UNIT II

PLANT LAYOUT
INTRODUCTION:-
The chief object of an industrial concern is to maximize the profit through the
minimization of cost of production. This object can be achieved only when the plant is of the
right size and at a right place where economies of all kinds in production are available
Plant layout is concerned with deciding wherein the factory to locate the machines, facilities,
equipment, operators and material how to organize and how to organize them within the
factory; production of goods or delivery of services. The issue of deciding on a factory layout
is one of the most important issues facing Production Managers. It is also one of the first
things that are noticeable about a factory. Layout not only determines the appearance of the
production facility but also has other important repercussions for the whole operation. Even
small changes in the layout such as position of a machine or stores can affect the flow of
material inside the factory. That is why the issue of production layout is always associated
with the issue of flow. Companies need to pay attention to layout and flow design.
The efficiency of production depends on how well the various machines; production facilities
and employee’s amenities are located in a plant. Only the properly laid out plant can ensure
the smooth and rapid movement of material, from the raw material stage to the end product
stage. Plant layout encompasses new layout as well as improvement in the existing layout
It may be defined as a technique of locating machines, processes and plant services within the
factory so as to achieve, the right quantity and quality of output at the lowest possible cost of
manufacturing. It involves a judicious arrangement of production facilities so that workflow
is direct.
PLANT LOCATION:-
The problem of location is generally and mostly faced by an entrepreneur while
starting a new industrial concern but it is equally important while taking a decision for
establishing a new branch of an existing plant or shifting the established plant to a new site.
The problem of location implies several economic and engineering implications and
therefore, before taking a decision for establishing a new plant or for shifting an existing
plant or for starting a new branch of an existing plant, all relevant factors affecting the
profitability of the concern should be taken into account because the location of the plant may
well have a substantial effect upon the operational viability of the concern.
The production manager generally feels the influence of wrong decision making in plant
location in the following two areas:
First, the location of the plant has a direct influence on the cost of production as well as on
the effectiveness of marketing. One authority has pointed out that manufacturing and
distribution costs may increase by 10 percent simply by virtue of the wrong choice of the
location; and
Secondly, once a plant location is chose, it cannot be changed in the near future without much
difficulty and the concern will be compelled to remain in that location for a long time.
Factors of plant location:
1. Transportation cost: The location of industries is governed in the first instance by the
cost of transportation. When the business people select the location near the market on that
time there is a chance for reducing the cost.
2. Labour cost: For the business location the labour also very important factors. So to choose
the area where the labour have more supply along with low cost.
3. Availability of raw materials: The idea location with reference to raw materials is one
where at least the main raw materials are available in required and that required quality.
4. Proximity to the market: Market is another factor effecting the location. Industrial units
using pure raw materials and tried locate near to the market.
5. Fuel and power: An uninterrupted and adequate supply of fuel and power is a major
factor determining the location of an industrial unit.6.climatic conditions:
6. Climate conditions: also influence the location decision. Some industries need special
type of climate to run the unit effectively.
7. Personal factors: Personal preferences and prejudices of an entrepreneur also play a vital
role in choice of location.
8. Govt. policy: In planned economy govt, also plays an important role on the location of
industry. In India govt. follows the policy of balanced regional growth of the country.
Other considerations:
1. Politics
2. Culture
3. Economic conditions
4. Momentum of early start
Selection of a site:
1. Urban area
2. Suburban area
3. Rural areas
MEANING AND DEFINITION:-
Location of a plant should be fixed in such a manner that people interested in its success can
sell goods most profitably and manufacture them with least expense. Plant location defined a
place where plant or factory or business unit is to be located for maximum operating
economy and effectiveness.
PLANT LAYOUT:-
“A good layout results in comforts, convenience, appearance, safety and profits. A poor
layout results in congestion, waste frustration and inefficiency”.
