Published by : International Journal of Engineering Research & Technology (IJERT)

http://www.ijert.org ISSN: 2278-0181

Vol. 8 Issue 05, May-2019

Efficiency Enhancement using Systematic Layout

Planning to Reduce the Overall Travelling Cost
Uzair Thakur, Ammar Sayyed, Sarfaraz Mapkar, Belal Ahmad, Afaqahmed M Jamadar
Mechanical Engineering Department
AIKTC-School of Engineering & Technology
Panvel, Maharashtra, India

Abstract— In this paper existing production process layout

of Magmachino forge pvt. ltd. are deliberated and a new layout II. LITERATURE SURVEY
is proposed using systematic layout planning tool in order to Plant layout refers to the physical arrangement of production
permit the quick flow of material, with lowest cost and least facilities. It is the configuration of departments, work centre
amount of travel distance between different workstations. The and equipment in the conversion process. The overall
efficiency of production is depend on how well the available objective of plant layout is to design a physical arrangement
resources such as machines, equipment and employee amenities that meets the required output quality and quantity most
are located in plant. The different techniques such as flow
process charts, activity relationship chart, string diagram has
economically.[1]The research paper presents solving an
been used. The existing and proposed layouts are compared and industrial problem using the principle of string diagram and
the proposed layout shows the cost and travel distance of simulation software .A string diagram can be used to plot the
product/material throughout plant from raw material to movements of equipment, material, and essentially when a
packaging are decreased. Thus efficiency of plant is improved work study person wants to find out how far the materials
thereby reducing overall cost. travel. A simulation study was under taken to find out the
overall efficiency of the plant.[2]
Keywords— Operation process chart, systematic layout A research paper on production process layout of jute
planning, activity relationship chart. industry where systematic layout planning pattern theory to
I. INTRODUCTION reduce production cost and increase productivity. The number
Systematic layout planning is the tool used to adjust the of equipment and travelling area of material in yarn
desired machines at workplace in such a way that it will production have been analyzed. The detailed study of the
minimize material handling throughout different workstations plant layout such as operation process chart, activity
and enhance productivity. Increasing global competition with relationship chart and relationship between equipment and
demand of product is increasing and resources are limited. area has been investigated.[3]
The industry should produce a product with standard quality The paper provided a detailed definition of plant layout and
which meets customer demand. The impotence to get listed efficient labour utilization, manufacturing and
production process right in workplace leads to delay, maintenance ease, enhanced productivity, manufacturing
excessive inventory, inefficiency, quality of product, high flexibility, effective utilization of staff, machines , materials ,
cost etc. hence the need of referring to technique which helps and equipment, as well as reduction of accidents, hazards and
in making right functional plant layout of an organization inventory handling cost as some of the benefits of well-
.The different techniques can be used to improve productivity designed plant layout.[4]
like TQM , QC, control chart, plant layout etc. Systematic A case study presenting overall picture processes happening
layout planning could be tool to improve productivity in in printing industry. The travel time was reduced by
industry by reduction in cost with proper workflow. The relocating machinery. Relocation is based on systematic
research paper presents solving of industrial problem using layout planning.[5]
systematic layout planning in which flow of product (pump The paper provided a detailed definition of plant layout;
impeller) from raw material to dispatch has been studied and and listed efficient labour utilization, manufacturing and
existing layout is made. While Designing new plant layout, maintenance ease, enhanced productivity, manufacturing
following entities need to be considered like parts, process, flexibility, effective utilization of staff, machines,
fixed position layout etc. The propose layout is made with materials, and equipment, as well as reduction of accidents,
help of activity relationship chart. The string diagram is used hazards, and inventory handling cost as some of the benefits
for measuring the travel distance by product through different of a well-designed plant layout. The numerous factors that
workplaces .it has been measured in both existing and determine the designing of a plant layout were also discussed
proposed layout. The travelling distance and Cost of material in full, after which the various types of plant layout were
handling between workstations is compared in both cases and analysedThe paper provided a detailed definition of plant
it has been concluded at the end that efficiency has been layout; and listed efficient labour utilization,
improved in proposed layout. manufacturing and maintenance ease, enhanced
productivity, manufacturing flexibility, effective utilization
of staff, machines, materials, and equipment, as well as
reduction of accidents, hazards, and inventory handling cost

