INVESTIGATION ON INDUSTRIAL LAYOUTS :

MODIFICATIONS BY A VARIED APPROACH

Nagarjuna Reddy Gayam, K.Shanmuganandam

Department of mechanical engineering,
saveetha school of engineering, SIMATS, chennai
[email protected]

1.ABSTRACT

This research paper objective is to investigate the existing industrial layout patterns by analyzing
their production time, cost involved in whole process, safety measures to workers and industrial
equipment, quality control and integrated management and suggesting improved industrial layout
to any one existing industry. By doing so the key factors responsible for production lag are
eliminated to the maximum and we can improve the output along with better working conditions.
By taking existing industrial layout, investigation proceeds and what modifications are required
to increase profits to the industry in general, workers in particular. After analyzing existing
layouts stage by stage, process by process , proposing a new reliable industrial layout is the key
motive behind this paper.

2.KEYWORDS
Production, layouts, quality integration, materials movement, industrial safety

3.INTRODUCTION
Ease of doing production and transportation are crucial parameters in Ease of doing
business. In order to improve the production various factors are involved in turn ranging from
industrial layout model, management, electricity, water availability, worker’s ability to work,
research and development, quality control and better transportation availability and more
freedom of space for logistics to move. From this, industrial layouts models are one of very high
weighted components in the production improvement.[1-2] Generally, it is known that industrial
layout means how should a good industry arranged in a maner that it reduces cost of production,
better industrial safety, easy material movement. Considering one carburetor manufacturing
industrial layout, as part of this research paper investigation proceeds for existing industrial
layout.[3]
4.INDUSTRIAL LAYOUTS
There are various industrial layouts ranging from product, process, cobined, fixed layout,
group technology, flexible manufacturing systems etc in existing industrial world. Product layout
only focus on product number and if any error occur in the gap between the machines, the entire
output may reduced or effected.[4] Inorder to rectify this, process layout is proposed. Here, all
the major working process like casting, maching, assembly process, quality, materials processing
are separated.[5] Now output is restricted to this individual processes only, then came combined
and fixed layouts where the benefits of both the product layout and process layouts are clubbed
together to improve the production.[6]

Group technology ,with the advent of this new industrial layout model production
improved in existing layouts, where the similar components of work are teamed or grouped
together in order to reduce the mismatch between the similar items. It is a task oriented cellular
manufacturing layout, the only disadvantage in this type of layout is the lack of communication
between the the group of working process as they mainly focus on their productivity.[7-8]

Flexible manufacturing system also one type of industrial model where technology of
adjusting machines, production output to our requirements is available, this has optimum
production and optimum varities of products as it’s features.[9] Cellular manufacturing and
flexible manufacturing systems enhanced the production output tremendously, even though it
improved output there is lag in the time between heavy CNC machines and next small machines
due to their time consuming nature and lot to do with the assembly line and linkage between
rejected products and recasting modes.[10]

5.EXPERIMENTAL STUDY
After analyzing how an existing layouts are there, now testing of various parameters
involved in the carburetor producing industry layout and to suggest modifications for it to
improve production are done, (a)ranging from time involved to obtain complete a product(s) by
taking time values between casting process, machining process and stage by stage assembly
process and to bring materials to near stage of production, infrequent quality inspection at the
last and irregularities in packing and no connection between the the substages and entire line in
turn entire production.[11-12] After this time study now, (b)worker friendly layouts as easy to
escape during emergency, better alarming devices, basic amenities like restrooms, recreation
breaks and easy way to food section, office, first aid room, to way out. Then, (c)integrated
management, including HR and his team, manager and research and development, their
availability to shopfloor. In one the carburetor industry, initially the steel alloy material bars are
supplied by logistics to casting section, it will cast for all four types of models it have to. Then
that material supplied to machining section where all work is done like send to assembly and
packing. Here intermediate distances are time consuming and lag in heavy machine processes.
Materials of last stage persons have to walk through long distances quality is confined to limited
persons. In order to overcome these limitations as shown in fig1, Convergent layout is proposed,
where casting is in centre position separately, divided machining processes into groups, assembly
lines are integrated with respected material rooms, rest rooms, easy emergency rooms and
segmented assembly lines with special storage blocks and integrating quality and rejection and
final storage rooms into casting process to reduce more time and involving two way
transportation.[13-15]

Figure 1 top view convergent layout

Figure 2 iso view convergent layout

6.RESULTS

Table 1 Comparision between existing layout and convergent layout

Existing Convergent Time

Components Inference
layout(min) layout(min) difference(min)
Logistics (unload) 30 30 - -

Casting 60 60 - -
Divided into
Casting – Storage 20 15 5
2 rooms
Available at
Machining (chemicals) 60 55 5
nearest location
Divided into
Machining – Storage 20 15 5
2 rooms
Materials 5 - 5 Segment wise

Assembly (1-5) 15 15 -

Gap (CNC) 3 1 2 Easy to bring

Aseembly (6-10) 15 15 -

Gap (Testing) 3 1 2 Easy to bring

Assembly (11-15) 20 20 -

Gap (oil) 3 1 2 Easy to bring

Assembly (16-last) 15 15 -

Packing 2 2 -
Dived into 4
Rejection – Storage 5 3 2
rooms
Repetitive
Storage – Casting 20 min* 15 min* 5 min*
(not counted)
Final Storage 20 15 5 4 rooms

Logistics 30 30 -

Total Time 328 min 295 min 33 min

 BENEFITS OF CONVERGENT LAYOUTT
100

80

60

40

20

0
WORKER COST OF EFFICIENCY
WELFARE PRODUCTION

EXISTING LAYOUT CONVERGENT LAYOUT

Figure 3 Benefits of convergent Layout

LOCATION

QUALITY LAYOUT WORKER

MANAGEMENT

Figure 4 Important parametrs of layout

From the above obtained graph in fig3, if the industry involving casting, machining,
assembly lines is investigated then we can reduce so much time between machines of working
process, the effectiveness of worker determines it’s efficiency. The layout plan shown in fig2, is
modified version of existing layout which will give maximum output. Due to global warming the
real working hours are reducing by legitamising errors, so there is need for keeping more cooler
production space by installing extra equipment of cooling devices for reducing that errors which
can impact not only production but the parameters shown in fig4.

7.CONCLUSION

After taking into account the assembly line model from product layout, processes from
process layout, segmentation and similar operations grouped together from group technology, we
obtained the convergent layout by applying minor modifications. If we increase the ease of doing
production, worker’s efficiency by special facilities we can improve ease of doing business,
which every industry wants to achieve. By following all these measures, as obtained earlier
10.06% efficiency and also improve worker’s safety, well being in industry and utilize his
maximum effectiveness.

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