Factors influencing Location decision
• Political, social and legal policies – • Presence of Similar industries
Plans, Regulations, incentives, taxes
Employee Factors
• Availability and Cost of land
• Availability of amenities – Power,
• Availability of labour and skills water, land, Transport, schools,
recreation, housing
• Availability of raw material
• Safety requirements
• Existing capacities
• Suitability of land and climate
• Proximity to the market
• Society – Values, systems, aspirations
• Infrastructure availability – Telecom,
and needs
power, transport, roads, ports
Plant Layout
Physical arrangement of equipment and facilities within a plant to
ensure a smooth flow of work, material, people and information.
Objectives: Reasons: • Production delays
• Minimize • New products • Spoilage of materials
Investment in equipment • Changes in demand • Labour dissatisfaction and
risks
Overall production time • Changes in product design
• Customer dissatisfaction
Utilize existing space • New machines due to poor service
effectively • Bottlenecks
Material handling cost • Too large buffers Advantages:
• Provide for employee • Too long transfer times • Increased Productivity
convenience safety and • Better quality
comfort Costs
• Improved security
• Maintain flexibility of • Space
arrangement operation • Movement of materials
Layout Levels and Types
Levels:
• Inter departmental
• Intra departmental
Types:
• Fixed position Layout
• Process Layout / Functional Layout
• Product Layout / Line Production
• Group Layout/ Cellular manufacturing
Layout Levels and Types
Fixed Product Layout
• When the product is too large
• Rather than taking the product to the processes, the processes are
brought to the product
• Example: Shipbuilding, aircraft, construction Industry
• It is developed by locating workstations around the product
• Involves huge amount of logistics
Layout Levels and Types
Product Layout / Line Production (FLOW Shop)
• Production line according to the processing sequence of the product
• High volume production and Short distances
Sub
Operation I Assembly
Testing Packing Shipping
Operation Operation
Assembling Testing
II III
Layout Levels and Types
Process Layout / Functional Layout (JOB Shop)
• All machines performing a particular process are grouped together in
a processing department
• Low production volumes
• Rapid changes in the product mix
• High interdepartmental flow
Process Layout
Sub
Receiving Assembling Stores Painting Grinding Turing Welding Plant Office Shipping
assembling
Layout Levels and Types
Problems in Layout
Product Layout
• Too large to make quick change both in the product and
process
• Inflexible
Process Layout
• Lack of communication
• Lack of appreciation
• Diversion of focus from product and company’s goal
• Intervention required to solve conflicts between work centres and
between people belonging to same work centre
Layout Levels and Types
Group Layout / Cellular Manufacturing / Group Technology
• Compromise between product layout and process layout
• Instead of functional centers there are groups of machines/short lines
CELL?
• Each of these short lines or groups of machines
Cellular Manufacturing?
• Manufacturing consisting of several cells or using such group technology
Production Volume & Production Variety
determines the type of layout
Product layout Group layout Process layout
Production volume
Product variety
Cost Value Matrix
Process Layout Group Layout
Cost
Group Layout Product Layout
Value
Activity Relationship Diagram
• To depict spatially the relationship between activities/processes/functions.
• Reflect the magnitude of material flow
• Pair of activities having greatest pair wise flow
• Pair of activities having smallest flow are of little importance
• Pair of activates having ‘A’ rating are adjacently located
Rankings in terms of degree of
• Pair having ‘x’ rating are located far apart Nearness/Closeness necessary
• Proximity is not the only way A Absolutely essential
• Communication – Video linking, intercoms E Especially necessary
I Important
O Ordinary
U Unimportant
X Not desirable
Muther Grid
Rankings in terms of degree of
Nearness/Closeness necessary
A Absolutely essential
E Especially necessary
I Important
O Ordinary
U Unimportant
X Not desirable
Activity Relationship Diagram
Computerised 3D Solutions
1. CRAFT - Computerized Relative Allocation of Facilities Technique :
• The best known of the heuristics approaches
• It attempts to minimize materials-handling cost by calculating cost, pair-wise
interchanging departments, calculating more costs until a good solution is
obtained.
2. CORELAP - Computerized Relationship Layout Planning:
• It attempt to maximize a nearness rating within the facility dimension constraint
3. ALDEP -Automated Layout Design Program
• It evaluates two layouts
4. PREP - Plant Re-layout and Evaluation Package
• It analyzes multilevel structures and is based on actual footage traveled by
materials-handling
Questions ?