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(This work is licensed under a Creative Commons Attribution 4.0 International License.)
Published by : International Journal of Engineering Research & Technology (IJERT)
http://www.ijert.org ISSN: 2278-0181
Vol. 8 Issue 05, May-2019

as some of the benefits of a well-designed plant layout. The The paper provided a detailed definition of plant layout;
numerous factors that determine the designing of a plant and listed efficient labour utilization, manufacturing and
layout were also discussed in full, after which the various maintenance ease, enhanced productivity, manufacturing
types of plant layout were analysed The paper provided a flexibility, effective utilization of staff, machines,
detailed definition of plant layout; and listed efficient materials, and equipment, as well as reduction of accidents,
labour utilization, manufacturing and maintenance ease, hazards, and inventory handling cost as some of the benefits
enhanced productivity, manufacturing flexibility, effective of a well-designed plant layout. The numerous factors that
utilization of staff, machines, materials, and equipment, as determine the designing of a plant layout were also discussed
well as reduction of accidents, hazards, and inventory in full, after which the various types of plant layout were
handling cost as some of the benefits of a well-designed plant analysed The paper on layout rearrangement of fashion
layout. The numerous factors that determine the designing of production lines realizing many small batches is rarely
a plant layout were also discussed in full, after which the developed according to well known engineering procedures.
various types of plant layout were analysed The paper In the present work ,the results of fashion manufacturing line
provided a detailed definition of plant layout; and listed re layout were compared by analysing the current situation
efficient labour utilization, manufacturing and maintenance with with solutions provided by homemade company design,
ease, enhanced productivity, manufacturing flexibility, both through a systemetic layout planning approach and a
effective utilization of staff, machines, materials, and broader lean reengineering activity.[6]
equipment, as well as reduction of accidents, hazards, and
inventory handling cost as some of the benefits of a well-
designed plant layout. The numerous factors that determine III. METHODOLOGY
the designing of a plant layout were also discussed in full, The data were collected of different machines , other
after which the various types of plant layout were analysed resources which are playing part in making product were
The paper provided a detailed definition of plant layout; counted in terms of flow of product throughout the
and listed efficient labour utilization, manufacturing and workplace. The flow process chart and activity relationship
maintenance ease, enhanced productivity, manufacturing chart have been used for analysing. The activity relationship
flexibility, effective utilization of staff, machines, chart shows the relation between different machines and
materials, and equipment, as well as reduction of accidents, resources on workplace. Basic flow process chart is shown
hazards, and inventory handling cost as some of the benefits below.
of a well-designed plant layout. The numerous factors that
determine the designing of a plant layout were also discussed
in full, after which the various types of plant layout were
analysed The paper provided a detailed definition of
plant layout; and listed efficient labour utilization,
manufacturing and maintenance ease, enhanced
productivity, manufacturing flexibility, effective utilization
of staff, machines, materials, and equipment, as well as
reduction of accidents, hazards, and inventory handling cost
as some of the benefits of a well-designed plant layout. The
numerous factors that determine the designing of a plant
layout were also discussed in full, after which the various
types of plant layout were analysed The paper provided a
detailed definition of plant layout; and listed efficient
labour utilization, manufacturing and maintenance ease,
enhanced productivity, manufacturing flexibility, effective
utilization of staff, machines, materials, and equipment, as
well as reduction of accidents, hazards, and inventory
handling cost as some of the benefits of a well-designed plant
layout. The numerous factors that determine the designing of
a plant layout were also discussed in full, after which the
various types of plant layout were analysed The paper Fig.No.1: Systematic layout planning operation flow process chart
provided a detailed definition of plant layout; and listed
efficient labour utilization, manufacturing and maintenance
ease, enhanced productivity, manufacturing flexibility,
effective utilization of staff, machines, materials, and
equipment, as well as reduction of accidents, hazards, and
inventory handling cost as some of the benefits of a well-
designed plant layout. The numerous factors that determine
the designing of a plant layout were also discussed in full,
after which the various types of plant layout were analysed

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Published by : International Journal of Engineering Research & Technology (IJERT)
http://www.ijert.org ISSN: 2278-0181
Vol. 8 Issue 05, May-2019

