PLANT LOCATION LAYOUT & MATERIAL HANDLING
Plant :-
A plant is a place where man,material, money,m/c and equipment are brought together for manufacturing products
# Plant location :-
It mean deciding a suitable area location or place where the factory will be setup it involve 2 major activities
1. To select a proper geographical region
2. Selecting a specific Site within the region
# Importance of plant location :-
Plant location plays an important role in the design of production selection as it determine the cost of getting suitable raw material processing raw material to finished goods and distribution of manufacturing products
No location can be ideal or perfect. A balance between various Factor affecting plant location is to be made
1. Nearest to the market :-
It will ensure a regular supply of product to customer and reduce the cost of transportation. A location near to Market is preferred if-
- The product are delicate
- After sale services are required
- Transportation cost of high and increase to over all cost significant
2. Nearest to raw material :-
Nearness to source of raw material is of special importance when the material is heavy as compared to it's volume and when the volume and weight are reduced significantly during the processing. The Place of production is likely to be at place of consumption. Where the final product is more expensive to carry. It reduces the lost of transportation as well as the chances of product getting damaged during transportation
3. Transportation facility :-
It is important for the location of the plant. Speedy transport facility ensured timely supply of raw material to the company and delivery of finished products to the customer depending upon size and type of material. Transport like road, rail, water or air is selected
4. Availability of labour :-
A stable Labour force of right kind adequate size and of positive attitude towards work at regionable rate. Few Factor that are considered so that company faces less strikes agitation and lockout to achieve lower labour cost per unit of production
5. Availability of fuel and power supply :- Many industries such as a steel company should be located where regular power supply is available easily and at regionable cost
6. Availability of water :-
It is an important point for plant location the process industries like paper, Chemical, cement etc by continues supply of water in large amount
7. Suitability of land climate :-
To setup a plant the land and climate survey is required to see the area shape of the Site drainage pass history of flood and earthquake
8. Social infrastructure :-
Availability of facilities like housing, education, post office etc should be kept mind before selecting a plant location
9. Supporting industries and services :-
Now a days a manufacturing organization does not make all the components by itself and it sub-contracts the work to evidence and ancillories
10. Law and location :-
The policies of state government and local bodies and labour loss, safety etc are considered in plant location to have a balance regional growth of industry both central and state government offer the package of insensitive to enterpreneur a particular location these day may be in form of tax, subsidy in electricity charges etc
Attitude :-
The sucess of industry depend very much on the attitude of thinking of the local people whether they want the plant to setup of not
@ Urban and ruler plant location :-
1. Plant location in urban area:-
# Advantage :-
- it is well connected by rail, road and air transport
- good market availability
- skilled labour is available
- Good supply of electricity and water
- presence of facilities like hospital, school, bank, marketing
-Easy training of worker and foreman
- Service expert and specialists are easily available
- Existing small industries can work as ancellaries
- Good security
# Disadvantage :-
- Limited area for building
- Lost of land and construction is high
- Less scope of expension
- high tax
- High labour charges
- more problems of unionism
2. Plant location in rule rules area:-
# Advantage :-
- Plenty of land is available for construction
- large scope of future expension
- Lost of land is low
- Labour is easily available
- non-union problem
- munciple and other regulation and taxes are not a burden
-more relaxation in law from government to develop rules areas
Disadvantage :-
- Skilled labour is not available
- less transportation facility
- shortage of regular power supply
- Ruler areas are for from selling market
- community facilities like hospital education etc. Are not available
- No axillary services
- Services experts and proffesionals are not available
# Objectives of plant layout :-
In a good plant layout the motive is to maintain best relation between output, space and manufacturing lost. Its good is maximum profits
The following are the objective of a good plant layout
1. Elimination of bottleneck and point of conjection
2. Efficient material handling and transportation
3. Proper designing of work station
4. Better working environment safety of employee and minimum accident
5. Minimization of worker movement
6. Reduce idle time
7. Better utilization of space
8. Improved work method
9. Easy plant maintainance, increase productivity and better product quality
10. Better supervision and controlled
11. Worker convience improve molar and high satisfaction
@ Types of Layout:-
# Product layout :-
It is also known as line layout m/c are arranged
# Work station design :-
It affects the production rate, effecienty and the accuracy with which an operation can be performed to reduce wastage and each level of operation and minimise material handling air must be taken in designing a with station .a work station not only need space for the worker and m/c not their are also a large number of other items which also need accomodation
# Factor consisdering in designing a work station :-
1. Space requirements :-
-Space for the employee to stand ,sit to turn comfortaly to operate
- Space for the m/c keeping in mind these our hand projection or overtravel m/c parts. Table of a milling m/c travel etc
- Space for the workplace if it is projecting out like a long bar different to a turned
- Space for storing incoming raw material and finished goods
- Space for storing necessary tools and other components required by the worker
