UNIT-3

Layout of Manufacturing/Service Facility

Introduction

For an organization to have an effective and efficient manufacturing unit, it is important that
special attention is given to facility layout.
Facility layout is an arrangement of different aspects of manufacturing in an
appropriate manner as to achieve desired production results. Facility layout considers
available space, final product, safety of users and facility and convenience of operations.
An effective facility layout ensures that there is a smooth and steady flow of production
material, equipment and manpower at minimum cost.
Facility layout looks at physical allocation of space for economic activity in the plant.
Therefore, main objective of the facility layout planning is to design effective workflow as to
make equipment and workers more productive.

Facility Layout Objective

A model facility layout should be able to provide an ideal relationship between raw material,
equipment, manpower and final product at minimal cost under safe and comfortable
environment. An efficient and effective facility layout can cover following objectives:

To provide optimum space to organize equipment and facilitate movement of goods and to
create safe and comfortable work environment.
To promote order in production towards a single objective
To reduce movement of workers, raw material and equipment
To promote safety of plant as well as its workers
To facilitate extension or change in the layout to accommodate new product line or
technology upgradation
To increase production capacity of the organization

An organization can achieve the above-mentioned objective by ensuring the following:

Better training of the workers and supervisors.

Creating awareness about of health hazard and safety standards
Optimum utilization of workforce and equipment
Encouraging empowerment and reducing administrative and other indirect work

Factors Affecting Plant Layout-

WHAT IS PLANT LAYOUT?

Plant layout is simply a mechanism which involves knowledge of the physical arrangement
of every component of the production Process for the facilities to additional space efficiency
for manufacturing cost reduction to continuous and steady movement of the production
cycle.
This arrangement includes the space needed for material movement, storage, indirect
labour and all other supporting activities or services.
Plant Layout is a master blueprint which provides for the most effective utilisation of
machine, manpower, materials for coordinating all operations performed inside the factory
to increase overall productivity.
Here are objectives of Plant Layout that we can achieve by using Effective Plant Layouting.

OBJECTIVE OF GOOD PLANT LAYOUT

oEffective Utilisation of installed machinery and Manpower

oMinimization of Material Handling
oElimination of Bottlenecks through the Line balancing
oElimination of physical efforts with Low Cost Automation
oHigh turnover with reduction in Delivery Failure
oWIP(Work in progress) reduction between processes
oNatural light,Ventilation,Control of noise and vibrations for better Ergonomics and Energy
Cost reduction
oSufficient work space for a better Work Environment
oAisle and Gangways planning for better Accessibility and Monitoring
oStore designed based on better Flow, Accessibility, Capacity of storage and Traceability of
materials
oReduction in changeover time through SMED (Single Minute Exchange of Die)
oDust control based on different types of Clean rooms/ ISO norms
oDistance travel reduction of Material and Manpower etc
oReduction in Labour cost
oReduction in manufacturing time
oIncreased flexibility
oFuture Expansion
The eight factors affecting plant layout are as follows: 1. Man Factor 2. Material Factor 3.
Machinery Factor 4. Movement Factor 5. Waiting Factor 6. Service Factor 7. Building Factor
8. Flexibility Factor.
Whatever be the type of layout being contemplated, the following factors are to be considered
because these factors have got significant influence on the design of the layout.
1. Man Factor:
The man is very flexible element who can be made suitable for all sort of layouts.
Main considerations are as follows:
(i) Safety and working conditions.
(ii) Man power requirements-skill level of workers, their number required and their training
programme.
(iii) Man power utilization in the plant.
(iv) Human relations.
2. Material Factor:
It includes the various input materials like raw materials, semi-finished parts and materials in
process scrap, finished products, packing materials, tools and other services.
The main considerations are:
(i) Design and specifications of the product to be manufactured.
(ii) Quantity and variety of products and materials.
(iii) Physical and chemical characteristics of various input materials.
(iv) Component parts or material and their sequence of operations i.e. how they go together to
generate the final product.
3. Machinery Factor:
The operating machinery is also one of the most important factors therefore all the
information’s regarding equipment and the tools are necessary for inspection, processing and
maintenance etc.
(i) The processes and methods should be standardized first.
(ii) Machinery and tools selections depend upon the type of process and method, so proper
machinery and other supporting, equipment should be selected on the basis of volume of
production.
(iii) Equipment utilization depends on the variation in production, requirements and operating
balance. Machines should be used to their optimum levels of speed, feed and depth of cut.
(iv) Machinery requirement is mostly based on the process/method.
(v) Maintenance of machines and replacement of parts is also important.
4. Movement Factor:
It mainly deals with the movement of men and materials. A good layout should ensure short
moves and should always tend towards completion of product. It also includes
interdepartmental movements and material handling equipment. This includes the flow
pattern reduction of unnecessary handling, space for movement and analysis of handling
methods.
5. Waiting Factor:
Whenever material or men is stopped, waiting occurs which costs money. Waiting includes
handling cost in waiting area, money tied up with idle material etc.
Waiting may occur at the receiving point, materials in process, between the operations etc.
The important considerations in this case are:
(a) Location of storage or delay points.
(b) Method of storing
(c) Space for waiting.
(d) Safeguard equipment for storing and avoiding delay.
6. Service Factor:
It includes the activities and facilities for personnel such as fire protection, lighting, heating
and ventilation etc. Services for material such as quality control, production control, services
for machinery such as repair and maintenance and utilities liked power, fuel/gas and water
supply etc.
7. Building Factor:
It includes outside and inside building features, shape of building, type of building (single or
multistory) etc.
8. Flexibility Factor:
This includes consideration due to changes in material, machinery, process, man, supporting
activities and installation limitations etc. It means easy changing to new arrangements or it
includes flexibility and expendability of layouts.
1.) Product
The layout will depend on the characteristics of the product like size, shape, volume, weight,
etc. If the product is heavy, then a fixed layout will be a good option. In the case of a small
product that requires mass production, then a line or product layout should be chosen.
2.) Machinery
If the machinery is heavy and required for a special purpose, then the product layout is
preferred. On another side, if machinery is required for general purposes, then process layout
will be the best option. It is essential to know about the space, shape, height, weight, the
number of machines & equipment required for the project.
3.) Labor
Labour has to be organized in the production process. The size of the labour and staff affects
the layout of the plant. Personnel qualifications, flexibility, the number of workers required at
a given time, the type of work to be performed are the things that should be kept in mind.
4.) Material Handling
The type, nature, weight, quantity, quality, storage space for material must be considered
while taking the facility layout decision. It is the material that determines the quality and
efficiency of the output. If possible, eliminating unnecessary and costly movements of
material which will ensure a smooth flow of production.
5.) Plant site
The geographical location is also an important factor to be considered while deciding on plant
layout. The connectivity with rail, roads, or water shows the smooth flow of inputs and
outputs. In this case, management can go with less space for storage.
6.) Auxiliary Services
Auxiliary Services Support the main production activities at the plant
a.) Related to labor - Accessibility paths, fire protection installations, supervision, safety, etc.
b.) Related to the material - Quality control.
c.) Related to machinery - Maintenance and supply of electricity and water.
7.) Building
There are two options available with the company to construct the building as per their
requirement or to shift to a ready-to-move-in building. If the company selecting a ready-to-
move-in building, then the company should check that the building can fulfill its purpose of
installing the layout of a specific type.
8.) Future Changes
The layout of the plant should be flexible. It’s important to forecast future changes to make
modifications in the plant whenever required. It should also be taken into consideration that,
if any extensions of the facility required in the future, then it can be done without any
difficulties.
 Types of Layout
What is Layout?

