An Efficient Plant Layout Equals Productivity
Introduction
Productivity is related to the concept of efficiency. It is a method use to measure how well an organization can convert its input resources to goods and services or simply just a ratio of input and output. Every industry aims for higher productivity rate because as the production increases it will soon follow the rate of increase in terms of profits. There are several ways on how to improve productivity. One of which that is being considered is having an efficient plant layout.
Every infrastructure requires having a layout. A layout is consisted of the detailed plan of the structure being constructed or reconstructed. It emphasizes the arrangements and proper positions of the basic elements of the plan. A layout serves as a guideline for the builders as well as the owners of the establishments to visualize the physical appearance of the infrastructure. A layout also includes the proper allocations of space and equipments that will be use within the production of the plant. It is a very importance aspect within the manufacturing cycle.
Plants should have an ideal layout in order to improve their productivity means. A properly laid out plant ensures a smooth rapid movement of materials and employees. However, plants layouts are dynamic in concept because it tends to adapt several changes regarding the need for improvement of the industry.
Production and Productivity
The difference between production and productivity is often neglected. These two economic terms are entirely different from each other. Production is all about the total amount of goods and services being produced while productivity refers to the efficiency of production. A manufacturing enterprise should always strive for higher productivity rate; a higher productivity means producing more within the given input resources or producing a given quantity with a lesser input resources. However, increase productivity should not be confused with an increase production because an increase production can be attained by increasing input resources while productivity will remain the same. Either way, productivity can be improved by the efficient use of input resources but at the same time the production may stay the same.
Productivity is important not only in manufacturing but also in the country itself. A higher productivity means a greater opportunity for prosperity. It also leads to a lot of benefits such as it decreases the cost of production which results to a domino effect that also decreases the cost of the product therefore it would become more affordable and available to the public. It tends to lower the production cost and it increase production as it increase the profits of the company. It promotes social and economic progress. It alleviates poverty. It improves working conditions of the workers as it increases their wages. Lastly it advocates exporting companies to compete more in foreign markets. The following benefits are possible with a proper management of productivity.
An Efficient Plant Layout
One of the aspects that can affect the productivity of an industry is the plant layout. The plant layout involves the planning path each component part of the product is to be followed within the plant. It also includes the proper coordination of each parts so that the process of manufacturing will be carried out in the most economical and practical manner. A plant layout is composed of a detailed plan of the infrastructure – the sketches, drawings that are carefully scaled on order to achieve the real visualization of the plan that is going to be implemented.
The main objective of the having a plant layout is to provide an overall satisfaction to all concerned. Meaning, it should enhance the productivity of the industry more. Hence, other objectives includes the prevention of accidents, promotion of the job satisfactory, reduction of productions delay and manufacturing time, simplification in control of production, avoid necessary capital investment, help effective utilization of employees, machine and services and lastly increase in productivity.
The need for a plant layout depends on the industry itself. The layout of each plant differs from the nature of the industry. The necessity for planning a layout may be due several reasons like a change in product design new which may have to be also a change in manufacturing operations or the sequencing of the processes. It can also be because of a relocation of existing departments or addition of new departments. This is the more usual reason why an industry asks for plant layout. This also includes renovations of the former establishments in the plants for improvement causes. Finally is the need for setting up a new plant. Maybe for further expansion or addition of a new product is utilize by the industry that is why they needed a plant layout for it.
Hence, a well-planned layout is always to be considered to ensure the efficient control over the various production processes.
Types of Plant Layouts
Layouts may differ according to the category of the business or units. These categories may be manufacturing units, traders and service establishments. In case of manufacturing units, there are four types of layouts considered: the product layout, process layout, fixed position layout and the combination layout.
The product or line layout ensures that each product follows an assembly line where different operations are being done in a sequential manner. Normally, materials are being fed into the machines and the other processes follow in order. Example of which is the paper industry.
The process layout or the functional layout is a type of layout that groups together equipments or workstations that are similar in task. Within this layout, the partly finished products may move from process to process and each batch may follow different routine. Industries engage in handicrafts products usually use this kind of process.
In fixed position layout, the major product is usually being fixed or produce in a fixed location, as it names implies. This is mostly use by large scale entrepreneur like ship yards. All of their production is done in one place which tend s to be their work center.
In combined layout, this may be the combination of both or even all of them. Industries involving fabrications of parts may use this method. They can engage with the combination of product layout and process layout.
Another category is the traders. In general, traders are the one who buy and sell goods for profit. There are three kinds of layout in retail operations, the self service, full service and special layouts. The possible example of self service layout is the groceries and department stores wherein the customers are fully exposed to the products. Customers should always be impressed and attracted by the service, efficiency and quality of the product. In the case of full service layout, an area or equipment is provided as much as possible. Just like in the fashion items stores, jewelry and accessories stores and furniture and appliances stores. The last layout for retail operations is the special layouts. These are the businesses that require special design like TV repair shop. Thus, a good retail layout should be the one that requires less time, labor and rent.
