4. Production planning
Production control
Factory building.
Provision of plant services
Plant layout
Physical environment
Method study
Inventory control
Quality control
Product department
5. Reduction of cost
Reduction of loss by in time availability of
resources
Saving by proper assigning and scheduling of
man, machine and material
Effectively assigning task an managing
Improve decision making
Overall improvement of production related
activities.
6. Poor customer performance
Too much stock
Shortage of components and raw materials
Fall in demand
Excessive expenditure and transportation
cost
Delay payment
Wrong decision
Selection design
Problem of plan layout
Priority is not clear
Lack of equipment
7. Product-
meet need and wants – performance – aesthetics
– quality – reliability- quantity – production cost
– delivery dates
Plant – layout , equipment, offices maintenance
– health and safety – environmental issue
Processes – available capacity – skills- type of
production – layout of plant and same.
Programs – purchasing patterns – cash flow –
need for – avalabitlity of storage –
transportation.
People – wages and salaries – safety and
training – work condition – leadership –
motivation – communication – unionisation
8. Location of facilities
2. Plant layouts and material handling
3. Product design
4. Process design
5. Production and planning control
6. Quality control
7. Materials management
8. Maintenance management.
9. Proximity of market
Integration with other parts of the firm
Availability of labour & skills
Availability of amenities
Availability of transport
Availability of inputs
Availability of services (electricity, drainage,
water, disposal waste)
Suitability of land & climate
10. Regional regulations
Room of expansion
Safety requirement
Site cost
Political Social & Economic situation
Special grants, regional taxes & Import Export
barriers.
11. It is layout that deals with low-volume, high
variety production in which like machines and
equipment are grouped together.
Here each product undergoes a different
sequence of operations.
A good example of process layout ins
Hospital and clinic.
Advantage- it’s flexibility in equipments &
labour assignment.
Break down in one machine will not hold the
entire process.
12. It is suitable specially for goods handling the
manufacturing of parts in small batches or
job lots and for production of variety of parts
in different size or forms.
Disadvantage- orders can take more time to
move through the system because of changes
in steps and unique material handling.
It is based on general purpose machine which
in turn requires skilled workers, and their
wages charges are higher.
13. When process layout is design the most
common tactic is to arrange department so as
to minimize cost of material handling.
It tries to minimize loads, times distance
related costs.
14. The graphic approach is fine for small problems,
it cannot however suffice for larger problem.
This program often add sophistication with flow
charts, multiple story capability, storage and
container placement, material volumes, time
analysis and cost comparisons.
Such programs include CRAFT(computerized
relative allocation of facilities technique),
ALDEP(automated layout design program),
CORELAP(computerized relationship layout
planning) & factory flow.
15. It is organized around products of families of
similar high-volume, low variety of product.
Repetitive production and continuous
production use product layouts.
Assumption are-
Volume adequate for high equipment utilization.
Product demand is stable enough to justify high
investment is specialized equipment.
Product standardized a phase of its life cycle that
justifies investment in specialized equipment.
16. Two types of product oriented layout-
fabrication and assembly line.
Fabrication line- a machine paced, product
oriented facility for building components,
such as metal parts of refrigerator.
Assembly line- an approach that puts
fabricated parts together at a series of
workstation; used in repetitive process.
17. Assembly line balancing- obtaining output at
each workstation on a production line so
delay is minimized.
Advantage-
Low material handling cost
Rapid throughput
Easier training and supervision
Reduced work-in-process inventories
18. Disadvantages-
High volume required because of large
investment needed to establish the process.
Work stoppage at any one point ties-up the
whole operation.