The Layout is the master plan or a blueprint of the printed/published work that lays out the
order of its various graphic elements.

The layout may refer to:

oPage Layout means the arrangement of visual elements on a page.

oComprehensive Layout means a proposed page layout that a designer presents to their
customers.
oLayout (computing) means the process used to calculate the position of the objects in the
space.
oIntegrated circuit layout signifies the geometric depiction of an integrated circuit.
oAutomobile layout signifies the description of a vehicle's engine and driving wheels
positions.
oKeyboard layout refers to the layout of keys on a typographic keyboard.
oLayout engine is another name of the web browser engine, the main software that displays
the content in a web browser.
oProcess layout a plant's floor plan, which arranges equipment based on its function.
oProduct layout means a plant floor design in which workstations and equipment are
arranged according to assembly sequence.

Characteristics or Features of a Good Layout

The following are the characteristics or features of a good layout:

1. Efficient Space Utilization

Real estate costs are constantly increasing. An optimal layout must use the available space in
a compelling manner. There should be no waste of space at all. Equipment, service points,
and staff must be arranged so that space is efficiently utilized.

2. Economy in Handling

When it comes to resources, work-in-progress, and finished stock, the layout must be cost-
effective. Handling must be decreased by the ideal utilization of truck lifts, conveyors, chutes,
and hoists.
3. Minimum Movement

The layout must be designed in such a way that equipment and people move as little as
possible. Movements must be quite far. Indirect material handling would needlessly increase
cost without adding any benefit. As a result, wherever possible, avoid using indirect handling.

4. Accessibility

The facility of manufacturing, maintenance, and servicing must be effectively available with
no prevention. There should be adequate space between equipment to accomplish this goal so
that the raw materials, machines, and men can move unreservedly from one place to another.

5. Flexibility

Manufacturing is a dynamic process. There is consistent advancement in sorts of products

manufactures and in equipment, methods, and production process. Hence, the layout has to be
designed in such a manner that it can adapt to changes.

6. Preservation of Materials and Equipment

The layout must comprise safeguards against fire, theft, moisture, and general deterioration of
equipment and materials. There should be sufficient and secure storage facilities. There
should be a system in place to store flammable goods separately and safely.

7. Reduction Discomfort

The layout should be created in such a way that the workers are as comfortable as possible. It
should have adequate lighting and ventilation and limit the effects of heat, smells, noise,
vibrations, and dust.

8. Visibility

Work must be organized so that there is no issue in oversight, organization, and control. Raw
materials, work in progress and finished goods should all have designated storage areas that
are always visible. This would lessen the issue of pilferage, stealing, etc.

9. Ensuring Co-ordination

A decent layout would have the option to coordinate all tasks. However, the format must be
planned considering the inter-relationships among several departments,
equipment, and personnel. As a result, it is critical to evaluate the entire picture of the
organization when creating the layout.

10. Adherence to Statutory Regulations

The layout must adhere to the guidelines of the Factories Act for the wellbeing, security, and
welfare of employees. Adherence to the above guidelines would lessen mishaps, decrease
absenteeism because of illness, resulting in increased productivity.

Types of Layouts

There are four basic types of layouts:

1. Process Layout

Process layout means the layout which group resources based on the similar processes or
functions. This type of layout can be found in companies that use intermittent processing
systems. A process layout is used in contexts where many different items are produced in
small quantities. Because there are so many different items are produced with distinct
processing requirements, it is not viable to allocate an entire facility to each item. It is more
effective to organize resources based on their function. The products are then shifted from
one resource to the next according to their specific requirements.

2. In process layout, the main challenge is to organize the resources to maximize efficiency
and minimize waste of the movement. If the process layout is not appropriately designed,
numerous items should be moved considerable distances, typically on a regular basis. This
kind of movement adds nothing to the worth of the product and contributes.

Advantages of Process Layout

There are various advantages of process layout:

1. Overheads Expenses are Reduced

Because of the low investment at the underlying level, the investment risk is reduced.
Likewise, there is no duplication of machines in this layout. Besides, various machines can be
worked and controlled by one operator because of the similarity of activities. In this way, per
unit overhead cost will be reduced.

2. More Flexibility

A single machine can conduct several similar operations in the process layout. So, in a
machine breakdown situation, another machine in a similar department can do a similar
operation, or even a comparable machine lies in another department that can do a similar
function. As a result, this layout provides more flexibility in processing production
operations.

3. Maximum Utilization of Machines

The machine can be used to its full potential because a machine is not linked to any specific
product in a layout during the process.

4. Low Investment in Equipment and Machines

There are no sets of operating sequence in the process layout that the equipment and
machines must pass through. As a result, products of various verities within the established
standards can be developed using this layout, and no duplication of equipment is necessary
for such a process. Hence, less capital is required because the machines' maximum potential
is utilized.

Disadvantages of Process Layout

There are various disadvantages of process layout:

1. More Processing Time

In process layout, the time required to finish a job will be longer because each project will
flow between several departments. When the work has been collected from the preceding
department, machine loading takes a long time.

2. Frequent Need for Inspection

The same manufacturing department manages many items in the process layout. As a result,
moving work to the next level of operation in another department, inspection is required on a
regular basis.

3. Bigger Space at Floor

Process layout takes up a significantly more prominent space on the floor. For machine
installation and locating several departments. The full available floor area cannot be used
because of the enormous size of the floor space.

4. Higher Material Handling Costs

Material management costs are higher in-process layouts due to different day-to-day routines
of various departments and longer distances to move jobs.