The last category of business unit is the service centers and establishments. These are the businesses inclined to provide services to the people. Among them are the restaurants, hotels, motels and travel agencies. This requires a great convincing factor on how a certain establishment can attract a client. They must also include a good ambiance, efficiency in giving services and a great quality of service. Usually, most clients look for approachable establishments that will offer them convenience regarding the service they ask for. Not to mention the price and its accessibility.
Factors Influencing a Plant Layout
There are several factors that can affect the layout of the plant and it would be advisable for every entrepreneur to consider these factors to minimize hazards during the plant construction. First, take note of the nature and size of the building. Determine if the area allotted is sufficient for the activity of the company. Make sure to consider proper ventilation within the space. Second, know the nature of the product. A uniform product requires a product layout while a custom-made product is more appropriate to process layout. The production process is also similar to this wherein the product layout is more considerable among assembly-line industry while process layout on the other hand is more desirable by intermittent manufacturing. Third, the equipments to be used, usually general purpose machines are arranged as per process layout and special purpose machine are arranged according to product layout. Fourth, the repairs and maintenance, negative circumstances should always be considered since it is cannot be avoided, every equipment in the factory should be arranged in an adequate position so that by the time that necessary repairs are needed there should be an allotted space for them to be moved and repaired. Fifth factor is the human needs. The plant layouts should also be meant not only for the equipment but also to the needs of the employees. There should also be enough facilities for them like wash rooms, cloak rooms, toilets and lockers that are only meant to comply with their needs. Finally, the last factor that influences the plant layout is the plant environment. The light, heat, noise, ventilation and other aspects should be duly considered. This part is somehow a prerequisite among plant layouts to minimize accidents in the plant especially if the plant is engage in production of hazardous materials. Adequate safety and precautions are also be made.
Plants Building Codes
All infrastructures require certain building codes to follow especially in the case of business buildings and plants. They must all comply with the building codes criteria implemented within their area to prevent accidents and hazards. Plant layout should indicate safety within each design and pass the specifications standards of the building codes.
The design of the plant is basically done to suit whatever purpose it might be intended but the most important is it should render safety. Each facility must provide fire exits and fire extinguishers, hydrants or even fire sprinklers that can be used in case of fire. The building should also comply with the standard building code allotted within the seismic analysis just in case of earthquakes.
The common design criteria for most building code that they need to comply is the safety it will bring to the occupants. Proper ventilation which includes air cons, blowers, dryers etc. is efficient to every industry. Also the proper installation of electricity is a requirement needed to be met with the building code as well as the water treatment supply. Storage and working areas should always be restricted only to the personnel using it to prevent contamination and accidents. Lastly, they should always provide a proper waste disposal area for their industrial waste, especially if the plant is capable of producing toxic chemicals.
Change for the Better
According to Professor John Bessant, the chair of Innovation Management, the changes brought by competitive and environmental conditions as well as the continuous emergence of the computer-integrated technology urges the need of manufacturing industry to step up to a new paradigm, part of changes that each industry can resolve to it having a tendency to rely on plant layouts to attain better changes within. Another fact, regarding these changes is incorporating the nature and human welfare through these transitions. The industry has been always linked to the nature. Part of the industrial production and consumption is a diverse waste disposal and as a result it damages our natural resources and pollution becomes prevalent.
Things like these are preventive if there is only a proper disposal of industrial wastes. Hence, industry owners are the one responsible with this type of problem. They must consult a systematic and reliable plant layout that will provide a detailed plan of all the things that is needed within the entire plant. As long as these layouts contain all the necessary improvements such consequences will be avoided. Every well planned concept of changes will provide industry a good means of productivity without compromising with the environment.
Conclusion
Considering a plant layout involves a long-term strategic decision that once taken, it cannot be changed. The entrepreneurs, especially those are who is still a neophyte in this field should consider every inch of the detail among the nature of the industry they are into. Most of them have been occupied by the thought of having large profits but before entering such façade there are still many things to be considered to really find progress within manufacturing.
It is true that with proper plant layout, it will help enhance the productivity more. Thus, great planning and care are just a few hints that should be considered. A plant layout is said to be efficient if it aims to achieve various objectives that an industry needed especially in terms of productivity because this is the main goal while entrepreneur have been engage with the concept of consulting plant layout.
The efficiency of production is greatly affected by rendering proper plant layout. As discuss, each industry has its own plant layout that will comply with their needs and functions. However, there are times that plant layouts are merely influences by several factors which every entrepreneur should learn to acknowledge first before directing to the plan. Layouts may differ from one plant to another but it is applicable to all types of plants. Special layouts are imposed to an industry that is more complicated and hazardous. Generally, plant layouts should be conducive to the health and safety of the employee and as well as it should provide satisfaction and convenience from time to time.
Remember that changes should always be for the better of things. We should seek for changes to have some improvements in our life. Plant layouts will definitely help improve the productivity but each industry should learn to adapt within the changes they want to pursue.
Credit:ivythesis.typepad.com
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