FACTORS INFLUENCING THE PLANT LAYOUT

Ø  PLANT LAYOUT
FACTORS
OBJECTIVES AND PRINCIPLES
OPERATION MANAGEMENT
PLAYLIST ON SHASHI AGGARWAL YOU TUBE
PRODUCTION AND OPERATION MANAGEMENT

•    CONTENT

1.     PREVIOUS PAPER

2.     MEANING

3.     OBJECTIVES

4.     FACTORS

5.     PRINCIPLES

• PREVIOUS PAPER OF OPERATION MANAGEMENT UNIT 1

Q1. WHAT ARE THE ELEMENTS OF OPERATING STRATEGY? WHAT IS THE ROLE OF ADVANCED MANUFACTURING TECHNOLOGY IN THE FORMULATION OF OPERATION TECHNOLOGY.

Q2. DISTINGUISH BETWEEN CONTINUOUS AND INTERMITTENT PRODUCTION SYSTEM. HOW THE PRODUCTION PLANNING DIFFERS IN BOTH THE SYSTEM? EXPLAIN UNDER WHAT CONDITIONS EACH ONE IS MORE SUITABLE

Q3. DISCUSS THE IMPORTANCE OF PLANT LOCATION AND HOW ARE PLANT LOCATION AND PLANT LAYOUT DECISIONS ARE RELATED.

 WHAT FACTORS DO AFFECT THE CHOICE OF LOCATION IN MANUFACTURING? HOW DO THE LOCATION DECISION FOR SERVICE FACILITIES DIFFER FROM THAT OF MANUFACTURING FACILITY

Q4. WHAT ARE THE OBJECTIVE AND ADVANTAGE OF LAYOUT. OUTLINE AND EXPLAIN THE FACTORS TO BE CONSIDERED FOR PLANT LAYOUT DEVELOPMENT? EXPLAIN  THE PROCEDURE OF DESIGNING FLEXIBLE LAY OUT.

MEANING OF PLANT LAYOUT

1.     PLANT LAYOUT REFERS TO THE ARRANGEMENT OF MACHINERY,EQUIPMENT AND OTHER INDUSTRIAL FACILITIES  SUCH AS RECEIVING AND SHIPPING DEPARTMENT,TOOL ROOM,MAINTENANCE ROOMS AND EMPLOYEE AMENITIES FOR ACHIEVING QUICKEST AND SMOOTH PRODUCTION.

2.     THE SUBJECT OF PLANT LAYOUT NOT ONLY COVERS THE INITIAL LAYOUT OF MACHINES AND OTHER FACILITIES BUT ALSO INCLUDES IMPROVEMENT/REVISION

3.     KNOWLES AND THOMAS,” PLANT LAYOUT INCLUDES THE FOLLOWING:-

4.     PLANNING AND ARRANGING MANUFACTURING MACHINERY,EQUIPMENT AND SERVICES FOR THE FIRST TIME IN COMPLETELY NEW PLANTS

5.     THE IMPROVEMENT IN LAYOUT ALREADY IN USE IN ORDER TO INTRODUCE NEW METHODS AND IMPROVEMENT IN MANUFACTURING PROCEDURES.

OBJECTIVES OF A GOOD LAYOUT

1.     PROVIDE ENOUGH PRODUCTION CAPACITY

2.     REDUCE MATERIAL HANDLING COSTS

3.     REDUCE CONGESTION

4.     REDUCE HAZARDS TO PERSONNEL

5.     UTILIZE LABOUR EFFICIENCY

6.     INCREASE EMPLOYEE MORALE

7.     REDUCE ACCIDENTS

8.     UTILIZE AVAILABLE SPACE EFFICIENTLY AND EFFECTIVELY

9.     PROVIDE EACH OF SUPERVISION

10.  FACILITATE CO ORDINATION AND FACE TO FACE COMMUNICATION

11.  PROVIDE EMPLOYEE SAFETY AND HEALTH

12.  ALLOW EASE OF MAINTENANCE

13.  ALLOW HIGH MACHINERY /EQUIPMENT UTILIZATION

14.  IMPROVE PRODUCTIVITY

FACTORS INFLENCING FACILITY LAYOUT

PRIMARILY THE LAYOUT OF A PLANT IS INFLUENCED BY THE RELATIONSHIP AMONG MATERIALS, MACHINERY AND MEN AND OTHER FACTORS ALSO INFLUENCE.

