Factors Determining Layout And Design

Factors Determining Layout And DesignFacility layout and purpose is an grand component of a capers overall trading operations, both in terms of maximising the effectiveness of the harvestion process and meeting the needs of employees. The basic objective lens of layout is to en confident(predicate) a smooth flow of figure, squ be, and education by dint of a system. The basic import of initiation is the shoes in which a businesss activities bundle place. The layout and object of that space impact greatly how the work is done-the flow of work, existents, and in public figureation through the system. The key to good prep atomic issuing 18dness layout and design is the integration of the needs of people (personnel and customers), materials (raw, finishes, and in process), and machinery in such(prenominal)(prenominal) a delegacy that they sack up out a single, well- percentageing system.FACTORS DETERMINING LAYOUT AND DESIGNSmall business owners need to ascertain many operational factors when building or renovating a facility for supreme layout effectiveness. These criteria include the following1. Ease of future expansion or change-Facilities should be designed so that they provoke be easily expanded or ad b arg only ifed to meet changing production needs. Although redesigning a facility is a study, expensive undertaking non to be done lightly, on that point is unceasingly the possibility that a redesign get out be prerequisite, Therefore, any design should be flexible. Flexible manufacturing systems most a great deal ar highly automatise facilities having intermediate-volume production of a variety of products. Their goal is to play cut out changeover or setup sequences for producing the different products while still achieving close to fiction fund (single-product) production rates.2. Flow of straitsment- the facility design should reflect erudition of the importance of smooth process flow. In the case of manufacturing form facilities, the editors of How to overflow a Small Business state that beau ideally, the plan will immortalise the raw materials entering your engraft at one end and the finished product emerging at the separate. The flow need not be a straight line. Parallel flows, U-shaped patterns, or even a locomote that ends up with the finished product back at the shipping and receiving bays tail assembly be functional. However, back cuting is to be avoided in whatever pattern is chosen. When parts and materials move against or across the overall flow, personnel and paperwork become conf utilise.3. Materials treatment-Small business owners should make certain that the facility layout makes it possible to handle materials (products, equipment, containers, etc.) in an orderly, expeditious-and p identifyably simple-manner.4. production needs- the facility should be laid out in a centering that is conducive to helping the business meet its production needs.1. Space physical exerc ise-This smell of facility design includes everything from making sure that traffic lanes are broad abundant to making certain that inventory storage warehouses or room utilize as much vertical space as possible.2. expatriation and receiving-counseled small business owners to leave ample room for this aspect of operations. patch space does incline to fill itself up, receiving and shipping rarely get enough space for the work to be done effectively, 3. Ease of communication and realize-Facilities should be laid out so that communication within various airfields of the business and interactions with vendors and customers underside be done in an easy and effective manner. Similarly, support areas should be stationed in areas that help them to serve operating areas.4. Impact on employee team spirit and job satisfaction-since count little studies become indicated that employee morale has a major impact on productiveness, owners and managers to heed this factor when ponderi ng facility design alternatives near ways layout design potful increase morale are obvious, such as providing for light-colored walls, windows, space. Other ways are slight obvious and not directly related to the production process. Some examples are including a cafeteria or even a gymnasium in the facility design. Again, though, there are costs to be traded off. That is, does the increase in morale due to a cafeteria increase productivity to the extent that the increased productivity covers the cost of building and staffing the cafeteria?5. Promotional value-if the business comm alone receives visitors in the form of customers, vendors, investors, etc., the small business owner whitethorn want to make sure that the facility layout is an attractive one that further burnishes the companys reputation. Design factors that can crop the degree of attractiveness of a facility include not only the design of the production area itself, but the impact that it has on, for instance, ease of fulfilling nutrition/cleaning tasks.6. Safety-the facility layout should enable the business to effectively operate in accordance with Occupational Safety and Health Administration guidelines and other profound restrictions.Facility layout must be considered very carefully because we do not want to constantly