LAYOUT
“Plant layout means planning for the location of all machines ,employee work
stations ,customer service areas ,and flow patterns of materials and people around, into and
within buildings,” –Norman Galther
MEANING OF PLANT LAYOUT:-
‘Plant layout’ broadly means the arrangement and location of different departments and of
the machinery and equipment within a department. It is one of the most important problems
for new industrial enterprises, after deciding the location of the plant, to make effective
arrangement for housing the plant. It is in more specific sense a planning of the space
available for the activities and facilities associated with the total manufacturing plant with a
view to enabling the plant to function most effectively.

OBJECTIVES OF PLANT LAYOUT:-

The principal objective of a proper plant layout is to maximize the production at the
minimum of the costs. This objective should be kept in mind while designing a layout for a
new plant as well as while making the necessary changes in the existing labour in response to
changes in management policies and processes and techniques of production. Besides, it must
satisfy the needs of all people associated with the production system, i.e., workers,
supervisors and managers.
If a layout is to fulfill this goal, it should be planned with the following clear objectives in
mind:
1. Economies in handling of materials, work-in-progress and finished stock.
2. Ensuring optimum utilization of men, materials, equipment and space available.
3. Minimizing work-in-process and maximizing inventory turnover. The material should
move rapidly through the plant and points of congestion should be eliminated to have low
levels of inventory.
4. Minimizing changes of delays and bottlenecks in production system. It, ensures a good
work flow avoiding accumulation of work at vital points.
5. Ensuring efficient supervision and production control.
6. Avoiding frequent changes so that production program is not upset causing the cost of
production to rise.
7. Ensuring satisfaction for the workmen by eliminating or at least minimizing the chances of
accidents.
8. Providing adequate and conveniently located service centers.
9. Boosting up employee movable by providing employee comforts and satisfaction.
10. Ensuring flexibility of layout for varying needs of the enterprise.
CRITERIA OR PRINCIPLES OF A PERFECT LAYOUT:-
The main objective of an enterprise is to maximize the production and minimize the cost.
The process of plant layout may be said to be an effective one in so far as it helps minimize
movement of machines and personnel, facilitates the manufacturing process and reduces the
cost of production. What is an efficient or perfect layout cannot be defined with any
precession. However the following criteria should be satisfied or the following principles
should be followed by an efficient plant layout:
1. Maximum Flexibility: A good layout will be one which can be modified to meet
changing circumstances. It must be capable of incorporating, without major changes, new
equipment to meet technological requirements or to eliminate waste.
2. Maximum Coordination: Layout must be considered as a whole and not in parts. It
should be a master blueprint for coordinating all operations. It should clearly define the
interrelationships between various machines, departments and personnel and should
provide for coordinated efforts. For example, entry into and disposal from any department
should be in such a manner that it is more convenient to the issuing or receiving
departments.
3. Maximum use of Volume: Maximum use of volume available should be made. For
example, conveyors can be run above head height and used as moving work in progress or
tools and equipment can be suspended from the ceiling. This principle is particularly true
in stores where goods can be stocked at considerable heights without inconvenience.
4. Maximum Visibility: The workers should be so arranged that there is no difficulty in
supervision, coordination and control. There should also be no ‘hiding-places’ into which
goods can be mislaid. Goods-raw materials and ready stock-must be readily observable at
all times. It will reduce the pilferage of material and labour.
5. Maximum Accessibility: All servicing and maintenance points should be readily
accessible without making any hindrance to the production process. For this purpose, there
must be sufficient space between different machines so that raw materials, machines and
workers may move easily and comfortably from one place to another. It will ensure a
regular flow in production.
6. Maximum Movements: The layout should be so planned that there must be least
movements of goods and workers. All movements should be as far as possible direct.
Unnecessary and indirect handling of materials will add to the cost of the product without
adding to its value and hence such movements should be avoided.