MATERIALS:

1.     NEED TO PROVIDE FOR THE STORAGE AND MOVEMENT OF THE RAW MATERIALS IN PLANT UNTIL THEY ARE CONVERTED INTO FINISHED PRODUCT

2.     MOVED MANUALLY/MECHANICAL OPERATIONS/CHEMICAL PROCESSING

3.     PROPER STORAGE ROOMS AND MOVEMENT EQUIPMENT

4.     INITIAL INVESTMENT AND RECURRING COST ON MATERIAL EQUIPMENT CRANES,TROLLEY AND PIPELINE . IT ALSO DEPENDS ON THE TYPE OF MATERIAL USE-LIQUID,SOLD/GAS AND THE AVAILABILITY

5.     FOR DETERMINING BEST PATH THE FLOW CHARTS ARE DRAWN TO VISUALIZE THE MOVEMENT OF MATERIALS.

PRODUCT:-

1.     NATURE OF THE PRODUCT:-HEAVY/LIGHT/BIG/SMALL/LIQUID/SOLID

2.     PRODUCT MOVES FROM WORK STATION TO OTHER WORKS STATION

3.     IN THE MANUFACTURE OF LOCOMOTIVES AND IN SHIP BUILDING THE PRODUCT IS STATIONERY

4.     POSITION OF THE PRODUCT IN RELATION TO OTHER PRODUCT MATTERS

5.     SALE AND DEMAND ALSO EXERCISE INFLUENCE ON THE PLANT LAYOUT

6.     EXPERTS ARE OF THE OPINION THAT PLANT LAYOUT SHOULD BEGIN FROM PRODUCT

WORKER:_

1.     SHOULD ALSO CONSIDER THE TYPE,POSITION AND REQUIREMENT OF THE EMPLOYEE

2.     POSITION OF THE EMPLOYEE

3.     EMPLOYEE FACILITIES HEALTH AND RELATED. SAFETY

MACHINERY:-

1.     THE TYPE OF PRODUCT,ITS VOLUME OF PRODUCTION,TYPE OF PROCESS AND MGMT POLICY DETERMINE THE SIZE AND TYPE OF THE MACHINERY TO BE  INSTALLED

2.     TYPE OF INDUSTRY:-

3.     TYPE OF THE INDUSTRY AND METHOD OF MANUFACTURE

TYPE OF INDUSTRY:-

1.     EXTRACTIVE INDUSTRIES:-SEPARATION OF ONE ELEMENT FROM ANOTHER IN THE CASE OF METAL FROM THE ORE

2.     A CONDITIONING INDUSTRY: INVOLVE A  CHANGE IN THE FORM OR PHYSICAL PROPERTIES

3.     ANALYTICAL INDUSTRY:CONVERTS RAW MATERIAL INTO VARIOUS ELEMENTS

4.     SYNTHETIC INDUSTRY: ALSO CALLED ASSEMBLING: PRODUCTION OF A PRODUCT BY THE USE OF VARIOUS ELEMENTS

5.     INDUSTRIES MAY ALSO BE CLASSIFIED: CONTINUOUS INDUSTRIES AND INTERMITTENT INDUSTRIES

LOCATION:-

1.     THE LOCATION ALSO INFLUENCES ITS LAYOUT

2.     SIZE AND TERRAIN OF THE SITE DETERMINE THE TYPE OF BUILDING WHICH IN TURN INFLUENCES LAYOUT

3.     LOCATION OF THE PLANT DETERMINE THE MODE OF TRANSPORTATION

4.     MAY ALSO BE DETERMINED BY THE FUEL REQUIREMENTS

5.     PLANT LAYOUT MAY ALSO PROVIDE STORAGE FACILITY AND ALSO CONSIDER THE REQUIREMENT OF POWER GENERATION

6.     DEMAND FOR FUTURE EXPANSION

MANAGERIAL POLICIES:-

1.     THE VOLUME OF PRODUCTION AND PROVISION FOR EXPANSION

2.     THE EXTENT OF AUTOMATION

3.     MAKING OR BUYING A PARTICULAR COMPONENT

4.     DESIRE FOR RAPID DELIVERY OF GOODS TO CUSTOMERS

5.     PERSONNEL POLICIES

PRINCIPLES OF LAYOUT

1.     THE PRINCIPLE OF MINIMUM TRAVEL

2.     PRINCIPLE OF SEQUENCE

3.     PRINCIPLE OF USAGE

4.     PRINCIPLE OF COMPACTNESS

5.     PRINCIPLE OF SAFETY AND SATISFACTION

6.     PRINCIPLE OF FLEXIBILITY

7.     PRINCIPLE OF MINIMUM INVESTMENT