PLANT-LAYOUT
Plant layout refers to the arrangement of physical facilities and services including work
centers for the manufacturing of products and good plant layout results:
• A good plant layout makes comfort, convenience, less fatigue, less wastage, good
appearance, and cubic space utilization and minimizes the cost of production per unit.
• A poor plant layout results in congestion, wastage, delays, frustration and inefficiency
in production process.
Objectives / purpose of plat layout: -
• To facilitate production process.
• To minimize the material handling, wastage and delays.
• To maintain flexibility in the operation.
• To provide optimum utilization of missionary and equipment and space.
• To reduce fatigue and risk hazards.
• To promote effective utilization of labour and assures safety and security of the
workers.
• To bring out higher productivity effectively and efficiently.
Principles of plant layout:
• Principle of overall integration:
• Principle of flow: - Proper line balancing technique by avoiding congestion points,
flow battle necks and back tracking.
• Principle of minimum distance:
• Principle of cubic space utilization:
• Principle of safety and satisfaction: -Towards workers by providing better working
conditions.
• Principle of flexibility: - For further development i.e. future expansion.
Production function: - creation of useful goods or products for sale with materials,
machinery, labour, land, capital and management is associated with factory production,
which is narrow view of production. The modern concept of production is much wide and it
includes all activities that create utility for individual and society. Mathematically a
production function can be written as …
Y= f (C1, C2, C3 … Cn)
Where as, Y is the quantity produced, which depends upon the quantities of different inputs
represented by C1, C2, C3 … Cn (relationship between output and or input.)
A function is an expression of the relationship amongst number of variables that give
a single result. The value of one variable depends upon the value of other.
Productivity
A measure of performance
Broadly a ratio of output to input, i.e. comparing amount produced (output) with
resources used (input)
Materials, machinery, labour, capital, energy --- a combination
What improvements have there been over the last 50 years in
o Construction productivity
o Payroll processing
o Car servicing
o Banking
2. Mass Production: - This also called as flow production. Here production is undertaken in
large through out the year irrespective of demand of a product or commodity with specialized
machines and processes. The main advantages of this type of production is offers the lowest
unit cost of production. The products such as food grains like rice, wheat and all consumer
goods such as TVs, air conditioners, cars etc., are manifatured through mass production.
Merits: -
o Mass production gives better and increased production
o Wastage in minimum
o In this method as raw materials are purchased on a large scale and hence higher
margin of products can be made while purchasing them.
o Promotional cost is low per unit
o Only few skilled and rest semiskilled workers are required hence labour cost is
reduced.
Demerits: -
o During the period of less demand, losses on the invested on the invested capital may
take place.
o All machines are used one purpose; it is not changeable to other type of production.
o Workers may get skill but they feel boar by doing job repetitively
o It can not fulfill individual taste.
3. Batch Production: - Here manufacturing is done on the basis of the batches and they are
similar in terms of type, cost, efforts, and consumption of inputs. This type of production is
adopted by medium size enterprises. It is bigger in scale of job production and smaller in
mass production. The products manufactured under this method are pharmaceutical, paints,
many consumer products such as mineral water bottles and so on.
Merits: -
o While comparing with mass production it requires less capital.
o If demand of one product decreases then product of another increases hence risk of
loss is very less.
o Comparing with job production it is more advantages commercially.
o Efficient maintenance of equipment and production control system is possible.
Demerits: -
o Comparing with mass production cost of sales and adverting per unit is more.
o Raw material purchased in less quantity than mass production so less quantity of
discount a-vile.
WORK STUDY
Generic term for management services and as system engineering techniques, used to
investigate
o Methods of performing work (method study) and improve its efficiency and
economy
o the time taken to do it (work measurement) with a view to rationalization,
routinisation, utilisation, cost and incentive improvement
The worker-work system-technology relationship: how this is best
designed and improved (ergonomics and the human-machine-information interfaces)
Work study investigates the work done in an organization and its principle aim is to
fined out the best and most efficient way of using available resources i.e. men, material,
money, and machinery (4Ms).
Work study is a systematic, objective and
critical analysis of all the factors that
govern the operational efficiency of any
specified activity to effect improvement.
According to British Standard Institutions
work study is generic term for those techs,
particularly method study and work
measurement which are used in the
examination of human work in all its
contexts, and which leads systematically to
the investigation of all the factors which
effect the efficiency and economy of the
situation being reviewed in order to effect
improvement. In simple terms, work-study is term used to embrace the techniques of method
study and work measurement.
Therefore, work-study can be defined as scientific study of work to find
o Exactly what has to be done
o One best way to do
o Inefficient work can be eliminated
o What equipment, condition, methods would make easier
and quicker and
o How long should take.