7. Minimum Discomfort: The layout must be designed in such a manner that may cause
minimum discomfort to the working force. Poor lighting, excessive sunlight, heat, noise,
vibrations and smells should be avoided or minimized. The statutory requirements of the
Factories Act 1948, should be faithfully followed.
8. Inherent Safety, Maximum Security, and Visible Routes: All layouts should be free
from any danger to any person working on the machine. Care must also, be taken for the
safety of passerby. Similarly, safeguards against fire, moisture, theft, and general
deterioration should be provided, as far as possible, in the original layout. Definite lines of
travels should be provided. No gangway should ever be allowed to use for storage
purposes, even temporarily.
ADVANTAGES OF A GOOD LAYOUT:
1. To the Worker :
a) Reduction in the effort of the worker.
b) Reduction in number of handlings.
c) Extension of the process of specialization.
d) Permits activities at maximum efficiency.
e) Better working conditions.
f) Reduction in the number of accidents.
2. In labour Cost:
a) Reduction in the number of workers.
b) Increase in production per man-hour.
c) Reduction in the length of haul.
3. In other Manufacturing costs:
(a) Maintenance and tool replacement costs are reduced.
(b) Spoilage and scrap is minimized.
(c) Greater saving in the waste of raw material consumption.
(d) Improved quality of product due to reduction in the number of handling.
4. In Production Control :
(a) Provision of adequate and convenient storage facilities.
(b) Better conditions for receipts, shipment and delivery.
(c) Increased pace for production.
(d) Enabling the prediction of production time.
(e) Moving of work in process by most direct times.
5. In Supervision :
(a) Helps in easing the burden of supervision.
(b) Reduces the amount of inspection.
 (c) Reduces the cost of supervision.
6. In Capital Investment :
(a) Investment in machinery and equipment is reduced because of
i. Increase in production per machine,
ii. Utilization of idle machine time, and
iii. Reduction in the number of operations per machine.
FACTORS INFLUENCING PLANT LAYOUT:
1. Nature of the Product: The nature of product to be manufactured will significantly
affect the layout of the plant. Stationary layout will be most suitable for heavy
products while line layout will be best for the manufacture of light products because
small and light products can be moved from one machine to another very easily and,
therefore, more attention can be paid to machine locations and handling of materials.
2. Volume of Production: Volume of production and the standardization of the product
also affect the type of layout. If standardized commodities are to be manufactured on
large scale, line type of layout may be adopted. If production is made on the order of
the customers, the functional layout is better to be adopted.
3. Basic Managerial Policies and Decisions: The type of layout depends very much on
the decisions and policies of the management to be followed in producing a
commodity with regard to size of plant, kind and quality of the product.
4. Nature of Plant Location: The size, shape and topography of the site at which plant
is located will naturally affect the type of layout to be followed in view of the
maximum utilization of space available.
5. Type of Industry Process: This is one of the most important factors influencing the
choice of type of plant layout. Generally the type of layout particularly the
arrangement of machines and work centers and the location of workmen varies
according to the nature of the industry to which the plant belongs.
6. Types or Methods of Production: Layout plants may be different according to the
method of production proposed to be adopted. Any of the following three methods
may be adopted for production
i. Job order production,
ii. Batch production, and
iii. Mass production.
Under job production goods are produced according to the orders of the customers
and therefore, specifications vary from customer to customer and the production
cannot be standardized. The machines and equipment can be arranged in a manner to
suit the needs of all types of customers.
7. Nature of Machines: Nature of machines and equipment also affects the layout of
plant. If machines are heavy in weight or creates noisy atmosphere, stationary layout
may reasonably be adopted.
8. Climate: Sometimes, temperature, illumination and air are the deciding factors in
deciding the location of machines and their establishments.
9. Nature of Materials: Design and specifications of materials, physical and chemical
properties of materials, quantity and quality of materials and combination of materials
are probably the most important factors to be considered in planning a layout.
