Mechano N4 Workshop layout
Notes
Workshop Layout
Symptoms of Poor layout
Not enough control.
Long transports routes.
Congestion.
Frequent accidents.
Delays in production lines(Bottlenecks).
Unnecessary handling of equipment.
Low worker performance.
Advantages of good workshop layout.
Low production costs.
Quality products are produced faster.
Control labour force easily.
There’s job satisfaction.
Production changes can be easily made.
Principles of good layout.
Felxible layout – Workshop plan must be
able to adapt to product change.
Co-ordinated services –
Accessible service & Maintenance points –
Service points and supply routes must be
easily accessible.
Clear transport routes – Transport routes
and aisles must be clearly marked for safety.
Optimum use of space – Everything must be
placed where it belongs.
Minimum travelling distances for staff and
material – Only direct and essential
movement should occur to minimise costs.
Minimum material handling – Limit handling
material, make use of conveyor belts cranes
etc.
One way flow of material – Production must
flow in one direction.
Pleasant working conditions – Discomforting
factors must be eliminated.
Safety of workers & Security of equipment –
Workers should not be exposed to any
danger.
Important factors influencing the layout
design
Type of production.
Most effective flow routes of product.
Size of work.
Inspection requirements.
Quality of equipment.
Production flow.
Regulations.
Additional services (e.g water).
Storage space.
Types of handling equipment.
Types of production and the main
characteristics of each.
Volume.
Processing time.
Size.
Complexity.
Movability.
Mass.
Mass production –
1. Large scale manufacturing.
2. Reduced labour costs.
3. Uniform quality of products.
4. Break even volume.
5. Mechanisation minimising handling.
6. One product per production line.
7. Computerised control.
8. Specialised machine.
9. Bulk storage.
Batch Production –
1. It is in groups.
2. Work is divided in different operations.
3. Considerable degree of specialisation.
4. Process layout is used.
5. Small scale of production.
6. Multi-purpose machine.
7. Methods are flexible.
8. Higher degree of training in workers.
Indivisual production – All effort is
concentrated on one item.
1. One product at a time.
2. Highly skilled workers.
3. High capital outlay.
4. Specialized equipment needed.
5. Flexible layout.
Types of layout and main requirements.
Product layout – Machines are in lines from
start to end.
Process layout – Machines of the same kind
are grouped together.
1. Requirements:
Product Process
a) Manufacture large a) Various sections
volumes. must be placed
b) Minimum number economically.
of changes. b) Shortest transport
c) Sufficient supply of routes must be used.
raw materials. c) Highly skilled
d) Sufficient spares of workers are needed.
machines. d) Strict control of
e) Strict inspection workers.
requirements. e) Adaptable methods
f) Production must be used.
planning. f) Production must
be carefully planned.
2. Advantages:
Product. Process.
a) Minimum amount a) There’s flexibility.
of material b) Production is not
handling. limited.
b) Production cycle is c) Machines can be
fast. fully used.
c) Production control d) No interruptions
is easy. when one machine
d) Effective control of breaks.
workers. e) Faulty parts are
e) Effective use of not rejected.
unskilled of f) Effective control in
workers. costs.
f) Production is
uninterrupted.
g) Continuous
inspection is
maintained.
3. Disadvantages:
Product Process
a) Lack of flexibility. a) Not continuous.
b) One machine break b) Extensive handling
whole operation of work piece.
stops. c) Costs are higher.
c) Large volumes d) More space
must be maintained. needed.
d) Faulty parts are e) Control is difficult.
rejected. f) Detailed scheduling
e) High capital outlay. of working activities
are needed.
Special requirements for the placing of
machines in the workshop
Handling of work pieces – Workers must
use lifting machines to lift heavy work
pieces.
Space above and around each machine –
Sufficient space around each machine is
needed for work not to be hindered.
Transport routes and aisles – Routes and
aisles must be marked and kept clear at all
times.
Storage facilities – Storage containers for
work pieces must be placed near machines.
Supply of services – Supply routes and
service points must be reached easily.
Carrying capacity of the floor – Floor must
be able to carry heavy loads safely.
Layout procedures
Drawings, diagrams and illustrations –
Easiest and mostly used method of planning
layout and it is the first step in planning.
Computers are used and are easy and quick.
Advantages of using Disadvantages of using
computers computers
1. Drawings can be done 1.Not all offices have
quickly. computers.
2. Changes can be made 2.Computers able to do
quickly. these drawings are
expensive.
3. Ideas can be changed 3.Highly skilled draughts
within few minutes. people with knowledge of
computer are needed.
4. Drawings can be done in
any colour.
5. 2D and 3D drawings can
be made.
6. Complicated calculations
can be done accurately.
7. Easy to store large
amount of information.
8. Assessment of a
drawing/project can be
easily done.
9. Portable computers
enable calculations to be
done anywhere.
Two-dimensional model layout
Advantages of 2D Disadvantages of 2D
1.Highly flexible. 1. Difficult to store
permanent record.
2.Model show precisely area 2. Cannot be taken to
to be occupied. workshop floor.
3.Different colours 3. Does not show height.
represent different aspects.
4. No specialised equipment
needed.
5. Unskilled person are
provided with a clear
picture of the layout.
6. Can serve as a
preparation for a 3D.
Three dimensional model layout
Advantaged of 3D Disadvantages of 3D
1. Can be made to precise 1.Very expensive.
scale.
2. Shows height clearly. 2.Not easily transportable.
3. Can be easily rearranged. 3.Difficult to store
permanent record.
4. Skilled technical people
are not needed.
5. Unskilled technical person
get a clear picture.
Phases in the design of a layout
Finding a suitable locality.
Comparing possible layouts.
Dividing the locality
Placing equipment and services in the relevant
areas.