redesign the facility, Some of the goals in designing the facility are to visualise a minimal meat of materials use, to avoid bottlenecks, to minimize machine interference, to curb high employee morale and galosh, and to ensure flexibility. Essentially, there are both plain types of layout. Product layout is synonymous with assembly line and is orientated toward the products that are existence made. Process layout is oriented around the processes that are used to make the products. Generally, product layout is applicable for high-volume repetitive operations, while process layout is applicable for low-volume custom-made goods.AN IDEAL LAYOUT 1. Transport Movement of materials is a waste. Minimize the summation of movement by arranging processes in close proximity to distributively other. Factory layouts can often be the fundamental cause of repletion transportation. When appropriate, re-laying out the machines within a factory from a functional to a cellular layout has been found by many companies to help not just reduce transportation waste but excessively reduce WIP and waiting. Items being moved unnecessarily detect oneself a cost.2. Inventory Many companies have above what is demand to fulfill the order, this may be due to feel problems along the production process or the often mistaken touch sensation that is saves money by manufacturing larger quantities. Too little inventory can lose sales too much inventory can underwrite problems. 3. Motion Generally, this waste applies to production personnel having to move out of their work area to locate tools, materials, etc. Remove unnecessary motion of the operations and improve th e ergonomics of the workplace. People moving unnecessarily withal incur a cost. 4. Waiting Minimize waiting time (operators waiting for machines or products waiting around in factories either as finished goods or work in progress) Aim for a smooth flow.5. Overproduction unendingly aim to make exactly what the customer orders, just in time, to the improve quality standard. On the shop appal, this generally occurs because changeover times are high, equipment is unreliable, the process is unreliable (causes defects), and standard cost accounting metrics are used. However, probably the biggest reason for overproduction is poor information flow (communication) surrounded by facilities. 6. Over Processing Use machines which are of an appropriate capacity and undefended of achieving the required quality standard. This usually refers to using larger scale equipment than necessary it in like manner refers to building in rework to a process. It can also refer to using the wrong supplie rs and/or the wrong process.7. Defects Reducing the number of defects directly reduces the amount of waste. Aim for zero defects. The efficiency of production depends on how well the various machines production facilities and employees amenities are primed(p) in a plant life. Only the tight-lacedly laid out plant can ensure the smooth and rapid movement of material, from the raw material typify to the end product stage. congeal 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 proper(ip) quantity and quality of sidetrack at the lowest possible cost of manufacturing. It involves a judicious disposition of production facilities so that workflow is direct. deeds layout refers to the arrangement of natural facilities such as machinery, equipment, furniture etc. within the factory building in such a manner so as to have quickest fl ow of material at the lowest cost and with the least amount of handling in processing the product from the receipt of material to the freightage of the finished product.The overall objective of plant layout is to design a physical arrangement that most economically meets the required output quantity and quality., represent layout ideally involves al spatial relation of space and Arrangement of equipment in such a manner that overall operating costs are minimized.IMPORTANCE nominate layout is an important decision as it represents long-term commitment. An ideal plant layout should come through the optimum relationship among output, floor area and manufacturing process. It facilitates the production process, minimizes material handling, time and cost, and allows flexibility of operations, easy production flow, makes economic use of the building, promotes effective example of manpower, and provides for employees convenience, asylum, comfort at work, maximum exposure to natural l ight and ventilation. It is also important because it affects the flow of material and processes, labour efficiency, supervision and guarantee, use of space and expansion possibilities etc.ESSENTIALS REQUIREMENTSAn efficient plant layout is one that can be instrumental in achieving the following objectivesa) Proper and efficient utilization of visible(prenominal) floor space.b) To ensure that work proceeds from one point to other point without any delay.c) forget enough production capacity.d) Reduce material handling costs.e) Reduce hazards to personnel.f) Utilize labour efficiently.g) Increase employee morale.h) Reduce accidents.i) Provide for volume and product flexibility.j) Provide ease of supervision and control.k) Provide for employee safety and health.l) Allow