10. Type of Machine and Equipment: Machine and equipment may be either general
purpose or special purpose. In addition. Certain tools are used. The requirements of
each machine and equipment are quite different in terms of their space, speed and
material handling process and these factors should be given proper consideration
while choosing out a particular type of layout.
DIFFERENT TYPES OF PLANT LAYOUT:
 There are three basic types of plant layout:
(i) Product or line layout,
(ii) Functional or process layout, and
(iii) Stationary layout.
1. PRODUCT LAYOUT: Product or line layout is the arrangement of machines and
equipment in a line (not always straight) or a sequence in which they would be used in
the process of manufacture of the product or group of related products. In this layout,
materials are worked out into finished stock through a series of integrated operations
(operated one after the other in a sequence) that is arranged in a line. The machines
under this plan may be arranged either in U –shaped or in line ape as shown below.

This layout is best suited to manufacturing units carrying out continuous mass
production where raw materials are fed at one end and the finished products are taken
out at the other end. There may be separate product line for each type of product using
different types of machines or using machines of the same type.

Line Shaped
Advantages of Product or Line Layout:
1. Smooth Flow of Production: This plan ensures steady flow of production with economy
because bottlenecks or stoppage of work at different points of production is got
eliminated or avoided due to proper arrangement of machines in sequence.
2. Mechanization of Material Handling: Since machines are arranged in sequence of
operations, the continuous flow of materials in a line through mechanical devices of
materials handling like conveyors is ensured. In this way materials can move quickly and
economically under this type of layout.
3. Economy in Manufacturing: Since materials are fed one end of the machine and
finished product is collected at the other end, there is no transportation of raw materials
backward and forward. It shortens the manufacturing time because it does not require
any time consuming internal transportation till the completion of the process of
production.
4. Saving in Material Handling Costs : Under this type of layout, since machines are
arranged in sequence of operations, materials move from one machine to another
automatically and hence no transportation cost for movement of materials are involved
till the process of manufacture is completed. In this way, there is saving in the costs of
material handling.
5. Lesser Work-in-progress: The semi-finished product or work-in-progress is the
minimum and negligible under this type of layout because the process of production is
direct and uninterrupted.
6. Easy Inspection: As because the production process is integrated and continuous,
defective practice can easily be discovered and segregated. This makes inspection easy
and economical.
7. Introduction of Production Control: The continuous nature of production enables the
management to introduce and enforce production control. Production control refers to the
planning of operation and the adoption of measures to complete the work according to
the prepared plans.
8. Maximum Utilization of Available Space: Under this type of layout, machines are
arranged in sequence of operations (not necessarily in the straight line) and it makes the
maximum utilization of space available. It may be adopted even in congested space be
arranging the machines in U – shaped.
9. Effective Utilization of Available Sources: This type of layout provides effective
utilization of men, machines and materials because of
a. Minimum possible movement of workers from one place to another;
b. Continuous process of production and therefore lesser wastage of materials;
c. Lesser work- in –progress and
d. Mechanization of materials handling.
DISADVANTAGES OF PRODUCT OR LINE LAYOUT:
1. Expensive: This type of layout is costly because machines under this system are
arranged in sequence of operations and not according to functions. It results in
duplication of similar type of machines needed for different line of production. In thats
why, it is more expensive in terms of equipment.
2. Inflexible: The system is quite inflexible, as the operations are performed in sequence,
adjustment in the course of production cannot be made without much difficulty.
3. Difficulty in supervision: Since there are no separate departments for various types of
work, specialization in supervision is also difficult.
4. Difficult in Expansion: Under this type of layout, it is usually not possible to expand the
production beyond the capacity of each line of production.
5. Stoppage of Work through Breakdown: Any breakdown in any of the machines along
the line can disrupt the whole work of production.
