FACILITY LAYOUT

A facility layout is an arrangement of everything needed for production of goods or

delivery of services.
A facility is an entity that facilitates the performance of any job.
It may be a machine tool, a work center, a manufacturing cell, a machine shop, a
department, a warehouse, etc.
The layout design generally depends on the products variety and the production
volumes.

To decide about layout planning, few questions must have an answer:

• Which centers do we have to consider?
• How much space and capacity are required for each center?
o If there is not enough space, productivity may be reduced.
o Too much space is expensive and may also reduce productivity.
• How must the space be configured at each center?
o Space quantity, shape and the elements of the work center are related
to each other.
• Where should each center be located at within the facility?
o The allocation of the different centers may affect productivity.

Objectives of Facility Layout

A facility layout problem may have many objectives.

In the context of manufacturing plants,

• Minimizing material handling costs is the most common one.
• Other objectives include efficient utilization of
o space
o labor
• Eliminate
o bottlenecks
o waste or redundant movement
• Facilitate
o organization structure
o communication and interaction between workers
o manufacturing process
o visual control
• Minimize
o manufacturing cycle time or customer flow time
o investment
• Provide
o convenience, safety, and comfort of the employees
o flexibility to adapt to changing conditions
 Factors affecting Plant Layout

The final solution for a Plant Layout must consider a balance among the characteristics
and considerations of all factors affecting plant layout, to get the maximum
advantages.
The factors affecting plant layout can be grouped into 8 categories:
• Materials
• Machinery
• Labor
• Material Handling
• Waiting Time
• Auxiliary Services
• The building
• Future Changes
Materials
• The layout of the productive equipment will depend on the characteristics of the
product to be managed at the facility, as well as the different parts and materials
to work on.
• Main factors to be considered: size, shape, volume, weight, and the physical-
chemical characteristics, since they influence the manufacturing methods and
storage and material handling processes.
• The sequence and order of the operations will affect plant layout as well,
considering the variety and quantity to produce.
Machinery
• Having information about the processes, machinery, tools, and necessary
equipment, as well as their use and requirements is essential to design a
correct layout.
• The methods and time studies to improve the processes are closely linked to
the plant layout.
• Regarding machinery, we must consider the type, total available for each type,
as well as type and quantity of tools and equipment.
• It’s essential as well to know about space required, shape, height, weight,
quantity and type of workers required, risks for the personnel, requirements of
auxiliary services, etc.
Labor

• Labor must be organized in the production process (direct labor, supervision,

and auxiliary services).
• Environment considerations: employees’ safety, light conditions, ventilation,
temperature, noise, etc.
• Process considerations: personnel qualifications, flexibility, number of workers
required at a given time as well as the type of work to be performed by them.

Material Handling
• Material handling does not add value to the product; it’s just waste.
 • Objective: Minimize material handling as well as combining with other operations
when possible, eliminating unnecessary and costly movements.

Waiting time - Stock

• Continuous Material Flow through the facility, avoiding the cost of waiting time
and demurrages that happen when the flow stops.
• On the other hand, the material waiting to flow through the facility not always
represents a cost to avoid. As stock sometimes provides safety to protect
production, improving customer service, allowing more economic batches, etc.
• It is necessary then to consider space for the required stock at the facility when
designing the layout.
• For Example: Resting time to cool down or heating up, etc.

Auxiliary Services
• Support the main production activities at the plant:
• Related to labor: Accessibility paths, fire protection installations, supervision,
safety, etc.
• Related to material: quality control.
• Related to machinery: maintenance and electrical and water lines.
• The auxiliary services represent around 30% of the space at a facility.
• The space dedicated to auxiliary services is usually considered as waste.
• It is important to have efficient services to ensure that their indirect costs have
been minimized.

Building
• If it has been already selected, its characteristics will be a constraint now of
designing the layout, which is different if the building must be built.

Future changes
• One of the main objectives of plant layout is flexibility.
• It’s important to forecast the future changes to avoid having an inefficient plant
layout in a short term.
• Flexibility can be reached keeping the original layout as free as possible
regarding fixed characteristics, allowing the adjustment to emergencies and
variations of the normal process activities.
• Possible future extensions of the facility must be considered, as well as the
feasibility of production during re-layout.
Types of Layouts
• Process Layout
o Used in a job shop for a low volume, customized products
• Product Layout
o Used in a flow shop for a high volume, standard products
• Fixed Position Layout
o Used in projects for large products e.g., airplanes, ships, and rockets
• Cellular layouts
o A cell contains a group of machines dedicated for a group of similar parts
o Suitable for producing a wide variety part in moderate volume

PROCESS LAYOUT

A process layout is a functional grouping of machines.