ease of maintenance.m) Allow high machine or equipment utilization.n) emend productivity.FACTORS INFLUENCING LAYOUTWhile deciding his factory or unit or shaping or store, a small-scale businessman should watch th e following factors in minda) Factory building The temper and size of the building determines the floor space available for layout. While designing the special requirements, e.g. air conditioning, sparge control, humidity control etc. must be kept in mind.b) Nature of product product layout is suitable for uniform products whereas process layout is more(prenominal) appropriate for custom-made products.c) labor process In assembly line industries, product layout is better. In job order or intermittent manufacturing on the other hand, process layout is desirable.d) Type of machinery General purpose machines are often put as per process layout while special purpose machines are arranged according to product layout.e) Repairs and maintenance machines should be so arranged that adequate space is available between them for movement of equipment and people required for repairing the machines.f) Human needs Adequate arrangement should be made for cloakroom, washroom, lockers, drinking water, toilets and other employee facilities, proper provision should be made for disposal of effluents, if any.g) do environment Heat, light, noise, ventilation and other aspects should be duly considered, e.g. paint shops and metal plating section should be located in another hall so that dangerous fumes can be removed through proper ventilation etc. Adequate safety arrangement should also be made.Thus, the layout should be conducive to health and safety of employees. It should ensure free and efficient flow of men and materials. Future expansion and diversification may also be considered while planning factory layout.DYNAMICS OF PLANT LAYOUTPlant layout is a dynamic rather than a static concept meaning thereby if once done it is not permanent in nature rather improvement or revision in the existing plant layout must be made by keeping a track with ripening of new machines or equipment, improvements in manufacturing process, changes in materials handling devices etc. But, any r evision in layout must be made only when the savings resulting from revision exceed the costs involved in such revision. Revision in plant layout may become necessary on account of the following reasonsa) Increase in the output of the existing productb) Introduction of a new product and diversificationc) Technological advancements in machinery, material, processes, product design, fuel etc.d) Deficiencies in the layout unnoticed by the layout engineer in the beginning.APPLICABILITY OF PLANT LAYOUTPlant layout is applicable to all types of industries or plants. Certain plants require special arrangements which, when incorporated make the layout look distinct form the types already discussed above. Applicability of plant layout in manufacturing and service industries is discussed below.In case of the manufacturing of detergent powder, a multi-story building is specially constructed to house the boiler. Materials are stored and poured into the boiler at different stages on different f loors. Other facilities are also provided around the boiler at different stations. Another applicability of this layout is the manufacture of talcum powder. Here machinery is arranged vertically i.e. from top to bottom. Thus, material is poured into the jump-year machine at the top and powder comes out at the bottom of the machinery located on the ground floor.Yet another applicability of this layout is the newspaper plant, where the time element is of supreme importance, the accomplishment being gapped in seconds. Here plant layout must be simple and direct so as to eliminate distance, delay and confusion. There must be a perfect coordination of all plane sections and machinery or equipment, as materials must never fail. Plant layout is also applicable to five star hotels as well. Here lodging, bar, restaurant, kitchen, stores, liquid pool, laundry, shaving saloons, shopping arcades, conference hall, parking areas etc. should all find an appropriate place in the layout. Here importance must be given to cleanliness, elegant appearance, convenience and compact looks, which attract customers. Similarly plant layout is applicable to a cinema hall, where emphasis is on comfort, and convenience of the cinemagoers. The projector, screen, sound box, firefighting equipment, ambience etc. should be of utmost importance.A plant layout applies likewise the grouping of machinery, to an arrangement for other facilities as well. Such facilities include receiving and dispatching points, control facilities, employee facilities, storage etc.Generally, the receiving and the dispatching departments should be at either end of the plant. The storeroom should be located close to the production, receiving and dispatching centers in order to minimize handling costs. The inspection should be right next to other dispatch department as inspections are done finally, before dispatch. The maintenance department consisting of lighting, safety devices, fire protection, collection an d disposal of garbage, scrap etc. should be located in a place which is