Discuss the principles of a good plant layout What are its objectives Mention the factors affecting a plant

layout?

In: Manufacturing

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Answer:

Improve A scientific criteria for determining a good Plant Layout: 1. Integration: Integrates of men, materials and machines and support services in order to get the optimum output of resources. 2. Cubic space utilization: Utilization of both horizontal and vertical spaces and height is very important to use the space as much as possible. 3. Minimum distance: Minimum travel of men and material should be implemented means; the total distance travel by the men and material should be minimized as much as possible. Further straight line movements should be promoted. 3. Floor: Arranging the floor to move the material/finished products in forward direction towards the final stage. 4. Maximizing coordination: Entry into and disposal from any department should be in such manner that it is most convenient to the issuing or receiving departments. The layout should be consider as a whole. 5. Minimum flexibility: The layout should be able to modify when necessary. 6. Maximum accessibility:

All servicing and maintenance points should be readily accessible. For example; equipment should not be placed against a wall because necessary servicing or maintenance cannot be carried out easily. Further; equipments or other necessary units keep in front of a fuse box will impede the work of the electrician. 7. Safety security: Due consideration to industrial safety methods is necessary. Care must be taken not only of the persons operating the equipment, but also of the passes-by, who may be required to go behind equipment as the back of which may be unsafe. 8. Minimum handling: Reduce the material handling to the minimum. Material being worked on should be kept at working height and never have to be placed on the floor if it is to be lifted later. The following principles also can be taken in to account when planning for a good plant layout; The geographical limitations of the site; Interaction with existing or planned facilities on site such as existing roadways, drainage and utilities routings; Interaction with other plants on site; The need for plant operability and maintainability; The need to locate hazardous materials facilities as far as possible from site boundaries and people living in the local neighborhood; The need to prevent confinement where release of flammable substances may occur; The need to provide access for emergency services; The need to provide emergency escape routes for on-site personnel; The need to provide acceptable working conditions for operators.

Principles of a good plant layout: Overall integration of factors: A good layout is one that integrates men, materials, machines and supporting activities and others in a way that the best compromise is obtained No layout can satisfy each and every principle of a good layout. Some criterion may conflict with some other criterion and as a result no layout can be ideal it has to integrate all factors into the best possible compromise.

Minimum movement: A good layout is one that permits the minimum movement between the operations. The plant and machinery in case of product layout and departments in case of process layout should be arranged as per sequence of operations of most of the products. Since straight line is the shortest distance between any two points, men and materials as far as possible should be made to move along the straight path A door may be made in a wall or a hole may be drilled in a ceiling if that eliminates or reduces material handling in place of stairs or a distant door. Uni-direction flow: A good layout is one that makes the materials move only in the forward direction, towards stage of completion, with any backtracking. Since straight line is the shortest distance between any two, points, materials as far as possible should be made to move on the principle of straight-line flow. And when straight line flow is not possible, other flows like U-shaped flow, circular flow or zig zag flow may be adopted, but the layout may ensure that materials move in the forward direction. To ensure forward flow, equipment if necessary may be duplicated. Effective use of available space: A good layout is one that makes effective use of available space both horizontal and vertical. Backtracking and duplicated movements consume more time, involve un-necessary materials handling, add to cost and lead to inefficiency. Raw materials, work-in-progress and finished goods should be piled vertically one above another rather than being strewn on the floor. Pallets or equivalents should be made use of to pile up several layers one above another. Area below the work tables or in the cupboards built into the wall are welcome since they reduce requirement of space. Maximum visibility: A good layout is one that makes men, machines and materials ready observable at all times. All departments should be smoothly integrated, convenient to service and easy to supervise. Every piece of positioning or screening or partitioning should be scrutinized and carefully planned. Special cupboards, enclosures, offices, partitions etc. should be avoided except when their utility is established beyond doubt. Maximum accessibility: A good layout is one that makes all servicing and maintenance point readily accessible. Machines should be kept sufficiently apart and with reasonable clearance from the wall so that lubrication, adjustment and replacement of belts, removal of parts at the time of repairs etc can be done conveniently by the maintenance staff. Area in front of electrical panels and fire extinguishers should be kept free from obstructions.