Special Issue - 2018 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
ICIATE - 2018 Conference Proceedings
Efficient Plant Layout Design of a Small Scale
Textile Industry-A case study
Mr. S. B. Naik 1 Dr. Srikant Kallurkar 2
Asst. Professor, Dept. of Mechanical engineering, Principal & Professor,
Walchand Institute of Technology, Solapur Atharva college of Engineering, Malad
Solapur, India Mumbai, India
Abstract— In today's competitive global market, effective i) Data collection and analysis
utilization of industrial resources play a vital role. Here lies the ii) Searching among the possible layout solution.
importance of efficient layout or re-layout of the industry. The iii) Evaluating alternatives and selecting the best layoutt”.
physical arrangement of all the departments, storage areas,
utilities areas must be critically planned to avoid the wastages III. CASE STUDY
and the bottlenecks.
This paper presents a case study undertaken to develop the
This paper refers to a small scale Textile Industry
efficient plant layout by using Systematic Layout Planning manufacturing Turkish towels and napkins.
(SLP) technique, The basic analysis of existing layout was done The manufacturing process involves the flow of material
by establishing relationship of different activities in the process as shown in the figure (1)
flow. The material flow analysis was done by considering load
matrix and cost matrix. After analysis of existing plant layout,
three alternative layouts are developed by using SLP technique.
The efficient plant layout developed has resulted in 55.25%
savings in material handling distance and about 16.66%
increase in productivity.
Keywords— Plant layout, SLP, load matrix, relationship
Figure 1: Manufacturing Process
I. INTRODUCTION IV. MOTION AND TRANSPORTATION
In competitive environment, productivity of the industrial The term motion is used for movement of people and
unit has got ultimate importance. Efficient plant layout is one transportation for the movement of the material. Quantitative
of the effective tool to enhance the productivity. Most plant data was obtained to calculate the total distance travelled in
layouts are designed for initial conditions of the business. terms of motion and transportation during the manufacturing
However these layouts provide many bottlenecks during process of existing plant layout. (Table 1). The table
growth period. Hence as long as capacity grows, it has to represents the distance between different locations for each
adapt the internal and external changes for which efficient re- major process in the manufacturing. The data serves as the
layout is necessary. baseline and is useful in determining the degree of closeness
Many researchers have provided a number of techniques to necessary between different departments for material flow.
optimise the layouts. The quantitative and the qualitative Efforts are made in the layout design to place the
measure of the techniques may differ, however the objectives departments, having more material flow, close to each other
are same. Hence the selection of a best alternative technique is to minimize the material handling cost. It was seen that in
a matter of justification. the existing plant layout (Fig. 2) the work flow was not
optimum due to poor adjacency of the departments.
II. METHODOLOGY The various departments shown in the layout are
1. Administrative office
To design or redesign the facility layout of a manufacturing
2. H .R .Office
process, it is possible to apply many techniques. Each one is
3. Raw material storage
based on a specific idea and goal to be achieved. The
4. Doubling section
comparison can be made based on the production process
5. Dyeing section
parameters such as material flow, material handling cost,
6. Warping section
time, throughput etc.
7. Power loom section
In the case study of a small scale textile industry, the
8. Finishing section
Systematic Layout planning technique is used to develop
9. Inspection section
three alternative layouts. SLP is one of the most frequently
10. Packing section
used methods in the layout design of the facilities. It includes
11. Security
three specific phases :
12. W/C
Volume 6, Issue 12 Published by, www.ijert.org 1
Special Issue - 2018 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
ICIATE - 2018 Conference Proceedings
Development of alternatives by using SLP transportation in modified plant layouts A,B and C are
By applying SLP technique and considering the constraints analysed and presented in the table 2.
three possible alternative plant layouts A, B and C were
developed as shown in Figure 2. The motion and
Figure 2: Alternative Plant Layout
Table 1: Motion and transportation in existing plant layout
Sr. no FROM (i) TO (j) Distance Number of Loads Time in Total Total Time
In meters Second distance
01 Doubling Dying 28.97 10 45 289.7 450
02 Dying Warping 42.09 25 80 1052.25 2000
03 Warping Power Loom 30.5 03 330 91.5 990
04 Power Loom Finishing 18.3 32 30 585.6 960
05 Finishing Inspection 3.66 30 06 109.8 180
TOTAL 2128.85 4612
Volume 6, Issue 12 Published by, www.ijert.org 2
Special Issue - 2018 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
ICIATE - 2018 Conference Proceedings
Table 2: Motion and transportation in new plant layouts A,B and C
Sr. FROM (i) TO (j) DISTANCE Number of Total
no In meters Loads Distance
A B C A B C
01 Doubling Dying 12 12 12 10 120 120 120
02 Dying Warping 10 12 10 25 250 300 250
03 Warping Power Loom 18 19 22 03 54 57 66
04 Power Loom Finishing 23 13 16 32 736 416 512
05 Finishing Inspection 07 02 02 30 210 60 60
TOTAL 1370 953 1008
V. RESULTS savings in labour requirement so that 31 labours are not
required.
Comparing the results of new developed layouts A,B and C * Automation of material handling is suggested by using
with existing layout, it is observed that : trolleys and beam lifting devices.
Layout A results in 785.85 meters savings in total distance.
( 39.91% )
Layout B results in 1175.85 meters savings in total distance REFERENCES
( 55.23% )
Layout C results in 1120.85 meters savings in total distance [1] A. Arun Senthil Kumar and et.al, " Implementation of cellular
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Innovative Research in Science, Engineering and Technology,
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VI. CONCLUSION [2] Anucha Watanapa et.al," Analysis plant layout design for effective
production", Proceedings of intentional MultiConference of
Engineers and Computers Scientists 2011 Vol. II, IMECS, March
In new layouts A,B and C all the departments are 16-18, Hong Kong.
systematically arranged so that efficient material flow is [3] Filippo De Carlo et.al," Layout Design for a low capacity
obtained. Manufacturing Line -A Case study" International journal of
* Maximum material flow distance is saved in plant layout engineering business management special issue on Innovations in
Fashion Industry Vol.5 , 2013
B ( 55.23%) [4] Ram D. Vaidya , Prashant N. Shende," Design and improvement of
* Plant layout C is provided with effective utilization of plant layout", International journal on theoretical and applied
available floor space in weaving section and thereby research in mechanical engineering, Vol. I, Issue-2, 2012
increasing the production by 33.33% [5] Rekha Bhowmik," An approach to the Facility Layout Design
Optimization" IJCSNS Vol.8 No.4, April 2008
* Plant layout C is also provided with the flexibility to adapt
Auto looms in weaving section which will result in great
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