easily accessible to all the other departments in the plant. The other employee facilities like toilet facilities, drinking water facilities, first aid room, cafeteria etc. This can be a little by from other departments but should be within easy reach of the employees. Hence, there are the other industries or plants to which plant layout is applicable.The importance of a layout would be better appreciated if one understands the influence of an efficient layout on the manufacturing function it makes it smooth and efficient. Operating efficiencies, such as economies in the cost of handling materials, minimization of production delays and avoidance of bottlenecks all these depend on a proper layout.An ideally laid out plant reduces manufacturing costs through reduced materials handling, reduced personnel and equipment requirements and reduced process inventory.The objectives or advantages of an ideal layout are ou tlined in the paragraphs that follow. The advantages are common to all the plants, disregarding of age and whether a plant employs 50 histrions or 50,000 makes no contrast in so far as the applicability of the plant layout advantages is concerned.Some of these advantages areEconomies in HandlingNearly 30% to 40% of the manufacturing cost is accounted for, by materials handling. Every effort should, therefore, be made to cut down on this cost. Long distance movements should be avoided and specific handling operations must be eliminated. A cynic may say that the cheapest way to handle materials is not to handle them at all. But, in a factory, materials have to be handled and therefore, it all depends on the layout.Effective Use of Available stadiumEvery inch of the plant area is valuable, especially in urban areas. Efforts should therefore be made to make use of the available area by planning the layout properly. Some steps for achieving this end are location of equipment and serv ices in order that they may perform multiple functions development of up-to-date work areas and operator job assignments for a full utilization of the labor force.Minimization of Production DelaysRepeat orders and new customers will be the result of prompt execution of orders. Every management should try to keep to the delivery schedules. Often, the deadline dates for delivery of production orders are a bug-a-boo to the management.Plant layout is a significant factor in the timely execution of orders. An ideal layout eliminates such causes of delays as shortage of space, long-distance movements of materials, spoiled work and thus contributes to the lively execution of orders.Improved Quality ControlTimely execution of orders will be meaningful when the quality of the output is not below expectations. To ensure quality, inspection should be conducted at different stages of manufacture. An ideal layout provides for inspection to ensure better quality control.Minimum Equipment Investm entInvestment on equipment can be minimized by mean machine balance and location, minimum handling distances, by the installation of general purpose machines and by planned machine loading. A good plant layout provides all these advantages.Avoidance of BottlenecksBottlenecks refer to any place in a production process where materials tend to pile up or are produced at a amphetamine, less rapid than the previous or subsequent operations. Bottlenecks are caused by pathetic machine capacity, inadequate storage space or low speed on part of the operators. The results of bottlenecks are delays in productions schedules, congestion, accidents and wastage of floor area. All these may be overcome with an efficient layout. bankrupt Production ControlProduction Control is concerned with the production of the product of the right type, at the right time and at a reasonable cost. A good plant layout is a requisite for good production control and provides the production control officers with a systematic basis upon which to build organization and procedures.Better managementA good plant layout ensures better supervision in two ways1. Determining the number of workers to be handled by a supervisory program and2. Enabling the supervisor to get a full view of the absolute plant at one glance.A good plant layout is, therefore, the first step to good supervision.Improved Utilization of LaborLabor is compensable for every hour it spends in the factory. The efficiency of a management lies in utilizing the time for productive purpose. A good plant layout is one of the factors in effective utilization of labor. It makes possible individual operations, the process and flow of materials handling in such a way that the time of each worker is effectively spent on productive operations.Improved Employee MoraleEmployee morale is achieved when workers are cheerful and confident. This state of mental condition is vital to the succeeder of any organization.Morale depends on(a) Better w orking condition(b) Better employee facilities(c) Reduced number of accidents(d) Increased earnings.Plant layout has a bearing on all these.Avoidance of unnecessary and costly changes.A planned layout avoids patronize changes which are difficult and costly.The incorporation of flexibility elements in the layout would help in the avoidance of revisions.