• For example, a group of lathe machines are arranged in one area, drill
machines in another area, grinding machines in another area and so on.
• Different job jumps from one area to another differently. Hence, the flow of jobs
is difficult to distinguish.
• This type of layout is suitable for a make-to-order or an assemble-to-order
production environment, as in a job shop where customization is high, demand
fluctuates, and volume of production low.
• Since a wide variety of products are produced, general purpose equipment and
workers with varied skills are needed.
• A process layout provides flexibility
PRODUCT LAYOUTS

A product layout arrangement of machines is as per sequence of operations.

• Every job visits the machines in the same order.
• This type of layout is suitable for a make-to-stock or an assemble-to-stock
production environment, as in a flow shop where products are standard,
demand stable, and volume of production high.
• Since variety is low, special purpose equipment’s and workers with a limited
skill are needed.
• A product layout provides efficiency.

Product vs. Process Layouts

• Inventory
• A product layout has a low work-in-process inventory and high finished
goods inventory because production is initiated by demand forecast.
• On the other hand, a process layout has a high work-in-process
inventory and low finished goods inventory.
• Material handling
• A product layout can use automatic guided vehicles which travels in a
fixed path.
• But variable path forklifts are suitable for a process layout.
• Scheduling/line balancing
• In case of a process layout, jobs arrive throughout the planning period.
• A process layout requires dynamic scheduling where a new scheduling
decision is made whenever a new job arrives.
• In case of a product layout, sequencing and timing of product flow are
standard and set when the line is designed.
• With a change in demand, a product layout may need a new line
balancing decision.
Cellular Layouts
• Every cell contains a group of machines which are dedicated to the production
of a family of parts.
• One of the problems is to identify a family of parts that require the same group
of machines.
• These layouts are also called as group technology layouts.

Advantages of Cellular Layouts

• Reduced material handling and transit time
• Reduced setup time
• Reduced work-in-process inventory
• Better use of human resources
• Better scheduling, easier to control and automate
 Disadvantages of Cellular Layouts
• Sometimes cells may not be formed because of inadequate part families.
• Some cells may have a high volume of production and others very low. This
results in poorly balanced cells.
• When volume of production changes, number of workers are adjusted and
workers are reassigned to various cells. To cope with this type of
reassignments, workers must be multi-skilled and cross-trained.
• Sometimes, machines are duplicated in different cells. This increases capital
investment.

Activity Relationship Chart

An activity relationship chart is a graphical tool used to represent importance of

locating pairs of operations near each other.
Importance is described using letter codes defined below:
A - Absolutely necessary
E - Especially important
I - Important
O - Ordinarily important
U - Unimportant
X - Undesirable

Computerized Layout Planning:

ALDEP- Automated Layout Design Program
CORELAP- Computerised Relationship Layout Planning
CRAFT- Computerised Relative Allocation of Facilities Techniques

Recent Trends in Layout

• Flexible
• Modular
• Easy to reconfigure
Designing Product Layouts- Assembly Line Balancing

• Identify the tasks and immediate predecessors

• Determine the output rate
• Determine the cycle time
• Amount of time each workstation is allowed to complete the task
• Compute the Theoretical Minimum number of workstations
• Assign tasks to workstations
• Compute efficiency, idle time and balance delay

Case:
Determine Cycle time & Theoretical number of workstations required for Output of 60
units/hour using Assembly Line Balancing

Task Immediate Task time (sec)

Predecessor
A - 50
B A 5
C B 25
D C 15
E D 12
F D 10
G D 15
H E,F,G 18
I H 15

Assembly Line Balancing

A B C D F H I

G
 Determine Cycle time & Theoretical number of workstations required

𝐴𝑣𝑎𝑖𝑙𝑎𝑏𝑙𝑒 𝑇𝑖𝑚𝑒/ℎ𝑟 60 𝑚𝑖𝑛/ℎ𝑟∗60 𝑠𝑒𝑐/𝑚𝑖𝑛

Cycle Time = = = 60 sec
𝐷𝑒𝑠𝑖𝑟𝑒𝑑 𝑜𝑢𝑡𝑝𝑢𝑡/ℎ𝑟 60 𝑢𝑛𝑖𝑡𝑠/ℎ𝑟

Theoretical number of workstations required

𝑇𝑜𝑡𝑎𝑙 𝑇𝑎𝑠𝑘 𝑡𝑖𝑚𝑒𝑠/𝑢𝑛𝑖𝑡
=
𝐶𝑦𝑐𝑙𝑒 𝑇𝑖𝑚𝑒
165
= = 2.75 3 workstations
60

Assign tasks to workstations

Work Eligible Task as Task Task time Idle Time (Sec)

station per precedence Selected (sec)