Need of work-study:
Work-study is needed to explore improvement in doing job and to reduce problems in
the complexities of modern organizations. Hence, it is required in
o Industries
o Marketing and sales and distribution
o Office, stores and ware houses
o Material handling
o Design
o Building and other constructions
o Transport hospital
o Army and
o Agriculture
Advantages of work study:
o Uniform and improved production flow
o Higher productive efficiency
o Reduced manufacturing cost
o Fast and accurate delivery dates
o Better employee – employer relations
o Better service to customers
o Job security and job satisfaction to workers
o Better working and other conditions and
o Higher wages to workers.
Objectives of work study:
The main objective of work-study is to assist management and to obtain optimal use
of all resources namely psychological and physical resources (4Ms) for accomplishment of
work.
o To ensure most effective use of existing human and material resources
o To eliminate wasteful, unnecessary and ineffective work
o To improve existing methods and to establish best way of ding job
o To reduce unnecessary efforts and delays
o To find out most economical way of ding job
o To determine the time required (standard or allowed time) to perform a job as
accurately as possible.
o To check the operative effectiveness with the help of standard time
o To increase productivity, there by increasing production per hour
o To effect saving in production process
A work-study curriculum - 1
Historical development & commitments of Work Study
-Basic concepts, objectives and procedures
Method Study approaches and tools of Method Analyst
-Flow Diagrams & Process Charts etc
-Critical questioning techniques
Work Measurement and calculating times for Jobs
-Defining job elements & calculating
-Performance rating and standard/basic times
-Determining allowances: fatigue, unavoidable & avoidable delays, extra
allowances
various incentive plans
A work-study curriculum - 2
Examining worker-machine relationships
Workload & line balancing & staff/machine inefficiencies
Material handling, human controls, tools and devices
Workstation layout & design (EU workstation directive)
Occupation Health & Safety: signals, reaction times, eyes, backs, RSI safety
criteria, preventing accidents
Ergonomics & human-machine-environment interfaces
Use of visual displays for dynamic information
Designing for: lighting systems, industrial noise, thermal controls, vibration
etc
Systems analysis the human-machine information system
Data capture and processing
Design of the user interface
Business process re-engineering (BPR)
Method study uses formal techniques to record the sequence of activities, the time
relationship between different activities, the movement of materials and the
movement of staff. The main techniques used for recording the time relationships
between parts are: Multiple-activity charts; Simo charts. The main techniques that are
used to record movement are: Memo-motion analysis; Micro-motion analysis; Flow
diagrams. The most commonly used technique is the flow process chart. There are
three types of process charts: Outline process charts; Flow process charts; Two-
handed process charts.
Apply critical examination - challenge job components & necessity (purpose, place,
sequence, method).
Develop alternative methods & present proposals
Document as base for new work system
Install, monitor (slippage) & maintain
Models / Symbols and Process Charting: - this will be developed by work study members
to suite the particular production process.
Introduced by ‘Sir Walter A Shewart’ in 1931 statistical process control (SPC) is part
of SQC. These are concerned with monitoring and control of production process. That
depends up on Quality cycle:
Quality Control and Inspection are place a vital role in order
to maintain statistical quality control in production process.
Quality Control: - Quality is not an accident it is the result
of an intelligent effect. There must be will for management or
that particular business to produce superior things. There are
two main areas to control the quality of product or services.
They both are cost sensitive.
Quality control measures will be taken into two areas of
production. They are
Off-line quality control: - The improvement of product quality along with the process
at various stages of product design or design development and after the production.
On-line quality control: - The monitoring of correct manufacturing process through
verification of dimensions. It is a real time quality control. These are three forms…
o Process diagnosis and adjustment (process control).
o Prediction and control (control through feed back).
o Measurement and action (inspection)
Quality control is an effective system integrated to quality development, quality
maintenance and quality improvement.
Top management must support the program of quality control willfully (no
compromising for quality) by providing training, proper maintaining machines and
equipment.
Benefits of SQC:
The use of SQC ensures rapid and efficient inspection at a minimum cost. It
minimizes waste by identifying the causes of excessive variability in quality of product.
Following are the important advantages of Statistical quality control.
o Statistical quality control process is free from the sources of variations.
o It involves identification and removal of undesirable causes.
o The product can be more safely guaranteed.
o Inspection can be reduced ultimately thus reducing the inspection cost and in turn the
cost of production.
o Statistical quality control enables to determine and eliminate experimental errors.
o Statistical quality control reduces the cost of scrap, rework and adjustment.
o Statistical quality control is very much useful for product development and to reduce
the cost of production.
SQC can be achieved by considering the following areas:
Controlling the manufacturing information:
o Carefully prepared instructions to operators.
o Understandable drawings.
o Good communication system.
o Implement through directive.
Control of purchases, storage of raw materials:
o Obtain correct materials incorrect quantity at current time.
o Store to prevent deterioration or damage.
o Good relations and communication with suppliers.
Control of manufacturing process:
o Prevent fabrication of defective products.
o Good maintenance of processing machines.
o Clear directive from management.
Control of finished products:
o Adequate verification.
Control of measuring instruments.
Control of corrective actions.
SQC exerts more effective pressure for quality improvement than 100% inspection.