2. FUNCTIONAL LAYOUT:
This system is based on the functions performed by a department. Under this system of
layout, machines or equipment of the same functional type are grouped together in a
separate department. In other words, separate departments are established for each
specialized operation of production and machines relating to that functions are assembled
there. The specialized department works for all the times of production. For example,
welding equipment may be placed in one department, i.e., welding department that will
perform wilding function for the benefit of all the lines of production.
Process Layout:

Receiving Services Shipping

Surface finishing Packaging
Lath dept. Milling dept. Assembling Inspection
Offices
ADVANTAGES OF PROCESS LAYOUT:
1. Flexibility: The process layout is known for its flexibility. Changes in operations as well
as their order can be made at any time without disturbing the existing layout. Any new
operation may be added by adding simply a new department. Likewise any existing
department or operation may be scrapped, if not needed.
2. Scope for Expansion: The capacities of different lines can be expanded under this type
of layout by adding new machines and labour without upsetting the existing order.
3. Maximum Utilization of Equipment: Process layout requires fuller utilization of
machines and equipment because general purpose machine are used commonly for each
department. Duplication of machines is thus avoided as far as possible.
4. Lower Financial Investment: This type of layout requires lesser financial investment in
machines and equipment because general purpose machines, which are usually of low
costs, are used and duplication of machine is avoided. Moreover, general purpose
machines do not depreciate or become obsolete as rapidly as specialized machines. It
result is lower investment in machines.
5. Better Working Conditions: Process layout facilitates installation of machines and
equipment in different areas without any dependence of on other operation sequences.
The layout makes it easy to isolate the machinery that produces excessive noise,
vibrations, fume or heat, thereby resulting in healthy working conditions in the work
place. It boost the employee movable.
6. High Output Rate: Process layout is less vulnerable to breakdowns. Machine
breakdown in a process layout hold up production only on that particular machine and
the whole process does not came to a standstill though breakdowns, will affect the
production adversely on succeeding operations. Besides, it is easier to transfer the
production of that machine to other machines of the same type.
7. Better Supervision: Under process layout, better and efficient supervision is possible
because of specialization in operation.
DISADVANTAGES OF PROCESS OR FUNCTIONAL LAYOUT:
1. Inefficient Material Handling: Efficient material handling is difficult to practice in
process layout because fixed path material handling equipment like conveyor belts,
chutes etc. cannot be possible to use.
2. Diseconomy to Floor Space: Under this type of layout requires more floor spaces than
the product layout because a distinct department is established for each operation.
3. High Inventory Investment: Compared to line layout inventory investments are usually
higher in case of process layout. The materials have to be carried forward and backward
very frequently. This means both delay and waste. It increases the need of working
capital in the form of inventory.
4. High Cost of Supervision: Under process layout, cost of supervision is high because :
(i) The number of employees per supervisor in less that results in reduced supervisory span
of control. And
(ii) The work is checked after each operation.
5. Accumulation of Work – in- progress: Each department or operation is independent,
the material moves slowly from one department to another. It results in accumulation of
work-in- progress of semi – finished goods.
3. STATIONARY LAYOUT Or FIXED LAYOUT:
 Under this type of layout, materials remain at a fixed place and the complete
job is done at a fixed station with materials.

ADVANTAGES OF STATIONARY LAYOUT:

1. Flexible: This layout is fully flexible and is capable of absorbing any sort of change
in product and process. The project can be completed according to the needs of the
customers and as per their specification.
2. Lower Labour Cost: People are drawn from functional departments. They move
back to their respective departments as soon as the work is over. This is economical,
if a number of orders are at hand and 3each one is in a different stage of progress,
besides, one or two workers can be assigned to a project from start to finish. Thus it
reduces labour cost.
3. Saving in Time: The sequence of operations can be changed if some materials do not
arrive or if some people are absent. Since the job assignment is so long, different sets
of people operate simultaneously on the same assignment doing different operations.
4. Other Benefits :
(a) It requires less floor space because machines and equipment are in moving
position and there is no need of fixing them.
(b) This arrangement is most suitable way of assembling large and heavy
products.
