The literal meaning of “layout” is to arrange various things in a planned manner. In the context of the facility, especially concerning a manufacturing entrepreneur, it relates to the set-up of different types of machinery, equipment and other facilities incidental to the core manufacturing activity, viz. department for receiving (raw materials), department for dispatching (finished goods), tool rooms, maintenance department looking after the work relating to employees welfare, etc. In this article, you know the factors influencing and objectives of plant layout.
Definitions of Plant Layout
According to Keith and Gubellini, “Plant layout deals with the arrangement of the physical facilities and the manpower required to manufacture a product or perform a service”.
According to J. Lundy, “Plant layout ideally involves the allocation of space and the arrangement of equipment in such a manner that overall operations costs are minimized.”
7 Major Objectives of Plant Layout
The basic objectives of plant layout in a manufacturing unit is to cut the cost of production and bring it to the minimum possible level. Other objectives, which may not be considered so important and may be referred to as the subsidiary objectives, are as follows:
1) Handling and transportation of materials are facilitated, which leads to the handling of such materials cost-effectively.
2) Available floor space is put to use most optimally.
3) Various resources, viz. plants, machinery, equipment and even human resources are utilized economically.
4) As the production activity is smoothened due to a reduction in delays and other hurdles to a great extent, the work-in-process (WIP) inventory remains at the minimum level. The outcome is maximum inventory turnover.
5) The entire process of production may be planned and monitored efficiently.
6) Manpower involved in the production process develops high morale because of the security and facilities available under a good plant layout.
7) It provides service center’s in abundance at appropriate locations.
These are the subsidiary objectives of plant layout.
10+ Different Factors Influencing Facility Layout
At times, layout changes become inevitable; certain factors play a significant role. Such factors have been explained in the following points:
1) Product and Material Specification
Various features of the material used (e.g. its form, weight, physical and chemical qualities, etc.) may have a substantial impact on the decision of plant location. These aspects influence all the criteria of the layout. Production processes which involve risky and unsafe operations require segregation of the facility rather than integration thereof on a line basis. It is one of the important factors influencing facility layout.
2) Location and Site of the Plant
The site selection may play a major role in finalizing the layout. The location of two departments, viz., receiving department and shipping department, is paramount as they are where raw materials are received, and products are dispatched to the market respectively. They need to be strategically located with the view to ensure that these two operations are carried out smoothly without any interruption. Besides the undisturbed supply of power and water, the community attitude is equally important, which must be considered before finalizing the location.
3) Manufacturing Process
This is the core of the entire production activity and, as such, needs to be considered during layout preparation. It is the most important aspect, which forms the basis of decisions concerning the flow of material, the type of machines required and the requirement of the material handling facilities. Manufacturing process is the important factors influencing facility layout. Further decisions concerning the required working area and additional space for storing WIP inventory may be taken based on the size and weight of the machine and raw material. Any negligence in the manufacturing process may lead the management to troubled spots at a later stage.
4) Material Handling
Material handling is an integral part of any manufacturing process, which results in cost-addition but no value-addition. Therefore, material handling must be exercised at the lowest possible level, intending to contain the overall production cost. Material handling covers the different manufacturing stages of handling, e.g. raw-material handling, handling of WIP inventory, handling of finished goods, handling of waste and scrap, etc. Plant layout and material handling are directly interconnected, and it is necessary to ensure their integration during the preparation of plant layout.
5) Storage of In-Process Inventory
The waiting period for materials at various stages of the production process must be minimized to the extent that a long waiting period means an increase in the overall cost.
The layout should be framed so that materials do not get struck up between any two processes for a time more than necessary. The proper vision and foresightedness are required, and the layout should be designed accordingly to achieve this.
6) Plant Personnel and Employee Facilities
While preparing the layout, appropriate provisions for various amenities, such as emergency medical support, canteen, protection against the machines, vehicle parking, rest/cloakrooms, etc., should be given serious attention.
7) Service Facilities
Service facilities in respect of personnel, material, machinery, equipment and operations perform the twin role of reducing the overall cost and increasing productivity. As such, they should be taken into account during the preparation of the layout.
8) Design of Building
The design of the building is crucial in an indirect manner for the performance level of individual employees and overall productivity. The availability of natural light and ventilation in the building plan should be ensured. Further, there must be sufficient room for the convenient expansion in the building, if need be, in future.
9) Flexibility
With time, the best processes and machinery also become obsolete and warrant changes to keep pace with the changing times. The layout must be changed because of the changes in the market demand for products, changes in the materials used, or changes in the processes. The layout should have maximum flexibility; the requisite changes should be effected with the least difficulty. Thus, flexibility should be kept in view during layout preparation.
10) Work Areas and Equipment
The designing of work areas should be done in such a manner that the following conditions are fulfilled:
i) There is no hindrance in the movement of workers.
ii) Materials can be handled conveniently.
iii) Maintenance staff finds it easy to carry out the repair or maintenance of various machines.
11) Working Conditions
Working conditions should be provided in the work area to maximize productivity. The following points need to be given due consideration:
i) Availability of sufficient light intensity and quality with no trace of any direct or indirect.
ii) There should be a control mechanism concerning temperature and humidity to suit the workers.
iii) Noises caused by various processes should be reduced to the extent possible.
12) Disposal of Waste and Dangerous Gases
An appropriate system needs to be implemented to ensure proper disposal of waste materials. A far-off and remote place should be selected for such disposal so that the workers and neighboring communities remain protected from the harmful impacts of such waste materials.