Assosa University

Department of Mechanical Engineering

Industrial Management & Engineering Economy

Chapter – î
Inst. Fekadu G.
Chapter ፫ - plant layout

Objectives
After completing this chapter you will be able to understand
 Different types of plant layout
 The basic concept of ergonomics and industrial safety

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Plant layout

 It is a plan of the most effective arrangement of the physical facilities

and personnel for the manufacturing of the product.
Product

Layout
Logistics Process
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The Facilities Layout Problem
 Determining the best layout for a facility is a classical
industrial engineering problem.

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Objectives of plant layout

Objectives of plant layout may include the following

1. Efficiency of production
2. Stability of utilization of production facilities
3. Small work-in-process inventories
4. Flexibility and adaptability o f production
5. Economy of production

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Inputs to layout decision

1. Organizational structure
2. Type of production/operating system
3. estimation of product demand on the system.
4. Processing requirements in terms of number of operations and amount
of flow between departments and work centers.

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Inputs to layout decision
5. Space requirements for the elements in the layout.
6. Space availability within the facility itself.
7. The equipment needed to carry out the operations
8. The volume of buffer stocks and main store

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It should include a careful study of the following:
1. external transportation facilities
2. Receiving operations (unloading, inspection, stores)
3. production activities
4. material handling
5. service and auxiliary operations
6. quality control and inspection areas
7. packaging operations
8. storage operations
9. shipping operations
10. offices

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Principles of plant layout

1. principle of over all integration

2. principle of minimum distance
3. principle of flow(avoid or minimize back tracking)
4. principle of cubic space
5. the best lay out is one in which all the available space both vertical and
horizontal is most economically &effectively used.
6. principle of satisfaction and safety
7. Principle of flexibility
8. principle of expansion

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Patterns of Flow
 to minimize the materials handling cost - a flow analysis of the
facility is necessary.

Francis and White (1974)

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Factors affecting plant layout

1. Material - size, shape, volume, weight, and the physical-

chemical characteristics
2. 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.
3. Labor – environmental and process consideration
4. Material handling – it does not add any value
5. Waiting time stock -

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Factors affecting plant layout

6. Auxiliary service – supervisor …

7. The building – is the building already exist?
8. Future changes - One of the main objectives of plant
layout is flexibility. Possible extensions of the company.

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Symptoms of bad lay out

1. congesting of machines, materials, parts, assemblies and

even workers
2. excessive amount of work in process – buffer
3. poor utilization of available space
4. long materials flow lines
5. Uneven loading of machines
6. Excessive handling by skilled workers

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Symptoms of bad lay out

7. long production cycles

8. delay in delivery
9. Excessive mental or physical strain of workers
10. difficult to supervise and control properly

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Signs of successful layout

1. Directed Flow Patterns – minimum

backtracking
2. Predictable Processing Time
3. Little WIP in Facility
4. Open Floors: allow communication and
easy tracking of work & employees
5. Bottleneck operations under control
6. Work Stations close together

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Signs of successful layout

7. Orderly Handling & Storage of Raw

Materials and Finished products
8. No extra handling or unnecessary
handling of materials
9. Can easily adapt to changing conditions
1. Considers demand growth or decline
2. Considers product change over
3. Considers technological change

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When do we need to change our plant layout?

The reasons for a re-layout are based on 3 types of

changes.
1. Changes in production volumes.
2. Changes in processes and technology.
3. Changes in the product.

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Types of layout

1. Product layout
 In this type of layout, only one product or one type of
product is produced in a given area.
 The product must be standardized and manufactured in
large quantities in order to justify the product layout.

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1. Product layout

In 1 2 3 4

Workers

Out 10 9 8 7

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Product layout
 Linear arrangement of workstations to produce a specific product
 Layout that uses standardized processing operations to achieve
smooth, rapid, high volume flow
 Requires standardized product, high production volume, stable
production quantities
 High equipment utilization, high investment in justified equipment,
large raw material and finished goods inventories

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2. Process(functional) layout
 A process layout groups similar machines having similar
functions
 most effective when there is a wide variation in the
product mix

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Process layout
Milling
Lathe Department Department Drilling Department
M M D D D D
L L

M M D D D D
L L

G G G P
L L

G G G P
L L
Grinding Painting Department
Department
L L
Receiving and A A A
Shipping Assembly
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3. Fixed position layout
 Some products are too big to be moved, so the product
remains fixed and the layout is based on the product size
and shape.

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4. Layouts based on Group technology
 parts must be identified and
grouped based on similarities in
manufacturing function or design.

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Study of plant layout

Process layout
Assembly

4 6 7 9

5 8

2 10 12

1 3 11

A B C Raw materials
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Process layout

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Process layout

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Process layout

Revised cellular layout Assembly

8 10 9 12

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4 Cell 1 Cell 2 6 Cell 3
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2 1 3 5

A B C
Raw materials
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Ergonomics and industrial safety

OSHA – occupational safety and health administration

what is Ergonomics
- Is away of designing workstations, work practices, and
work flow to accommodate the capabilities of workers.

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Ergonomics and risk factors
 Ergonomics studies the varies risk factors brought to a
job
1. Risk factor inherent in the worker
2. Risk factor inherent in the task
3. Risk factor inherent in the environment

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Ergonomics and risk factors
 Ergonomics studies the varies risk factors brought to a
job
1. Risk factor inherent in the worker
2. Risk factor inherent in the task
3. Risk factor inherent in the environment

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Risk factor inherent in the worker
 At the heart of ergonomic design is the idea that
equipment should be design so that it’s able to meet the
unique needs of each employee, not the general
population.
 Each worker has his/her own attribute – age, size,
strength, etc.

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The musculoskeletal system

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Risk factor inherent in the worker

1. Age
2. Gender
3. Strength and endurance
4. Physical fitness
5. Anthropometry – body characteristics – weight, physical
range of mobility and body dimension.

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Ergonomics and risk factors
 Ergonomics studies the varies risk factors brought to a
job
1. Risk factor inherent in the worker
2. Risk factor inherent in the task
3. Risk factor inherent in the environment

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Risk factor inherent in the Task
Work process are determined by the following factors

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Risk factor inherent in the Task
Physical effort required by a 9. Vibration
person – to do a task depend 10. Duration of the task
1. Type of grip 11. Number of repetitiveness
2. Object weight
3. Object dimension
4. Body posture
5. Type of activity
6. Slipperiness of the object
7. Temperature
8. pinching

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Ergonomics and risk factors
 Ergonomics studies the varies risk factors brought to a
job
1. Risk factor inherent in the worker
2. Risk factor inherent in the task
3. Risk factor inherent in the environment

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3. Risk factor inherent in the environment
 Risk factors the environment bring to the job
1. Heat stress – high temperature stress
 Heat stroke

Cold stress
 Shivering
 Pain in the extremities
 Clouded consciousness
 Dilated pupils
 Reduce grip strength and coordination

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2. Lighting

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3. Noise

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And others
 Ventilation Different colors have different psychological effects.
 Color  Red - Hot and heavy, exciting, stimulating.
 Orange - Hot, exciting and stimulating less than red.
 Yellow - Hot, exciting lovely.
 Green - Fresh and light, pacific.
 Blue - Light, pacific.
 Violet - Light, loneliness.
 White - Cold, brilliant (seems to increase volume).
 Black - Hot (seems to decrease volume) depressing.

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Industrial safety

1. CAUSES OF ACCIDEENTS
a. Human causes
b. Environmental causes
c. Mechanical causes

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Risk controls

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Q&A
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