DISADVANTAGES OF STATIONARY LAYOUT:
1. Higher Capital Investment: Compared to product or process layout, capital
investment is higher in this type of layout. Since a number of assignments are taken,
investment in materials, men and machines is made at a higher cost.
2. Unsuitability: This type of layout is not suitable for manufacturing or assembling
small products in large quantities. It is suitable only in case where the product is big
or the assembling process is complex.
Plant maintains
Plant maintenance usually refers to the methods, strategies, and practices used to keep an
industrial factory running efficiently. This can include anything from regular checks of
equipment to make sure they are functioning properly, to cleaning garbage bins and toilets.
The general aim of plant maintenance is to create a productive working environment that is
also safe for workers.
Since there are many different types of plants and factories, the ways to maintain these
facilities often vary. For example, a steel mill will have different machinery than a food
 processing plant. This means that each place of business generally has its own maintenance
plan, tailored to its particularities. A maintenance plan can include scheduling times for
equipment checkups, trouble-shooting, and general clean-up.
Most plants employ their own maintenance staff. This can include workers such as on-site
engineers, whose job is to make sure that machines continue to operate effectively. This is an
especially important for plants that use equipment designed for assembly lines, since a
stoppage of the line can be financially damaging.
In simple words maintenance may be understood as a set of activities which help keep plant
machinery and other facilities in good condition. A formal definition of maintenance is that
function of manufacturing management that is concerned with the day to day problem of
keeping the physical plant in good operating condition.

Scope of maintenance:
Every manufacturing organization needs maintenance because machine breakdown, parts
wear out and buildings deteriorate over a period of time of use.
The plant maintenance are two types
 Primary function
 Secondary function
The different types of plant maintenance types are
Plant Maintenance Services:
 Many times, janitors will be responsible for the maintenance of the factory floor — and
keeping it clean of any spills that could be dangerous to equipment operators. There are also
many private plant maintenance companies. These firms are generally contracted by a
factory to check equipment and make repairs.
 The use of maintenance records is particularly important in a factory setting, where a large
number of expensive machines are used daily. These records can help make sure that any
appropriate equipment maintenance or plant maintenance has been completed so that plant
operations will run smoothly.
Plant Equipment Maintenance:
 In some instances, it also can prevent the need for repairs of equipment. Recent
technological advances have made equipment maintenance software affordable to
businesses of all sizes. Since nonfunctional equipment and resulting repairs can decrease
 productivity levels and profits, an investment in this type of software hypothetically can save
a manufacturing company thousands of dollars in repairs and help the company gain an edge
over competitors.
 At other times, the maintenance process may require daily inspection of certain components
as a means of identifying potential issues before they can have any type of serious impact on
productivity. With plant equipment maintenance, the process is often a combination of
specific maintenance tasks that are required as part of a governmental compliance with
safety and environmental laws, as well as any inspection and equipment repair protocols
implemented by the business that are above and beyond those minimum governmental
requirements.
Plant Maintenance Management:
 Adjusting business approaches and philosophies can significantly reduce these maintenance
management costs. Recent breakthroughs in maintenance technology can also help improve
profit margins.
 The program must track issues that are relevant to a business so that important tasks will be
completed. Computerized maintenance management systems are often preferred over
paperwork systems because they tend to be faster and allow a more efficient use of
manpower.

Layout Tools and Techniques:

Various techniques are available for planning the lay out. The most commonly used
technique is the use of two-dimensional templates. Other techniques depend upon the method
of layout. For example, to design the process layout operations, sequence analysis is mainly
used, whereas line balancing is used to design the product layout.
