IEM

1. Plant Layout and Material
Handling

2. Tools and Techniques for developing plant layout
Totally there are 6 techniques
1) Operation Process Charts
2) Flow Process Charts
3) Process Flow Diagram
4) Machine Data Cards
5) Templates
6) Scale Models

3. OPERATION PROCESS CHARTS:
● Represents the basic activities - to produce a product
● Meant for new plant which is to be laid out
● Shows points at which materials are introduced into process
● Sequence of various operations
● Advantage: Manufacturing process is divided into separate
operations.

5. FLOW PROCESS CHARTS:
● Graphical representation of all production activities
● Considered as an elaboration of operation process chart
● Includes transportation, storage and delay
● Data required are collected - by tracing actual flow of work
occurring
● Provides complete information for analysis of plant

6. Advantages:
1. Work station, Storage space & inspection may be reallocated -
to minimize distances moved and labour time
2. Improved flow process chart provides a basis for revising an
existing plant layout
3. Also utilised to check and verify the efficiency of proposed
new layout.

8. PROCESS FLOW DIAGRAMS:
● To supplement the flow process chart
● diagram of building plan - graphically
● the relative position of productive machinery storage space,
gangways etc. and path followed by men or materials
● routes followed by different items are shown by joining
symbols with straight lines.

9. ADVANTAGES:
1. to trace out the undesirable characteristics of the layout -
which are responsible for increased transportation and delay -
by studying the process flow diagrams and flow process chart
2. shows nature of back tracking of present layout which there
by helps in improving the layout

11. MACHINE DATA CARDS:
● give complete specification of each machine to be installed
● showing its capacity, space and other requirements, foundations methods
of operation, maintenance and handling devices of machines etc

12. TEMPLATES:
● 2D representation
● Eliminates unnecessary handlings
● Minimize backtracking of materials
● Makes mechanical handling possible
● Provides visual picture for layout of plant
● Flexibility to meet future changes in production

14. SCALE MODELS:
● 3D representation
● improvement over the template technique
● These models may be of wood plastic or metals
● additional information about the height and of the projected
components of the machines are obtained
● useful for complete layout which initially requires huge
investment

16. ASSEMBLY LINE BALANCING
Assembly Line Balancing (ALB)
optimizes the mass production process
by dividing tasks into workstations and
allocating equal processing time to
each one without any delay

17. ● must be balanced - to ease the manufacturing process
efficiently
● involves the apportionment and allocation of the tasks into
several workstation
● the allotment must not impact the existing precedence
relationships

18. Following are the examples where there is a need to balance the
assembly line may arise:
● Manufacturing of Automobiles
● Assembling Aircrafts
● Shipyards, etc

19. WHAT IS ASSEMBLY LINE?
An assembly line is the number of production processes arranged
in a sequence.
It is a transformation process where the raw materials turn into a
finished product.
Also, assembling different parts and combining them to form a
single product.

20. WHAT IS BALANCING IN OPERATIONS MANAGEMENT?
Balancing the lines is grouping tasks under workstations and
assigning equal processing time to them.
There is a need for line balancing in order to keep the output rate
equal at all the workstations.

21. Objectives:
The objective of using ALB is to divide the entire work process
into several sub-stations. But, the division must not affect the
precedence relationships of the tasks and must not exceed the
cycle time.Also,
● Minimization of the cycle time
● Minimizing the number of the workstations
● Maximization of workload and smoothness
● Maximization of work-relatedness

22. ADVANTAGES:
1. Cost Reduction
2. Sequential Flow
3. Reducing Idle Time
4. Utilisation of Resources
5. Less Processing Time
6. Less wastage

23. STEPS INVOLVED:
1) DEFINE TASKS – list all the essential tasks involved in the production
2) IDENTIFY PRECEDENCE REQUIREMENTS – identify the precedence
relationships existing among the listed tasks
3) NUMBER OF WORKSTATIONS
4) SELECTION OF HEURISTICS – heuristics are experience-based methods used to
reduce the need for calculations pertaining to equipment size, performance, or operating
conditions
5) DETERMINE EFFICIENCIES – Post task allotment in workstations, we must test the
effectiveness and efficiency along the line
6) REBALANCING OF ASSEMBLY LINE – There is a need to rebalance the assembly
line, so as to remain competitive in a dynamic environment

24. Assembly Line Balancing is segregated into two groups as
follows:
Group – 1
1. Single Model: It is used where the production of a single
commodity takes place.
2. Multi-Line Model: In this, the manufacturing takes place
in batches, i.e. production of more than one commodity.
3. Mixed Model: Here, the production happens for the same
product’s variants simultaneously. But the production is

25. Group – 2
1. Simple ALB: It is the simplest and most systematic model
for line balancing. The production of a single commodity
takes place having features like: –
● Fixed-rate launching
● Equally equipped stations
● Serial Layout

26. 2. General ALB: All the models, excluding small ALB,
are the general ALB. It may include: –
● Balancing of mixed models
● Parallel, U-shaped & two-sided models
Therefore, by using gALB, firms can develop more realistic Line
Balancing models