namely forging, turning, drilling, milling,
grinding and inspection before the product is sent to the finished goods store for
packing and shipment. This layout is used for mass production and ensures smooth
flow of materials and reduced material handling. Breakdown of any machine in the
line in this layout may result in even stoppage of production.
Advantages
Its main advantages are:
1. It involves smooth and continuous work flow.
2. It may require less skilled workers
3. It helps in reducing inventory.
4. Production time is reduced in this layout.
5. Better coordination, simple production planning and control are achieved in this
layout.
6. For the same amount of production, less space requirements for this layout.
7. Overall processing time of product is very less.
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University of Basrah
College of Engineering
Mechanical Engineering Department
Lecture Notes of MANUFACTURING PROCESSES (ME337), 3rd Year (2015-2016)
Lecturer: Dr. Hassanein Ibraheem Khalaf
In this layout, it is noted that, no matter the product varies in size and type, the
sequence of operations remain same or similar. This layout is suitable when similar
activities are performed together thereby avoiding wasteful time in changing from one
unrelated activity to the next. It focuses on avoiding unnecessary duplication of an
effort. It is preferable for storing and retrieving information changing related to
recurring problems thereby reducing the search tin understanding information and
eliminating the need to solve the problem again. It is also useful when a number of
items are produced in same sequence but none of the items are to be produced in bulk
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University of Basrah
College of Engineering
Mechanical Engineering Department
Lecture Notes of MANUFACTURING PROCESSES (ME337), 3rd Year (2015-2016)
Lecturer: Dr. Hassanein Ibraheem Khalaf
and thus no item justifies for an individual and independent production line. There are
some merits, demerits and application of this layout which are given as under :
Advantages
The Advantages of this type of layout are:
1. Reduction in cost of machine set-up time and material handling of metals.
2. Elimination of excess work-in-process inventory which subsequently allows the
reduction in lot size.
3. Simplification of production planning functions, etc.
Disadvantages
The major disadvantages of this layout are :
1. Change of the existing layout is time consuming and costly.
2. Inclusion of new components in the existing component requires thorough
analysis.
3. Change of input component mix may likely to change complete layout
structure.
4. Change of batch size may change number of machines.
Application
Manufacturing circular metal saws, hacksaw, wooden saw, files and crank
shaft.
Table 2.1 Comparison of Line or Product Layout and Process or Functional Layou
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University of Basrah
College of Engineering
Mechanical Engineering Department
Lecture Notes of MANUFACTURING PROCESSES (ME337), 3rd Year (2015-2016)
Lecturer: Dr. Hassanein Ibraheem Khalaf
13 Work flexibility is very less in this layout Work flexibility is more in this layout
Space required for same amount of production is Space required for same amount of
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less. production is comparatively more.
Time taken in completion of product is
15 Time taken in completion of product is less
more.
16 Less skilled workers are required comparatively. More skilled workers are required.
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University of Basrah
College of Engineering
Mechanical Engineering Department
Lecture Notes of MANUFACTURING PROCESSES (ME337), 3rd Year (2015-2016)
Lecturer: Dr. Hassanein Ibraheem Khalaf
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