2. Product Layout
When all the processing equipment and machinery are positioned according to the product's
sequence of operations, this type of layout is known as product layout. The main focus of
product layout is the sequence of operations regarding the production or assembly needed for
a product or some of its parts manufacturing and assembling. Product layout is typically
advantageous for sectors that produce in large quantities or on a continuous basis, such as
automobile assembling, cement manufacturing, and oil refining.

When it comes to product layout, if there is a significant production volume of one or more
than one product, facilities can be aligned to ensure optimal material flow and reduce cost per
unit. For this purpose, specialized machines are used to perform the desired jobs in a timely
and reliable manner. However, it is not like process layout; product layout is not flexible
because it is designed for developing or assembling a single product.

We can see this kind of layout in flow shops where there is a lot of assembly repetition. To
generate more standardized goods in high numbers, flow shops need repetitive and highly
standardized operations. According to the product routing schedule, the resources in the
product layout are arranged in a specific order. Through this sequential layout, the complete
process is organized in a straight line. The flow of line can be divided again to ensure that
workers are used efficiently throughout the operation. Line balancing is widely used to
improve product layout efficiency. Line balancing is a method used to assign jobs to a
different workstation so that the time requirements at each workstation are roughly equal.

Advantages of Product Layout

There are various advantages of the product layout.

1. Cost of Material Handling is Lesser

In product layout, the machines are arranged based on the sequence of operations, so there is
no forward and backward movement. As a result, material handling expenses and time are
reduced. It also removes the transportation cost, which is associated with moving materials
between machines.

2. Time-Saving

The product layout aids in reducing the amount of time spent moving goods because
materials can be transported using various automated equipment such as conveyor belts. This
helps to save a substantial amount of time.

3. Use of Resources in Effective Way

In product layout, we can effectively use the resources because product layout helps to reduce
the movement of workers, eliminating waste, continuous manufacturing process, lowering
do7.wn the work-in-process.

4. Control Over Production

The product layout helps production control because of the continuous manufacturing
process. Management may find it simple to plan operations, and they may take steps to ensure
that the job is completed according to the plans.

5. Smooth Production Flow

Another advantage of product layout is smooth production flow. The entire production
process is incorporated into the product layout. As a result, there is no risk of production
being halted at any point during the manufacturing process. Thus, this layout ensures that the
production runs smoothly.

6. Lower Work-in-Progress

In product layout, the production process is continuous and flexible; the work-in-progress is
also reduced. Work-in-process needs less storage space and investment.

7. Utilization of Space in Optimum Way

We can appropriately use the available space because of the sequences of machines. Also, if
the space is limited, machines can be organized in a U shape to maximize efficiency.

Disadvantages of Product Layout

There are various disadvantages of product layout:

1. Difficulty in Expansion

It's difficult to increase production beyond the capability of production lines.

2. The Extra Cost of Surplus Workers

Workers that are skilled at working on specialized machines are inexperienced when it comes
to operating other machines. So, if a worker assigned to a specific task is away for a few days,
it has a negative impact on the entire workforce. In such circumstances, it may be necessary
to hire additional staff and train them to work on various machines.

3. Monotony

The product layout creates monotony because of the repetitive kind of work for workers. The
worker has very little opportunity to demonstrate their abilities.
4. Costly Layout

Product layout is viewed as an expensive layout because there may be duplication of

machines of similar kinds needed for various production lines because of the machine
arrangement based on the sequence operations.

3. Combination Layout

The advantages of both kinds of layouts are combined in a process and product layout. A
combination layout is possible when an item is manufactured in multiple types and sizes. The
machinery is grouped in a process layout, but the process grouping is then ordered in a
sequence to make a variety of goods of different types and sizes.

It is to be noted that the sequence of processes is consistent over a wide range of processes is
consistent over a wide range of items and sizes.

The following figure displays a mixed type of layout for manufacturing various sized gears.

4. Fixed Layout

The fixed layout permits a product to maintain at a particular place, and the needed resources
like manpower, machinery, material, equipment, etc. are transported to the product's
location.\

In other words, the place of the main element or the product section remains fixed because of
the larger size or substantial body.

Additionally, the expense of moving or transportation costs will be lesser on account of

moving assets when contrasted with the transportation cost associated with the movement of
the product.

As a result, it is more advantageous to move the necessary tools, staff,

hardware, and materials to the place where the product is gathered instead of shifting the
product. For example, different products such as heavy ships, airplanes, projects related to
construction are usually manufactured via a fixed-position layout. This layout is also often
utilized in various on-site services, such as service related to housecleaning, landscaping, pest
control, etc.

The fixed-position arrangement is used by a variety of organizations that manufacture boilers

and turbines. Transport to the construction site.
Correspondingly, this layout is appropriate for hospitals, where patients are the primary fixed
products, and doctors, medical personnel, medicines, and other necessary items are deployed
for the patient.

Advantages of Fixed Position Layout

There are various advantages of fixed position layout:

1.Provides greater flexibility

2.The layout has a low capital investment.
3.Enhances worker capabilities and facilitates job enlargement.

Disadvantages of Fixed Position Layout

There are various disadvantages of fixed position layout:

1. Work Schedule of Workers

A plant, which has implemented a factory position layout, necessities to design the plan for
getting work done for laborers in a cautious way, so every single one of them is allocated the
necessary chance to deal with the specific phase of the production process. If there should be
an occurrence of the non-availability of a specialist or the situation of the non-working limit
of the laborer, at that point, it might moderate the speed of different phases of the process.
This could cause the product's development time to lengthen, and the plant could lose money
due to higher overhead costs.

2. Limited Workspace

Limited workspace is one of the disadvantages of fixed-position layouts. Due to the number
of workers necessary in various manufacturing steps, there may be a constraint on the
workspace.

3. Cost of Equipment

Another disadvantage of fixed-position layout is the equipment's cost. The product remains in
a single area in a fixed position layout, and various tools, equipment, and machinery are
essential to moving the product's location. As a result, transportation, maintenance, and
equipment expenses are all extremely high.

4. Need Based Order of Material

One of the drawbacks of utilizing a fixed-position layout is that hardware and materials
should be moved when these are essential. Where hardware and materials can be stored and
kept in a safe working environment until they're needed for the next step in the production
process.
5. Group Technology or Cellular Layout

Group technology or cellular technology is viewed as a strategy via which it is feasible to

recognize and group comparable or related parts elaborate in the production process to take
advantage of the inherent economy of flow production methods.

In other words, in group technology or cellular manufacturing layout, different machines are
grouped based on the process requirements for a similar set of products or groups of
comparable parts that require a comparable sort of processing. Groups that are formed in such
a manner are named cells.