1 A A 50 10
B B 5 5
2 C C 25 35
D D 15 20
E,F,G G 15 5
3 E,F E 12 48
F F 10 38
H H 18 20
I I 15 5

Compute Efficiency & Balance Delay

Productive (Total task) time 165

Efficiency= = = 0.917 or 91.7%
No of Workstations ∗Cycle Time 3∗60

Balance Delay = 1- Efficiency = 1- 0.917= 0.083 or 8.3%

Idle Time=  Idle time for each workstation= 5+5+5= 15 sec
 Material Handling Equipment (MHE)

Material handling equipment (MHE) refers to a diverse group of tools, vehicles,

appliances, and devices used for moving, storing, and controlling materials and
products throughout various stages of manufacturing, distribution, warehousing, and
logistics processes.
These equipment types are essential for improving efficiency, reducing manual labor,
ensuring safety, and streamlining material flow in industrial settings.
Selecting the right material handling equipment depends on the specific needs and
requirements of a given operation, including factors like the type of material being
handled, the layout of the facility, and safety considerations. Effective material
handling equipment can significantly improve the efficiency, safety, and productivity of
industrial and logistics processes.

Objectives of MH:
• To increase efficiency of material flow by ensuring availability of materials when
where needed
• To reduce MH cost
• To improve facilities utilization
• To improve safety working conditions
• To facilitate manufacturing processes
• To increase productivity

Common types of material handling equipment:

Conveyors: Conveyors are mechanical systems used to transport materials from one
location to another. They come in various types, including belt conveyors, roller
conveyors, chain conveyors, and screw conveyors. They are widely used in
manufacturing, distribution, and assembly operations.
Forklifts: Forklifts are powered industrial trucks with forked platforms used to lift and
move heavy loads. They are commonly used in warehouses, manufacturing plants,
and logistics operations.
Pallet Jacks: Also known as pallet trucks or pallet movers, these are manual or
powered devices used to lift and move palletized loads within a facility.
Cranes and Hoists: Cranes and hoists are used for lifting and moving heavy materials
and equipment. Overhead cranes, gantry cranes, and jib cranes are common types
used in industrial settings.
Automated Guided Vehicles (AGVs): AGVs are autonomous or semi-autonomous
vehicles used for material handling tasks. They follow predetermined paths, often
using sensors and software for navigation.
Stackers and Retrievers: These machines are used to stack and retrieve goods from
high storage racks or shelves. They are often used in automated storage and retrieval
systems (AS/RS).
Shelving and Racking Systems: These systems are used to store and organize
materials and products. They come in various configurations, including pallet racks,
cantilever racks, and mezzanines.
Carts and Dollies: Carts and dollies come in different forms, such as platform trucks,
hand trucks, and pushcarts. They are used for manually transporting goods within a
facility.
Robotic Material Handling Systems: Robotic systems are increasingly used for tasks
like picking and packing, sorting, and transporting materials within warehouses and
distribution centers.
Conveyor Sortation Systems: These automated systems use conveyor belts and
diverters to sort and route items to their appropriate destinations, often used in e-
commerce and distribution centers.
Lift Tables: Lift tables are hydraulic platforms used for raising or lowering materials to
the desired working height, making it easier for workers to handle them.
Loading Dock Equipment: Loading dock equipment includes dock levelers, dock seals,
and dock shelters used to facilitate the loading and unloading of goods from trucks to
warehouses or vice versa.
Drum Handling Equipment: Drum handlers, such as drum lifters and drum tilters, are
used to safely handle and transport drums and barrels.
Conveyance Accessories: Accessories like chutes, hoppers, and diverters are used to
enhance the functionality of conveyors and facilitate material flow.
Air Casters and Rollers: These devices use air pressure to lift and move heavy objects
with minimal friction, making them suitable for sensitive or heavy-duty applications.

Conveyors:
Conveyors are used for moving materials continuously over a fixed path
Examples of different conveyors are
•Roller Conveyors
•Belt Conveyors
•Hand Conveyors
Advantage
• Permits high capacity for moving large number of items
• Their speed is adjustable
• Handling combined with other activities such as processing inspection is
possible
• They are versatile can be on floor or overhead
• Temporary storage of loads between work station is possible (particularly
overhead conveyors)
• .Load transfer is automatic does not require the assistance of many operators
Disadvantages
1.They allow a fixed path, serving only limited areas
2.Bottlenecks can develop in the system
3.A breakdown in any part of the conveyor stops the entire line
4.Since conveyors are fixed in position, they hinder the movement of mobile
equipment on the floor

