Food-Processing-Plant-Design-layout

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Food Processing Plant Design & layout7.1 Importance and functionModule- 4. Food plant layout Introduction, Planning and ExperimentationLesson 7. Plant LayoutPlant layout refers to an optimum arrangement of different facilities including humanresource, plant and machinery, material etc. Since a layout once implemented cannot beeasily changed and costs of such a change are substantial, the plant layout is a strategicdecision. A poor layout will result in continuous losses in terms of higher efforts formaterial handling, more waste and rework, poor space utilization etc. Hence, need toanalyze and design a sound plant layout can hardly be over emphasized. It is a crucialfunction that has to be performed both at the time of initial design of any facility, andduring its growth, development and diversification.The problem of plant layout should be seen in relation to overall plant design whichincludes many other functions such as product design, sales planning, selection of theproduction process, plant size, plant location, building, diversification etc. The layoutproblem occurs because of many developments including:change in product designintroduction of new productobsolescence of facilitieschanges in demandmarket changescompetitive cost reductionfrequent accidentsadoption of new safety standardsdecision to build a new plantPlant layout problem is defined by Moore (1962) as follows: “plant layout is a plan of, or theact of planning, an optimum arrangement of facilities, including personnel, operatingequipment storage space, materials handling equipment, and all other supporting services,along with the design of the best structure to contain these facilities”.44 www.AgriMoon.com
Food Processing Plant Design & layout7.2 Objectives and advantagesSome of the important objectives of a good plant layout are as follows:Overall simplification of production process in terms of equipment utilization,minimization of delays, reducing manufacturing time, and better provisions formaintenanceOverall integration of man, materials, machinery, supporting activities and any otherconsiderations in a way that result in the best compromise.Minimization of material handling cost by suitably placing the facilities in the bestflow sequenceSaving in floor space, effective space utilization and less congestion / confusion,Increased output and reduced in-process inventoriesBetter supervision and controlWorker convenience and worker satisfactionBetter working environment, safety of employees and reduced hazardsminimization of waste and higher productivityavoid unnecessary capital investmenthigher flexibility and adaptability to changing conditions7.3 Types of layout problems/situationsThe plant layout problems can be classified into four types as follows:Planning completely new facilityExpanding or relocating an existing facilityRearrangement of existing layoutMinor modifications in present layout7.4 Flow patternsAccording to the principle of flow, the layout plan arranges the work area for eachoperation or process so as to have an overall smooth flow through the production / servicefacility. The basic types of flow patterns that are employed in designing the layout are I-flow, L-flow, U- flow, S-flow and O - flow as shown in Figure 1. These are briefly explainedbelow:45 www.AgriMoon.com
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