In group technology or cellular layout, cells are formed by grouping various processes. This
process incorporates the identification of parts having comparable qualities in the context of
their design, example, shape, size, and function. Furthermore, qualities of a comparative
process, for example, required processing type, sequence of processing, and the type of
machinery to perform.

In this type of layout, workers are provided cross-training to improve their ability to operate
diverse equipment in a specific cell and be responsible for that cell's output. In a couple of
cases, the formation of a cell depends on using specific equipment for creating pieces of a
family without the need for actual equipment relocation into a physical cell. These cells are
named virtual or nominal cells. An organization can avoid the hassle of altering its current
arrangement by doing so.

An automated variant of the cellular layout, i.e., a Flexible Manufacturing System (FMS) is
also available. A system that uses this technology deals with the control of transferring parts
to various processes. A system that uses this technology deals with the control of transferring
part to various processes. This allows producers to acquire a couple of benefits product
layouts while still maintaining the manufacturing flexibility associated with small batches.

For instance, there is a manufacturing unit that produces 10,000 parts. These parts may be
grouped into one of 50/60 families of parts. Every family has a similar kind sort of design and
qualities of manufacturing.

As a result, all members of a family will be processed in the same way. This aids in the
production of manufacturing efficiencies.

Advantages of Group Technology or Cellular Layout

The following are the advantages of a group or cellular layout.

1. Enhances Motivation
Different personnel are provided cross-training to manage all machines in their cell in group
technology or cellular layout, which helps to increase their motivation by minimizing
monotony. This improves job ownership and autonomy because workers are accountable for
the production of their cells.

2. Increase Flexibility

Group layout or cellular allows for the production of small batches, which increases
flexibility to some level.

3. Reduced Cost

Group technology or cellular layout contains a number of benefits such as faster processing
time, reduced material handling time, less inventory in work-in-process, and less set-up time.
This is beneficial in terms of cost-cutting.

OR

TYPES OF PLANT LAYOUT

Plant Layout is the arrangement of machines, equipment and other physical facilities in a
planned manner.
We design Plant Layout according to many factors like- Machinery , Product , material etc.
On the basis of arrangement of the factors we have following 4 types of Plant Layout-
1-Product or Line Layout
2-Process or Functional Layout
3-Fixed or Position Layout
4-Combination Layout

PRODUCT OR LINE LAYOUT

If all the machines are arranged in a line sequence according to the sequence of operations of
the products then it is known as Product or Line Layout.
In this arrangement each following machine or section is arranged to perform the next
operation that is performed by its preceding machine or section,
i.e. raw material starts from one end of production lines and moves from one machine to next
with a storage and material handling and minimum work in process in a sequential path.
This type of layout is suitable for mass production and for the products having steady
demand.
This arrangement is also good for the continuous production system where the products have
small parts that are highly standardised and interchangeable.
 Product or Line Layout
ADVANTAGES

Low material handling cost

Less WIP (Work in progress)
Better utilisation of Machine and Manpower
Lesser time in Production
Less space requirements
Minimum possible cost of manufacturing

DISADVANTAGES

No flexibility
Breakdown of any machine in the line may shut down the whole production line
Difficulty in increase the production beyond the capacities of the production lines
If the output rate of one machine is slower than the other machine,over all production rate
decreases

PROCESS OR FUNCTIONAL LAYOUT

In Process or Functional Layout all the similar machines are positioned together so that all the
similar operations are performed at the same place.
Machines are arranged according to the nature or type of the operations or their functions.
For all the different types of functions separate machines are available i.e. For carrying out
tapping work, all the tapping machines are grouped together and for carrying out drilling
work all the drilling machines are arranged together.
This type of layout is useful where low volume of production is needed.
It is normally preferred for the industries involved in batch production, manufacturing and
maintenance activities of non- repetitive type.
ADVANTAGES

Inthis type of layout there is no need for layout change for different types of products
Breakdown of any machine can be easily handled by transferring work to another machine
Wide flexibility exists regarding allotment of work to workers and equipment
There is a better utilisation of all the machines
There is an improved product quality because of separate supervisors and workers for all
types of machines
Breakdown of any machine does not affect the production of other machines
Load distribution is easily controlled
DISADVANTAGES

High cost of material handling

Large space required
High investment required for inventory
High cost of supervision
Production time is longer
Bottlenecks occur due to more work is in queue and waiting for further operation
More floor area is required
Scheduling is tedious because work does not flow through definite lines

FIXED OR POSITION LAYOUT

In Fixed or Position type of layout the major part of a material remains at a fixed position and
all accessories, material, required tools , machinery and other supporting equipment are
brought to this location and this layout is also known as project layout.
This layout is good for extremely large items manufactured in very small quantities and
highly preferable when the cost of moving a major piece of material is high.
This layout is used in the manufacturing factory of boilers, hydraulic and steam turbines etc.

ADVANTAGES

Less material and workers movement

Less Capital investment
Highly flexible for varieties of products
Ensures Continuity
Less production cost

DISADVANTAGES

Complicated fixtures
Required highly skilled manpower
Movement of machines is time consuming
Machines are not fully Utilised
It is limited to large items only
COMBINATION LAYOUT

Combination Layout is also known as group layout.

In this layout we use a combination of all above layouts.
Every layout has its advantages and disadvantages therefore industries prefer to use a
combination of layouts.
These days most of the manufacturing industries have adopted this kind of layout.
In this type of layout we connect all the good features of all the types of layout to obtain a
compromise solution which will be more economical and flexible.

ADVANTAGES

Reduction in cost of material handling and machine set-up time

Elimination of excess work-in-process inventory
Simple production planning functions
Smooth flow of work

DISADVANTAGES

Change of the existing layout is costly and time consuming

Including new components requires thorough analysis
Complex to use
Here We discuss types of Plant Layout and their advantages & disadvantages after reading
that you can be confused to choose the perfect layout for your Plant so, let’s discuss the
factors you need to keep in mind when choosing layout for your plant.
HOW CAN YOU DETERMINE THE OPTIMUM LAYOUT FOR YOUR
FACTORY?