- Space for the additional attachment and fixtures
- Space to load large work on soff the m/c
2. Other factor's :-
- Easy excess to safety for in case of emergency
- Easy excess to m/c for lubrication, inspection, maintainance and repair
- Convenience for making foundation of machine
- Aisle Space between one m/c and the next m/c
- Appropriate ventilating, lightning and safety arrangements
# Material handling :-
It is the art of movements handling and Storage of material during different stages of production. Out of total time spent for manufacturing of product about 80% of the time is utilises in moving product from one space to another weightening for processing and storage
# Cooling and lubrication system :-
It is estimated as company spend 25 to 35% of the total expenditure on material handling. It however does not add value to product best plAnning and application of the reducing unnecessary movement of worker reducing ideal time of men and m/c and reducing overall lost of manufacturing. The cost of production can be lowered considerable by making a saving in material handling cost, also reduce accident as 35-40% of accident are result of improper material handling
# Need of material handling :-
The design cost and operation of material handling system depend on the objectives of material, main objective are
- To minimise cost of material
- To monimise delay and inderuption by easy to availability of material
- To increase the production capacity by effective utilization of available resources
- Safety in material handling by improving the working to raw material and finished products
- lower investment in improper inventory
- To maximize utilization of material handling equipment
# Factor considered while selectively the material handling device :-
The selection of material equipment is an imp. Decisions because it refer the costs effective of handling system
The following factor are considered in selection for a material handling device
1. Nature of operation :-
- Wheather handling is temporary and permanent
- Wheather the flow is continues
- If material flow is verticle
- If the type of laypout is process production
2. Material to be handelled :-
+ Size and shape of material
+ Material properties
+ Quantity and weight of the material
+ Damage during handling
3. Distance to be moved :-
- long distance
- Work station
- fixed distance
4 Installer and operating cost :-
+ Initial investment on material handling device
+ Operating and maintainance cost of device
5. Plant facility :-
- Type of building
- Floor capacity
6. Safety consideration :-
+ Proper handling direction
+ Proper use of material handling device
7. Eng. Factor :-
- Door and ceiling nothing
- Floor condition and structural strength
- Traffic safety
8. Equipment reliability :-
+ Use of standard device
+ Services and repair facilities
+ Suppliers reputation
@ Element of material handling
# Motion :-
Movement of raw material and products in most economic safe and effecient way
# Time :-
Timely delivery of raw material to it's destination
# Quatity :-
Supply of current quantity of raw material at each manufacturing point
# Space :-
Optimum and effecient use of resource floor space
Plant :-
A plant is a place where man,material, money,m/c and equipment are brought together for manufacturing products
# Plant location :-
It mean deciding a suitable area location or place where the factory will be setup it involve 2 major activities
1. To select a proper geographical region
2. Selecting a specific Site within the region
# Importance of plant location :-
Plant location plays an important role in the design of production selection as it determine the cost of getting suitable raw material processing raw material to finished goods and distribution of manufacturing products
No location can be ideal or perfect. A balance between various Factor affecting plant location is to be made
1. Nearest to the market :-
It will ensure a regular supply of product to customer and reduce the cost of transportation. A location near to Market is preferred if-
- The product are delicate
- After sale services are required
- Transportation cost of high and increase to over all cost significant
2. Nearest to raw material :-
Nearness to source of raw material is of special importance when the material is heavy as compared to it's volume and when the volume and weight are reduced significantly during the processing. The Place of production is likely to be at place of consumption. Where the final product is more expensive to carry. It reduces the lost of transportation as well as the chances of product getting damaged during transportation
3. Transportation facility :-
It is important for the location of the plant. Speedy transport facility ensured timely supply of raw material to the company and delivery of finished products to the customer depending upon size and type of material. Transport like road, rail, water or air is selected
4. Availability of labour :-
A stable Labour force of right kind adequate size and of positive attitude towards work at regionable rate. Few Factor that are considered so that company faces less strikes agitation and lockout to achieve lower labour cost per unit of production
5. Availability of fuel and power supply :- Many industries such as a steel company should be located where regular power supply is available easily and at regionable cost
6. Availability of water :-
It is an important point for plant location the process industries like paper, Chemical, cement etc by continues supply of water in large amount
7. Suitability of land climate :-
To setup a plant the land and climate survey is required to see the area shape of the Site drainage pass history of flood and earthquake
8. Social infrastructure :-
Availability of facilities like housing, education, post office etc should be kept mind before selecting a plant location
9. Supporting industries and services :-
Now a days a manufacturing organization does not make all the components by itself and it sub-contracts the work to evidence and ancillories
10. Law and location :-
The policies of state government and local bodies and labour loss, safety etc are considered in plant location to have a balance regional growth of industry both central and state government offer the package of insensitive to enterpreneur a particular location these day may be in form of tax, subsidy in electricity charges etc