Templates:
Templates are patterns which consist of a thin plate of wood or metal, which serves as
a gauge or a guide in mechanical work. A plant layout template is a scaled representation of a
physical object in a layout. This object may be a machine, materials handling equipment, a
worker or even materials, the templates are fixed to a plan drawing and are moved around the
drawing to explore the various layout possibilities until a layout, which eliminates
unnecessary handling and back-tracking of materials and offers flexibility to admit revisions
at the least cost, emerges. The template method is particularly useful in developing a layout-
for an existing department or building or when the configuration of the building is already
established through other layout techniques.
Where a layout is to be developed with no building around, other techniques, as
explained below,
Operations Sequence analysis: Being an early approach to process layouts, operations
sequence analysis develops a good scheme for arrangement of departments graphically
analyzing the layout problem.
Line Balancing: Line balancing is the phase of assembly line study that nearly equally
divides the work to be done among the workers so that the total number of employees
required on the assembly line is minimized. Line balancing is not simple in fact, there are
usually many alternative ways that the work can be divided among the workers. Operation
researchers have used linear programming, dynamic programming and other optimal methods
to study line balancing problems. Explanation to all these is beyond the scope of this text.
Operational process charts:
These are the graphical representation of major activities and entry point of materials.
Flow process charts:
They shows the floe and activities of component /man through a series of operations,
inspections, transportations etc
Travel charts:
They shows quantitative data on material flow by recording distance and frequency of
movements between different pairs of departments.
Diagrams:
These are useful to study different layout alternative to select best alternative extent of traffic
over different routes of the map.
Models:
To have better understanding of the depth ,height etc of machines three dimensions scaled
models provide full visualization of equipment and process.
 Computerized models:
 CORELAP(Computerized relationship layout planning)
 CRAFT(Computerized relative allocation of facilities technique)
 COFAD(Computerized facilities design)
 ALDEP(Automated layout design programme)
 CAN-Q(Computerized Analysis of network of queues)
Plant Maintenance: Objectives, Importance and Types
After reading this article you will learn about:- 1. Objectives of Plant Maintenance 2.
Importance of Plant Maintenance 3. Types 4. Schedule 5. Standard Data 6. Some Recent
Developments.
 Objectives of Plant Maintenance:
 (i) The objective of plant maintenance is to achieve minimum breakdown and to keep
the plant in good working condition at the lowest possible cost.
 ADVERTISEMENTS:
 (ii) Machines and other facilities should be kept in such a condition which permits
them to be used at their optimum (profit making) capacity without any interruption or
hindrance.
 (iii) Maintenance division of the factory ensures the availability of the machines,
buildings and services required by other sections of the factory for the performance of
their functions at optimum return on investment whether this investment be in
material, machinery or personnel.
 Importance of Plant Maintenance:
 (i) The importance of plant maintenance varies with the type of plant and its
production.
 (ii) Equipment breakdown leads to an inevitable loss of production.
 ADVERTISEMENTS:
 a. If a piece of equipment goes out of order in a flow production factory, the whole
line will soon come to a halt. Other production lines may also stop unless the initial
fault is cleared.
 b. This results in an immediate loss in productivity and a diminution of several
thousand rupees per hour of output.
 (iii) An un-properly maintained or neglected plant will sooner or later require
expensive and frequent repairs, because with the passage of time all machines or other
facilities (such as transportation facilities), buildings, etc., wear out and need to be
maintained to function properly.
 (iv) Plant maintenance plays a prominent role in production management
because plant breakdown creates problems such as:
 a. Loss in production time.
 b. Rescheduling of production.
 c. Spoilt materials (because sudden stoppage of process damages in-process
materials).
 d. Failure to recover overheads (because of loss in production hours).
 e. Need for over-time.
 f. Need for subcontracting work.
 g. Temporary work shortages-workers require alternative work.
 Types of Plant Maintenance:
 Maintenance may be classified into following categories:
 (a) Corrective or breakdown maintenance,
 (b) Scheduled maintenance,
 Preventive maintenance, and
 (d) Predictive maintenance.