Once a Plant layout is frozen it’s almost impossible or very cost-intensive to change the
layout especially after the civil works are completed and it is a critical investment for any
manufacturing company.
Do you know how much time your employees waste in moving for material, inventory and in
searching for tools?
How often does your machine break down and are workers satisfied with the current
workflow?
So, let’s discuss the factors that you need to consider before making a decision about which
type of Plant Layout is best for your company?
Factory building structure
The size and nature of the building determines available floor space and cubic area and
according to availability of area we can decide a particular type of Layout.
Nature of product
The nature of product that will be manufactured has a significant role to decide a Plant
Layout type of any factory.
For small and light products that can move from one machine to another with minimum effort
and time we can select Process or Functional Layout and for large products we can choose a
fixed layout and if the production is in sequence we can use Line Layout.
Nature of Material
Nature and state of material, Durability, Heat and cold resistance etc are many factors which
we need to keep in mind when we select type of Plant Layout because Dimensional tolerances
can be inconsistent, Cracking is possible and some materials environment so Processing can
be challenging.
Production volume
Production volume is also a big factor to choose the type of Plant Layout.
If a Factory is manufacturing the products on a large scale then Line Layout can be the best
option and if we have different products then we can go with Process Layout.
Machinery
The requirements of each machinery are quite different in terms of their space, speed,
maintenance and repair and material handling process so these factors should be given proper
consideration while choosing out a particular type of layout.
If we arrange machines according to our need then we can get adequate space between
machines and movement of inventory, people become easy.
Factory Location
Factory location also affects our Plant Layout decision.Climate, sun light, noise, ventilation
etc are factors to be considered for adequate safety arrangements.
The efficiency of any production depends on how well the various machinery, tools,
equipment and other supportive production facilities and employee’s amenities are located in
a plant.
Only an efficient Lean Plant Layout can ensure the smooth and rapid flow of material from
the raw material stage to the end product stage.
Everything can be improved let’s talk about Lean Layouting.

Difference Between Product and Process Layout

In the field of manufacturing and facility design, product layout and process layout are two
common approaches used to arrange resources, equipment, and workstations. These layout
strategies have distinct characteristics and are employed based on the nature of the
production process and the goals of the organization. This article aims to explore the key
differences between product layout and process layout, providing insights into their
definitions, features, and applications.

Points Product Layout Process Layout

Focus Organizes the physical Organizes the physical
arrangement of machinery, arrangement of machinery,
equipment, and workstations equipment, and workstations
in a sequence that optimizes based on the requirements of a
the production of a specific particular process or operation.
product or product group.
Product flow Designed to facilitate a Allows for flexibility in product
smooth and efficient flow of flow, as products move between
products through a fixed different workstations or
sequence of workstations or departments based on the
 departments. specific processes required.
Equipment Machinery and equipment are Machinery and equipment are
placement typically arranged in a linear arranged based on process
or U-shaped layout to create a requirements, with different
continuous flow of workstations or departments
production from one located strategically to
workstation to the next. accommodate specific process
steps.
Workstation Workstations in a product Workstations in a process layout
specialization layout are often specialized are more flexible, allowing for
and dedicated to performing multiple operations or processes
specific tasks or operations to be performed at each
related to the production of a workstation.
particular product.
Standardization Requires standardized Accommodates variations in
products with consistent product designs, specifications,
designs, specifications, and and production requirements, as
production requirements to the focus is on the efficient
maintain an efficient flow of completion of different
production. processes.
Production Suited for high-volume Suited for lower-volume or
volume production where the same or custom production where
similar products are different products or variations
manufactured in large are produced in smaller
quantities. quantities.
Equipment Optimizes equipment Equipment utilization may vary,
utilization utilization and minimizes as processes may require specific
material handling, as products equipment setups or
move through the production configurations, and products may
line with minimal need to be transported between
interruptions or delays. different workstations or
departments.
Labor Workforce may be Workforce may be more
specialization specialized, with employees versatile and adaptable, as
trained in specific tasks or employees may be required to
operations required for the perform different tasks or
production of a particular operations based on the specific
product. process requirements.
Efficiency Product layout is often Process layout may result in
associated with higher lower production efficiency
production efficiency, as it compared to product layout, as it
minimizes material handling, allows for more flexibility but
reduces setup time, and may require additional material
 enables a continuous flow of handling and setup time between
production. processes.
Changeover Changeover between products Changeover between processes
or product groups may may be relatively easier, as
require significant workstations or departments can
reconfiguration of the be adjusted or reconfigured to
production line or setup accommodate different process
changes to accommodate requirements.
different requirements.
Adaptability Less adaptable to changes in More adaptable to changes in
product designs, product designs, specifications,
specifications, or production or production requirements, as
requirements, as the layout is the focus is on accommodating
optimized for a specific different processes and
product or product group. operations.
Examples Assembly line production in A job shop where different types
the automotive industry, of products or customized orders
where each workstation is are produced, with workstations
dedicated to a specific task in or departments capable of
the production of a particular performing various processes.
model.
Importance Crucial for efficient mass Important for accommodating
production, achieving high process variability,
productivity, reducing cycle customization, and flexibility in
times, and streamlining production, often seen in job
material flow in a repetitive shops or industries with lower
manufacturing environment. production volumes or diverse
product portfolios.

Group technology Layout or Cellular Layout

Definition of Group Technology:

GT can be defined as “It is the realization that many problems are similar, and that
by grouping similar problems, a single solution can be found to a set of problems
thus saving time and effort”

The definition of GT is although quite broad, one usually relates GT to production flow
analysis only. GT can be applied in different area of production system. For component
design, it is obvious that many components have a similar shape. These similar
components can be grouped into design families and a new design can be created by
simply modifying an existing design from the same family. By using this concept,
composite components can be identified

Group technology is an approach to organising manufacture which can be applied in any

industry (machining, welding, foundry, press work, forging, plastic moulding, etc.) where
small-batch variety production is used. In this articles we will discuss group technology
process , advantages and disadvantages , application of GT.

What is Group Technology

The basic approach enables all aspects of manufacturing, from design, through estimating
and planning, to production, to be rationalised. It forms the basis for the development of
computer-aided procedures and flexible automation.

Group technology is a manufacturing philosophy or principle whose basic concept is to

identify and bring together related or similar parts and processes, to take advantage of the
similarities which exist, during all stages of design and manufacture.

If parts can be classified into families, and machines arranged into groups, then the
handling of parts during manufacture can be easily done by robot.

It must be understood that there exists relationship between finished products and the parts
from which they are made. While assemblies may bear little relation to each other, the
subassemblies from which they are constructed will exhibit some like features. By
exploiting the similarities which exist among such a population of parts, group technology
sets out to reduce the time and cost of manufacture.

The main theme is thus to identify somehow from the large variety of parts those families
which require similar manufacturing operations. Cells are created to manufacture defined
types and size ranges of parts.
GROUP TECHNOLOGY

Groups of machines, chosen for each family are situated together in a group layout, in
such a way that parts flow from one machine to the next in sequence of operation. It is not-
necessary for every part to visit each machine, but the machines in a cell should ideally be
capable of carrying out all the operations required in the family.

It may be remembered that in a functional layout, all like machines are grouped at one
place and thus a product has to move a lot of distance in a zig-zag manner. But in a cell
layout, various machines are arranged so that product flows from one machine to the next
in sequence.