Attitude :-
The sucess of industry depend very much on the attitude of thinking of the local people whether they want the plant to setup of not
@ Urban and ruler plant location :-
1. Plant location in urban area:-
# Advantage :-
- it is well connected by rail, road and air transport
- good market availability
- skilled labour is available
- Good supply of electricity and water
- presence of facilities like hospital, school, bank, marketing
-Easy training of worker and foreman
- Service expert and specialists are easily available
- Existing small industries can work as ancellaries
- Good security
# Disadvantage :-
- Limited area for building
- Lost of land and construction is high
- Less scope of expension
- high tax
- High labour charges
- more problems of unionism
2. Plant location in rule rules area:-
# Advantage :-
- Plenty of land is available for construction
- large scope of future expension
- Lost of land is low
- Labour is easily available
- non-union problem
- munciple and other regulation and taxes are not a burden
-more relaxation in law from government to develop rules areas
Disadvantage :-
- Skilled labour is not available
- less transportation facility
- shortage of regular power supply
- Ruler areas are for from selling market
- community facilities like hospital education etc. Are not available
- No axillary services
- Services experts and proffesionals are not available
# Objectives of plant layout :-
In a good plant layout the motive is to maintain best relation between output, space and manufacturing lost. Its good is maximum profits
The following are the objective of a good plant layout
1. Elimination of bottleneck and point of conjection
2. Efficient material handling and transportation
3. Proper designing of work station
4. Better working environment safety of employee and minimum accident
5. Minimization of worker movement
6. Reduce idle time
7. Better utilization of space
8. Improved work method
9. Easy plant maintainance, increase productivity and better product quality
10. Better supervision and controlled
11. Worker convience improve molar and high satisfaction
@ Types of Layout:-
# Product layout :-
It is also known as line layout m/c are arranged
# Work station design :-
It affects the production rate, effecienty and the accuracy with which an operation can be performed to reduce wastage and each level of operation and minimise material handling air must be taken in designing a with station .a work station not only need space for the worker and m/c not their are also a large number of other items which also need accomodation
# Factor consisdering in designing a work station :-
1. Space requirements :-
-Space for the employee to stand ,sit to turn comfortaly to operate
- Space for the m/c keeping in mind these our hand projection or overtravel m/c parts. Table of a milling m/c travel etc
- Space for the workplace if it is projecting out like a long bar different to a turned
- Space for storing incoming raw material and finished goods
- Space for storing necessary tools and other components required by the worker
- Space for the additional attachment and fixtures
- Space to load large work on soff the m/c
2. Other factor's :-
- Easy excess to safety for in case of emergency
- Easy excess to m/c for lubrication, inspection, maintainance and repair
- Convenience for making foundation of machine
- Aisle Space between one m/c and the next m/c
- Appropriate ventilating, lightning and safety arrangements
# Material handling :-
It is the art of movements handling and Storage of material during different stages of production. Out of total time spent for manufacturing of product about 80% of the time is utilises in moving product from one space to another weightening for processing and storage
# Cooling and lubrication system :-
It is estimated as company spend 25 to 35% of the total expenditure on material handling. It however does not add value to product best plAnning and application of the reducing unnecessary movement of worker reducing ideal time of men and m/c and reducing overall lost of manufacturing. The cost of production can be lowered considerable by making a saving in material handling cost, also reduce accident as 35-40% of accident are result of improper material handling
# Need of material handling :-
The design cost and operation of material handling system depend on the objectives of material, main objective are
- To minimise cost of material
- To monimise delay and inderuption by easy to availability of material
- To increase the production capacity by effective utilization of available resources
- Safety in material handling by improving the working to raw material and finished products
- lower investment in improper inventory
- To maximize utilization of material handling equipment
# Factor considered while selectively the material handling device :-
The selection of material equipment is an imp. Decisions because it refer the costs effective of handling system
The following factor are considered in selection for a material handling device
1. Nature of operation :-
- Wheather handling is temporary and permanent
- Wheather the flow is continues
- If material flow is verticle
- If the type of laypout is process production
2. Material to be handelled :-
+ Size and shape of material
+ Material properties
+ Quantity and weight of the material
+ Damage during handling
3. Distance to be moved :-
- long distance
- Work station
- fixed distance
4 Installer and operating cost :-
+ Initial investment on material handling device
+ Operating and maintainance cost of device
5. Plant facility :-
- Type of building
- Floor capacity
6. Safety consideration :-
+ Proper handling direction
+ Proper use of material handling device
7. Eng. Factor :-
- Door and ceiling nothing
- Floor condition and structural strength
- Traffic safety
8. Equipment reliability :-
+ Use of standard device
+ Services and repair facilities
+ Suppliers reputation
@ Element of material handling
# Motion :-
Movement of raw material and products in most economic safe and effecient way
# Time :-
Timely delivery of raw material to it's destination
# Quatity :-
Supply of current quantity of raw material at each manufacturing point
# Space :-
Optimum and effecient use of resource floor space
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