TABLE I. DISTANCE AND COST INVOLVED WITH EXISTING

LAYOUT

V. ANALYSIS OF PLANT LAYOUT BASED ON

ACTIVITY RELATIONSHIP CHART
After study of the manufacturing process, it was found that
the distance travel by the raw material needs to be reduced
and it is done by applying systematic layout planning. The
relative importance of having one department near another is
displayed in relationship chart. “Robert Muther” developed
the REL chart. The relationship diagrams recognize the need
for exploring relationship rather than calculating exact flow
and cost. Here we are using similar technique in which three
different colours are used to indicate the closeness desired
between machines and other resources. Since, it is small scale
Fig.No.2: Operation flow process chart
company we are listing all resources. After making activity
IV. ANALYSIS OF EXISTING PLANT LAYOUT relationship chart the proposed layout is made.
The existing layout of company is shown in Fig.No.3 and Different machines with other resources are listed below.
present detail of company is discussed :
1. Stablizer-1 11. Storage area-2(raw material)
2. Stablizer-2 12. Storage area -3(scrap)
3. Tool rack-1 13. Static balancing (inspection)
4. Tool rack-2 14. Desk
5. CNC-1 15. Compressor -1
6. CNC-2 16. Compressor-2
7. VMC 17. Compressor-3(useless)
8. Drilling 18. Hacksaw (useless)
9. Cutter 19. Packaging area
10. Storage area-1

Fig.No.3: Existing layout

The operation process flow is shown in Fig.No.2. According

to existing layout the total distance travelled by material and
the unit cost and total cost is discussed below. The total cost
involved with production is machining cost, raw material
cost, transportation cost and wages. The data we obtain from
company shows that the transportation cost is 7.33 per feet. Fig.No.4: Activity relationship chart
Our aim is to rearrange all machines and other resources such
a way that total cost and travel distance will be reduced.

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Published by : International Journal of Engineering Research & Technology (IJERT)
http://www.ijert.org ISSN: 2278-0181
Vol. 8 Issue 05, May-2019

VI. ANALYSIS OF PROPOSED LAYOUT VII. RESULT

After analyzing the existing layout the overall distance and
The new layout is based on activity relationship chart, where cost of handling the material is 216.67 ft and Rs.1587.68
by altering position of different machines and resources we while it is reduced to 93.641 ft and Rs. 686.3504 for the
are reducing total travel distance by material throughout proposed layout. The total handling cost can be reduced by
workplace also we are proposing the door between two 56.8% according to the layout which is proposed. It is due to
sections. The proposed layout is shown in Fig.No.5 while reduction in total distance travel by the material throughout
Table.No.2 shows the total cost and travel distance of work place.
proposed layout.
VIII. CONCLUSION
This research paper has provided good exposure about plant
layout by using systematic layout technique in consideration
with travel distance and cost to improve existing layout. The
problem with existing layout is large distance between some
machines which leads to higher cost. In proposed layout we
are using activity relationship chart to alter the position of
machines and other resources. Therefore the overall
efficiency of company is increased thereby reducing the
overall cost and the spacing is increased in a company which
can be utilize for different purpose.

REFERENCES

[1] Martand telsang “Industrial engineering and production management”.

[2] A research paper “Efficiency improvement of plant layout” , IJIREST,
vol .3,issue4,April 2014.
[3] A research paper ” Increasing Productivity through Facility Layout
Improvement using Systematic Layout Planning Pattern Theory”,
Global Journal of Researches in Engineering: J General Engineering
Volume 14 Issue 7 Version 1.0 Year 2014.
[4] “PLANT LAYOUTS’ ANALYSIS AND DESIGN”, Department of
Industrial/Production Engineering, Nnamdi Azikiwe University,
Fig.No.5: Proposed layout P.M.B. 5025 Awka, Anambra State, Nigeria.
[5] ” A Case Study Of Printing Industry Plant Layout For Effective
TABLE II. DISTANCE AND COST INVOLVED WITH PROPOSED Production”,1,2,3 Department of Mechanical Engineering, Amrita
LAYOUT School of Engineering, Bengaluru, Amrita Vishwa Vidyapeetham,
Amrita University, India.
[6] ”Layout Design for a Low Capacity Manufacturing Line: A Case
Study”,International Journal of Engineering Business Management
Special Issue on Innovations in Fashion Industry..

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