Cranes & Hoists

Cranes/ Hoists are items of overhead equipment for moving loads intermittently
within a limited area
Bridge Cranes,
Monorail Cranes,
Advantages
1.Lifting as well as transferring of material is possible
2.Interference with the work on the floor is minimized
3.Valuable floor space is saved for truck rather than being utilized for installation of
handling equipment
4.Capable of handling heavy loads
5.Can be used for loading unloading of materials
Disadvantages
1.They require heavy investment (especially bridge cranes)
2.They serve a limited area
3.Some cranes move only in straight line & thus cannot make turns
4.Utilization may not be as high as desirable since cranes are used only for a short
time during daily work
5.An operator must be available for operating some types, such as bridge cranes

Hoists Cranes & Hoists

TRUCKS
Hand or Powered Trucks move loads over varying paths
Examples of such Trucks include
• Lift Trucks,
•Fork Trucks,
•Trailer Trains,
•Automated Guided Vehicles Trucks

Advantages
 •They do not require to follow a fixed path of movement & therefore can be
used any where on the floor where space permits
• They are capable of loading, unloading, & lifting, in addition to transferring
material
• Because of their unrestricted mobility, which allows them to serve different
areas, trucks can achieve high utilization
Disadvantages
•They cannot handle heavy loads
•They limited capacity per trip
•Aisles are require; other wise the trucks will interfere with the work on the
floor
•Most trucks have to be driven by an operator
•Trucks do not allow handling to be combined with processing & inspection,
as other type of eqpt do

Degree of Mechanization In Material Handling

• A MH System can be completely manual or fully automated
• Different degrees of mechanization also exist between these two extremes
• Level of Mechanization in MH System is classified with respect of Source of
power for handling, degree of human involvement computers in operating the
eqpt
Level of Mechanization can be classified as
1. Manual Dependent on Physical Effort
This level also includes manually driven equipment such as
hand truck
2. Mechanized
Power instead of physical effort is used for driving the eqpt Some
trucks, conveyors, cranes fall into this level Here operators are needed
for operating the eqpt as opposed providing the power
3 Mechanized Complemented with Computers
It is an extension of 2 nd level The function of the computers is to
generate documents specifying the Moves Operations
Level of Mechanization can be classified as 4- Automated
Minimum human intervention is used for driving operating the eqpt most
of these functions are performed by computers
 Examples includes Conveyors, AGVs, AS/RS
The equipment usually receives instructions form key boards, pushbuttons,
tape or card readers

Level of Mechanization can be classified as 5- Fully Automated

This level is similar to the 4 th level, but computers perform the
additional task of on line control, thus eliminating the need for human
intervention
The cost complexity of designing the system increases as the degree
of mechanization increases
However, efficiency of operations labor savings can result
 AGV’s:

Principles of MH
• There are no definite rules that can be followed for achieving a successful
material handling system
• There are, however, several guidelines that can result in reducing the system
cost in enhancing efficiency
• These guidelines are known as Principles of Material Handling

20 Principles of Material Handling

1. Planning: Plan all MH Storage activities to obtain maximum overall operating

efficiency
2. System Flow: Integrate as many handling activities as is practical into a
coordinated system of operations covering vendor, receiving, storage,
production, inspection, packaging, warehousing, shipping, transportation and
customer
3. Material Flow: Provide an operation sequence equipment layout optimizing
material flow
4. Simplification: Simplify handling by reducing, eliminating, or combining
unnecessary movements &/or equipment
5. Gravity: Use gravity to material handling whenever practical
6. Space: Utilization Make optimum utilization of the building cube
7. Unit Size: Increase the quantity, size or weight of unit loads or flow rate
8. Mechanization: Mechanize handling operations
9. Automation: Provide automation to include production, handling storage
functions
10. Equipment Selection: In selecting handling equipment, consider all aspects
of the material handled, the movement, the method to be used
11. Standardization: Standardize handling methods as well as type sizes of
handling equipment
12. Adaptability : Use methods equipment that can best perform a variety of tasks
applications when special purpose equipment is not justified
13. Dead Weight: Reduce the ratio of dead weight of mobile handling equipment
to load carried
14. Utilization: Plan for optimum utilization of handling equipment manpower
15. Maintenance: Plan for preventive maintenance & schedule repairs of all
handling equipment’s
16. Obsolescence: Replace obsolete handling methods & equipment when more
efficient methods of equipment will improve operations
17. Control: Use material Handling activities to improve control of production,
inventory & order handling
18. Capacity: Use handling equipment to help achieve the desired production
capacity
19. Performance: Determine the effectiveness of handling performance in terms
of expense per unit handled
20. Safety: Provide suitable methods & equipment for safe handling