Advantages of Group Technology:

The advantages of group technology are:

(i) Better lead times result in fast response and more reliable delivery.

(ii) Material handling is reduced considerably.

(iii) Robots can be easily used for material handling.

(iv) Better space utilisation.

(v) Smaller variety of tools, jigs and fixtures.

(vi) Improved quality and less scrap.

(vii) Output is improved due to improved resource utilisation.

(viii) Work in progress and finished stock levels are reduced.

(ix) Simplified estimating, accounting and work management.

(x) Improved plant replacement decisions.

(xi) Improved job satisfaction, morale and communication.

(xii) Reduced product design variety.

Disadvantages of Group Technology:

The disadvantages of group technology are:

(i) Additional cost of implementation of this system.

(ii) Rate of change in product range and mix.

(iii) Difficulties with out-of-cell operations.

(iv) Coexistence with non-cellular systems.

Uses of Group Technology:

Survey of product and use of group technology:

Group technology technique can be conveniently followed using a classification system.

In any assembly, a variety of parts exist. These varieties of parts can be-segregated in three
broad areas, viz.

(i) Standard and proprietary parts (like nuts, bolts, screws, keys, washers, etc.)

(ii) Similar parts (like shafts, gears, bearings, levers, etc.)

(iii) Product specific parts (like gear box, bed, saddle, etc.)

It may be noted that the group technology is not concerned with categories (i) and (iii) but
relates to category (ii). The aim thus is to group the range of parts under category (ii) in
some way, for the purpose of manufacture.
What is Material Handling?

Material handling is the movement of materials and goods from one location to another. It
includes protecting, storing, and controlling the materials, from manufacturing to
distribution.

Material handling can be used across industries, but is typically utilized in warehousing,
where goods need to be securely stored, retrieved, and shipped.

Material handling equipment utilizes manual, semi-automated, and automated equipment

to assist the movement and storage of materials within the warehouse.

Principles of material handling

Planning: All material handling operations should be carefully planned to optimize

efficiency.
Standardization: The methods, equipment and software needed for material handling
should be standardized without compromising flexibility.
Work: Material handling work should be simplified as much as possible to improve
productivity. Unnecessary movement should be eliminated by shortening routes, moving
multiple products together, etc.
Ergonomics: The capabilities and limitations of humans should be considered when
planning material handling tasks and ordering equipment in order to protect worker safety.
Unit load: Individual items should be consolidated into unit loads (e.g. on pallets) to
optimize movement efficiency.
Use of space: Use all available space effectively and efficiently. Keep storage areas
organized and make the most of vertical space.
System: All material handling activities should be coordinated to form a single integrated
operational system.
Automation: Material handling operations should be automated or mechanized wherever
possible to improve efficiency and worker safety.
Environment: Material handling systems should be designed with environmental impact
and energy consumption in mind.
Life cycle cost: Material handling equipment and systems should undergo thorough
economic analysis that accounts for their entire lifecycle.

Material handling equipment is any machine or tool that is used to transport, process,
store, or package materials. For example, forklifts, conveyors, shelves, and even
autonomous mobile robots (AMRs).
Using material handling equipment improves efficiency and can help automate processes
that would otherwise require a lot of manual labor, saving you time and money. Common
uses for material handling equipment include processing agricultural products like grain,
organizing and storing inventory in a warehouse, and loading and unloading dirt or
hardscape.

In this post, we go over the four material handling categories and the equipment within
each category, so you can choose the right tools for your workflow.

4 Categories of Material Handling Equipment

The four main categories of material handling equipment are storage and handling
equipment, industrial trucks, bulk material handling equipment, and engineered systems.

This chart breaks down the common uses and tools for each category:
Industri
al
Storage Bulk
Trucks Engineered Syst
and Handling Equi Material Handling Equi
and ems
pment pment
Machin
es

Transpor
Storage and ting
Storing, transporting, or Packaging,
Used inventory, materials
processing materials in shelving, or
for organization, and to a
bulk storing materials
preparation designat
ed area

Forklifts
Palletizers,
, order
Shelves, storage automated
Type of pickers, Conveyors, hoppers, and
racks, and guided vehicles,
tools and reclaimers
mezzanines and warehouse
pallet
robots
jacks
Types of Storage Handling Equipment

Storage and handling equipment is the most basic of the four categories. As the name
implies, it is used to store products that are being held as inventory or materials that are
awaiting the next part of the production process. This equipment helps you maximize your
space, particularly your vertical and floor space.

Common types of storage equipment include:

Bins and drawers: These hold small to medium-sized items. Bins have open tops,
allowing employees or automated systems to quickly grab inventory. Drawers allow for
high-density storage and may maximize space better than shelves.

Mezzanines: Mezzanines are semi-permanent structures that add another floor between
the floor and the ceiling. This increases a warehouse’s usable space, providing additional
workspace or a larger storage area.

Pallets: Pallets store packaged loads, making it easier to move and transport them with
industrial trucks or pallet jacks.

Pallet stacking frames: These attach to pallets, allowing you to stack palletized loads on
top of each other. They require minimal storage space when they’re not being used.

Storage containers: Storage containers, also called shipping containers, can come in
a variety of sizes, but are generally designed to store large objects or large amounts of
materials.

Storage racks: Similar to shelving, storage or pallet racks help teams make use of their
vertical space by providing several horizontal platforms. Drive-in racks allow forklifts to
drive in and load pallets, increasing storage space, but minimizing accessibility.

Industrial Trucks and Machines

These machines are used to load and transport materials. They can be manual, like hand
trucks, or motorized, like forklifts. Industrial trucks primarily use fork attachments, which
are compatible with palletized loads.

The most common types of industrial trucks for material handling are:
Forklifts: Most standard warehouse forklifts can handle loads up to 5,000 pounds and lift
10 to 15 feet. Large-capacity models can carry much heavier loads.
Order pickers: Order pickers raise warehouse employees, allowing them to pick orders
off of elevated shelves. Their load capacity is typically around 3,000 pounds and they can
raise up to 32 feet.

Palletjacks: Also known as pallet trucks, these machines come in manual and electric
versions. They typically only transport one to two pallets at a time and their load capacity
maxes out around 5,500 pounds for standard models, though you can also find high-
capacity options.

Side loaders: These are a type of forklift with forks at the side instead of the front. This
allows the machine to navigate in narrow aisles, like between warehouse shelving, and
load products without turning the cab.

Walkie stackers: Walkie stackers don’t have a cab – the operator stands behind the
machine while operating it. Similar to pallet jacks, walkie stackers have a limited load
capacity, ranging from 2,000 to 4,000 pounds. They can typically lift 5 to 10 feet.