 (a) Corrective or Breakdown Maintenance:
 Corrective or breakdown maintenance implies that repairs are made after the
equipment is out of order and it cannot perform its normal function any longer, e.g.,
an electric motor will not start, a belt is broken, etc. Under such conditions,
production department calls on the maintenance department to rectify the defect. The
maintenance department checks into the difficulty and makes the necessary repairs.
After removing the fault, maintenance engineers do not attend the equipment again
until another failure or breakdown occurs.
 This type of maintenance may be quite justified in small factories which:
o Are indifferent to the benefits of scheduling;
o Do not feel a financial justification for scheduling techniques; and
o Get seldom (temporary or permanent) demand in excess of normal operating
capacity.
 In many factories make-and-mend is the rule rather than the exception. Breakdown
maintenance practice is economical for those (non-critical) equipment whose down-
time and repair costs are less this way than with any other type of maintenance.
Breakdown type of maintenance involves little administrative work, few records and a
 comparative small staff. There is no planned interference with production
programmes-.
 Typical Causes of Equipment Breakdown:
o Failure to replace worn out parts.
o Lack of lubrication.
o Neglected cooling system.
o Indifference towards minor faults.
o External factors (such as too low or too high line voltage, wrong fuel, etc.)
o Indifference towards -equipment vibrations, unusual sounds coming out of the
rotating machinery, equipment getting too much heated up, etc.
 Disadvantages of Breakdown Maintenance:
o Breakdowns generally occur at inopportunate times. This leads to poor,
hurried maintenance and excessive delays in production.
o Reduction of output.
o Faster plant deterioration.
o Increased chances of accidents and less safety to both workers and machines.
o More spoilt material.
o Direct loss of profit.
o Breakdown maintenance practice cannot be employed for those plant items
which are regulated by statutory provisions, for example cranes, lifts, hoists
and pressure vessels.
 (b) Scheduled Maintenance:
 Scheduled maintenance is a stich-in-time procedure aimed at avoiding breakdowns.
Breakdowns can be dangerous to life and as far as possible should be minimized.
Scheduled maintenance practice incorporates (in it), inspection, lubrication, repair and
overhaul of certain equipment which if neglected can result in breakdown.
 Inspection, lubrication, servicing, etc., of these equipment are included in the
predetermined schedule. Scheduled maintenance practice is generally followed for
overhauling of machines, cleaning of water and other tanks, white-washing of
buildings, etc.
 (c) Preventive Maintenance:
 A system of scheduled, planned or preventive maintenance tries to minimize the
problems of breakdown maintenance. It is a stich-in-time procedure. It locates weak
spots (such as bearing surfaces, parts under excessive vibrations, etc.) in all
equipment, provides them regular inspection and minor repairs thereby reducing the
danger of unanticipated breakdown. The underlying principle of preventive
maintenance is that prevention is better than cure.
 Preventive Maintenance (or PM) Involves:
  Periodic inspection of equipment and machinery to uncover conditions that lead to
production breakdown and harmful depreciation.
 Upkeep of plant equipment to correct such conditions while they are still in a
minor stage.
 Preventive maintenance is practised to some extent in about 75% of all manufacturing
companies, but every preventive maintenance programme is tailored as per the
requirements of each company. The key to all good preventive maintenance
programmes, however, is inspection. Help can be taken of suitable statistical
techniques in order to find how often to inspect.
 Objectives of PM:
(i) To minimize the possibility of unanticipated production interruption or major
breakdown by locating or uncovering any condition which may lead to it.
(ii) To make plant equipment and machinery always available and ready for use.
(iii) To maintain the value of equipment and machinery by periodic inspections, repairs,
overhauls, etc.
(iv) To maintain the optimum productive efficiency of the plant equipment and
machinery.
(v) To maintain the operational accuracy of the plant equipment.
(vi) To reduce the work content of maintenance jobs.
(vii) To achieve maximum production at minimum repair cost.
(viii) To ensure safety of life and limbs of the workmen.