Bulk Material Handling Equipment

Bulk material handling equipment helps to move, load, and process large quantities of
items. This includes small items like grain or rocks, and larger items like consumer
packaged goods.

You may find this equipment in indoor and outdoor environments. For example, silos may
store bulk food items on a farm and conveyors transport packages in a warehouse.

Common types of bulk material handling equipment include:

Conveyors: A conveyor system helps move and process materials en masse. Similar to
an old-school assembly line, it uses a system of belts and pulleys to keep things moving
from point A to point B.

Bucket elevators: A bucket elevator, also called a grain leg or grain elevator, hauls
flowable bulk materials vertically. It’s typically used in an agricultural setting, moving
loose materials like grain or fertilizer.

Bulk-handling cranes: Building on the design of a basic crane, a bulk-handling crane

includes a two-piece hinged grab to lift and balance bulk cargo like coal or mineral ore.
Dump trucks: A dump truck is a vehicle designed for transporting and unloading large
quantities of materials. It’s often used in construction to offload or haul away debris or
loose materials.

Hoppers: Often used in agriculture, hoppers are containers that transport bulk products
like grain and corn, unloading them through compartments at the bottom.

Stackers and reclaimers: A reclaimer is typically used in conjunction with a stacker.

The stacker piles bulk material like ore or coal. The reclaimer loads it, guiding it to a
conveyor to be transported.

Silos:Silos are tall, cylindrical containers that provide high-volume storage for items like
coal, woodchips, or feed.

Engineered Systems

Engineered systems are completely automated. As the name implies, they use multiple
systems to minimize the need for manual labor. This type of material handling equipment
is commonly found in manufacturing and warehousing.

These are some of the most common engineered systems:

Automated storage and retrieval systems (AR/RS): AR/RS is a type of robotic delivery
system that can place and retrieve materials from set storage locations.

Automated guided vehicles (AGV): Sometimes called self-guided vehicles, AGVs are
designed to drive and operate themselves, following marked lines, wires in the floor, or
other programmed controls for navigation.

Autonomous mobile robots (AMRs): AMRs are more advanced than AVGs. They can
map and adapt to their surroundings using sensors.

Palletizers: Palletizers replace the need for humans to load pallets. They stack items on a
pallet and release the pallet onto a conveyor for further processing.

Sortation systems: Sortation systems can automatically detect objects and route them to
the desired location.
Warehouse robots: Warehouse robots are AI designed for use in warehouse applications
to automate simple, repetitive tasks, like picking products off of a shelf.

How to Choose Material Handling Equipment

As you can see, there are many different types of material handling equipment to assist
with manufacturing, warehousing, agricultural, or construction needs. Choosing the right
piece of equipment depends on a variety of factors.

Function and Space

The purpose of material handling equipment is to improve efficiency. Consider how you
can productively use all your space. For example, you may want to add a mezzanine to a
warehouse to increase your square footage.

The Type of Materials

The size and shape of your material will dictate the type of material handling equipment
you need. Granular items may need to be packaged, while boxed items can easily be
palletized.

If you’re working in an outdoor environment, you may require a crane to move large,
heavy materials or a reclaimer to sift through stockpiles.

Automation vs. Labor

Automation increases efficiency, but it comes at a cost. You’ll likely use a combination of
automated and manual equipment. For example, robotic delivery systems may pick
products in a warehouse and deliver them to a human for quality assurance and packaging.

Storage Method-
What’s block stacking?
This storage technique consists of stacking unit loads (pallets, boxes, or products) one
on top of the other on the floor of the warehouse, without resorting to racks.
The goods may or may not be palletized, depending on the type of product being handled.
The only condition is that they be strong enough to withstand the weight of the rest of the
products. Otherwise, if the product is fragile, the structure could break.
Pros and cons of block stacking
Block stacking in a warehouse brings the following benefits:

Cost savings: this is probably the main plus point. Block stacking is the most economical
technique of all, as it doesn’t require racks.
Space maximization: space is optimized by eliminating unnecessary aisles, as is volume,
by stacking the loads (as compared to placing only one pallet on the floor).
SKU management: for block stacking to be efficient, it’s crucial to form high-density
groups of a single SKU. This serves to control the stock and easily locate each product.

On the other hand, block stacking does have some significant disadvantages that we need
to take into account, for instance:

Height limitations: this depends on the type of load stored. That is, if a large amount of
product is stacked, the structure could become unstable and collapse. Only racks can
guarantee storage of loads at great height.
Damage to goods: if the weight of the stacked load is excessive, the merchandise located
on the lower levels could become damaged.
Risk of accidents: racks are sturdy and remain intact, minimizing impacts from handling
equipment and ensuring total stability of the loads they hold. By contrast, block stacking
doesn’t have these benefits, making it more prone to risks and accidents.

Generally speaking, the primary advantage of this storage method is its low initial
investment. However, to ensure the physical integrity of the goods and the operators, racks
are a must.

Drive-in racking-
The Drive in and Drive Through Racking System is a high density storage solution that
maximizes available space and height in the warehouse by reducing the forklift operating
aisles. It is made up of an easy-to-assemble and -reset modular structure, which makes it
easy to maintain.

Drive-in racking and drive-through racking eliminates the need for down-aisle picking
aisles. Both drive-in racking and drive-through racking offer a variety of benefits to
warehouse efficiency.
REB Storage Systems International is a material handling systems integrator that provides
full project management of drive-in and drive-through racking systems. Our services
include design, permitting support, subcontractor management, procurement of materials,
and installation.
Read below to learn more about REB’s drive-in racking and drive-through racking
systems.
3.Static Pallet Racking
A pallet rack is an upright structure made of steel framing. Its beams and connectors are
bolted, welded, or clipped together to form a pallet storage unit that stores inventory and
equipment. In warehousing, pallet racks are an essential component that provides a safe,
sturdy method for organizing and locating stored materials. The design and configuration
of pallet racks make it possible to store any type of product, from food and clothing to
heavy machinery and tools.

One of the reasons for the popularity of pallet racks is their versatility and ability to be
reconfigured to meet the needs of any warehousing plan. Easy accessibility is a key factor
for warehousing storage, which is the reason for the inclusion of pallet racks.

In a well-defined pallet racking system, pallets are stored in horizontal rows at multiple
levels. The number of levels varies according to the pallets’ contents and the number of
beam levels, which can vary from three up to six or seven. Pallet racks use otherwise
wasted vertical space and provide an efficient, safe, and well-organized method for storing
valuable inventory.

Types of Pallet Racks

Pallet racking is available in a wide variety of styles, designs, and capacities, depending on
the types of products being stored and the capacity of the building. The materials used to
produce pallet racks determine their capacity and use. Most pallet racks are made of steel
and can store several tons of products, merchandise, and materials.

The material handling business necessitates a wide selection of pallet racking types since
every customer has different requirements and specifications. Depending on the
application, there are several varieties, with basic features that all pallet racking must
adhere to, which include forklift accessibility and components capable of supporting
palletized materials.

Types of Pallet Racks

Cantilever Pallets
Cantilever pallet racking can store pallets if designed properly. They are used to store
longer products that cannot be stored on traditional racks. The key to cantilever racks is
their weight capacity, which can vary to meet the needs of a particular product. They are
made using upright columns, arms to secure the product, and horizontal braces between
the storage bays.
Selective Pallet Racking
In the selective pallet racking system, every pallet rack position is accessible from the
aisle. This pallet system is the most common since it makes it possible to remove a pallet
from the shelving without moving another pallet. Every item is visible for loading and
unloading due to easy access. During inventory, there isn’t any need to remove an item
from a pallet, which makes counting and calculations efficient.

Double Deep Pallet Racking

Double deep pallet racking is for warehouses that have limited space and require quick
handling. It is ideal for the first in, last out (FILO) system of warehousing. Double deep
pallet racking is similar to selective racking with the exception that instead of there being
one pallet on a shelf, there are two, with one in front of the other. The configuration is one
rack placed tightly behind another such that the first pallet placed on the shelf is pushed
back behind a second pallet placed on the shelf.

A special forklift is required to remove the second pallet since it is a full rack’s width back
on the shelf. Double deep pallet racking decreases the number of aisles and makes greater
use of the available space.

Push Back Pallet Racking

Push back pallet racking is ideal for density storage when there is limited space. The
system is similar to a double deep system but includes far more than two pallets on a shelf.
Pallets are loaded on carts or shelf trays that ride on rails set in the rack frame, which
allows them to be easily pushed back when a pallet is loaded onto the shelf.

The system allows for multiple-sized pallets, up to six deep, to be placed on a shelf and is
ideal for the last in and first out (LIFO) warehousing system.

Drive In Drive Through Racking

Drive in drive through racking systems are designed for warehouses that have constantly
shifting and moving inventory. Unlike a static system, with rows and aisles of racks, a
drive-in racking system has a denser placement and makes efficient use of the available
space.

In the drive in or drive through system, the forklift operates inside the racks, which do not
have specified lanes between the rows. The forklift enters and exits through the same
opening. The system is ideal for cold storage where there is only one entry point allowed.
Pallet Flow Racking
Pallet flow racking, also known as gravity flow racking, uses roller tracks to form a
gravity flow lane. The tracks are set at a decline that allows pallets to move easily from the
rear of to the front of the rack. Brakes in the system control the rate at which the pallets
move to ensure safe handling. A pallet flow racking system is rather extensive, capable of
placing two to twenty pallets on the tracks of the rack.

Much like some of the other systems, the pallet flow racking system is designed for
warehouses with limited space and is a FIFO system. It is ideal for products that are time
sensitive or perishable.

Pallet Racking Accessories

Any number of add-ons can be included in a pallet racking system, including those
specially designed to meet the specific needs of a product. Though pallet racks can store
every form of product, certain products require racks designed to accommodate their
unique features.

Anti-Collapse Mesh – Anti-collapse mesh is attached to racking to offer protection

against falling objects. It can also serve as a boundary for protection from harmful
equipment.
Wire Mesh Decking – Wire mesh decking sits on the racking beams and acts as shelving
material. Though it is lightweight and easy to install, it is sturdy and durable enough to
hold any type of material. Wire mesh is made from solid galvanized steel and allows the
racking of small cartons.

Shelving Panels - Much like wire mesh, shelving panels fit across the horizontal beams
and offer a heavy-duty surface for storing small loads.
Wooden Decking – Wooden decking is another form of shelving solution that may not
be as sturdy as wire mesh or metal panels but can provide stability for small to medium
loads.
Dividers – Dividers provide individual adjustable compartments for separate products
and avoid inventory getting mixed or intermingled. In most cases, dividers are specially
designed to meet the needs of products and sized accordingly.
Pull Out Casters – Pull out casters can be added to an existing racking system. They
allow easy access to materials and avoid the need to use a forklift to inspect inventory. The
durability of casters is dependent on the materials used to manufacture them and the
products they will handle.
Barrel Supports – Several industries store their raw materials in barrels, which can be
stored upright on a rack or in a horizontal position. To prevent barrels from rolling on a
pallet rack and to maintain the stability of their contents, barrel supports can be attached to
the horizontal supports of the racking.
Cable Reel Suspension – Cable reel suspensions are supported on pallet racking with an
axle rod placed through the center of the cable reel. The carriers for the reel are bolted to
the side, front, and back vertical supports of the pallet rack. In order to adjust the cable
reel suspension, adjustments are added such that the cable and axle can be positioned
correctly.
The few accessories listed above are only a small sampling of the accessories that pallet
rack suppliers provide. Engineers and designers work with customers to develop
customized accessories to meet the needs of special applications.

4. Mobile Pallet Racking

Pallet racking, Mobile Rack, is suitable for pallet storage simplifying location control and
expediting forklift input/output operation. With its smooth dolly movement, user-friendly
interface, and several safety devices, Daifuku's Mobile Rack has a great reputation in the
material handling industry.
Features

The mobile pallet racking system consists of two fixed racks at either end of the system,
with racks on dollies in-between. Compared to conventional fixed racks that require aisle
space every two rows, the mobile rack needs only 1 aisle space per system since dollies
slide to open an aisle where needed. This system reduces the storage rack footprint by
50%.

Convenient operation modes

The system comes standard with three modes that are useful for warehousing with
forklifts, manual case picking, and inventory work.

Full width passage mode

Full width passage mode allows quick forklift access to an aisle. By combining with guide
rail and 3-way forklift or order picker forklift, aisle width can be reduced further.

Half-width passage mode

Half-width passage mode allows manual case picking in two aisles at the same time.

Equal Spacing mode

Equal spacing mode is useful for inventory-taking operation. It is also beneficial for air-
conditioning efficiency in cold/frozen warehouse as it provides moderate space between
stored items and lets chilled air circulate evenly.

User-friendly interface
The switch used to open and close the passageway has a large hemispherical button that is
highly visible and easy to press from any angle. Its user-friendly design, including an
operation panel that displays operating status and error details, has been highly evaluated
at work sites.

Relationship Charts and Load Distance Cost Matrix-