Unit III

Physical layout of the plant

 Determine the physical space of a
productive plant, taking into
count the three surfaces
used in this study.
Create the block diagrams
for the realization of the
physical layout of the plant.
Prepare the plans
corresponding to the distribution
physics for all areas (offices,
production areas, warehouses,
service and support areas, etc.)
Apply the different methods of
evaluation for the design of the
production process and of the
Unit Competencies workstations
corresponding.
 Evaluation System
Exam 30%
Practice 20%
Evidence 20%
Activities 20%
Assistance 10%
 3.1. Determination of the size of a facility.

By this method, the will be calculated

physical spaces that will be required in
the plant. It is necessary to identify the
total number of machinery and equipment,
and also the total number of
workers and handling equipment
materials
 Calculations of the Guerchet Method

St= total surface

N = number of mobile or static elements of a type
Ss= Static surface
Sg = gravitational surface
Se= Surface evolution k=0-3
 Static Surface

It corresponds to the area they occupy

furniture, machines, and equipment.
It must include the deposits, the
levers, the boards, the pedals
and other necessary objects for
its operation.

Ss = length x width
 Gravitational Surface

It is the surface used by the

operator and for the material for the
operations of the positions of
work.
It is obtained, for each element,
multiplying the static surface
by the number of sides from
of which the furniture or the machine
must be used.
Sg = Ss x n
N = number of sides
Ss= static surface
 Example

Circular n=2

The teams whose

plan view sea
a circle
(tanks, between
others),
n= 1 n=2 n=3 normally it
consider n= 2 and the
formula 2for
the calculation of the
static surface
 Surface in Evolution
It is the area for displacements.
of the staff, of the team, of the
means of transportation and for the departure
of the finished product

The factor 'k' is used for its calculation.

called coefficient of
evolution, which represents a
weighted measure of the relationship
between the heights of the elements
mobile and static elements.
= +
 Typical values of 'k'
For its calculation, the factor 'k' known as the evolution coefficient is used,
what represents a weighted measure of the relationship between heights of
the gravitational elements and the static elements.

Large industry, food with overhead crane: 0.05-0.15

•Chain work with mechanical conveyor: 0.10-0.25
Textile-yarn: 0.05-0-25
Textile-weaving: 0.50-1
Watches, jewelry: 0.75 - 1
Small mechanic: 1.5-2
Mechanical industry: 2-3
Considerations

For the operators, it is considered

a static surface of 0.5m2
and an average height of 1.7
The warehouses properly
separated from the areas of
process, through walls,
malls, among others, do not form
part of the Guerchet analysis
The developed method is
approximate areas, remaining
to make the necessary adjustments
according to the circumstances.
 Formula
= + +
St = total surface
N = number of mobile or static elements of a type
Ss = Static surface
Sg = gravitational surface
Se = Surface evolution k = 0-3
Example
Using k=2, calculate the total area required for the machines.
for the manufacture of the grills, it must contain the following
elements:

Machines N n Long Wide Ss Sg If St

I return 2
Welder 3
Milling machine 1
Doubler 2
Roller 1
3.2. SLP: distribution of reception areas and
boarding, distribution of the areas of
production and design of stations of
work, office distribution
distribution of parking areas,
distribution of support areas.
The plant layout involves the arrangement of
necessary spaces for movement of
material, storage equipment or lines of
production, industrial equipment, management
services for the staff, etc.
The objectives of plant layout are:
Integration of all factors that affect distribution
•Movimiento de material según distancias mínimas
Work circulation throughout the plant.
Effective use of all space
Minimum effort and safety for workers
Flexibility in the arrangement to facilitate adjustments or expansions.
 Plant Distribution
The S.L.P method is a set of phases that allows us to systematically approach a
plant distribution process

Location

General Distribution

Detailed Distribution

Installation

Phases I and IV often do not form part of the specific distribution planning project.
The planner will focus on phases II and III.
Phase I: Location
It must be decided where the distribution area will be, which can be:

An existing plant
A completely new plant. Total reorganization in the current plant
Minor adjustments in the current plant

The characteristics
The characteristics
physics of the
physics of the
installations will be a
installations are the given that they will restrict
result of the study
the design of the
of the distribution.
distribution.
PHASE II: General Distribution
Systematic Layout Planning (SLP)

This method can be used in

any distribution project in
plant, you just need to adjust the importance
of each stage as appropriate.
PHASE III: Detailed Distribution

The detailed distribution involves the

location of each part, machine
the team, hallway and area of
warehouse and do this for each
department.
Phase IV: Installation
The person who handles the plant layout is sometimes responsible for
make the distribution correctly implemented. More often, it is
The plant engineer is in charge and advised by the designer.
Generally, the necessary information includes:
A list of the machinery and equipment to be installed or of the current equipment
that needs to be moved.
A plan, drawing, or photograph explaining the details of the new
placements.
A movement program
A specification sheet to show how each machine will be
disconnected, moved and reinstalled
 Fundamental Steps to apply this
SLP method

Determine the
relationships between Diagram the
Propose the Layout
departments and/or relationships
activities
1. Determine the relationships between activities
and/or departments
Knowing the journey of the products, the type and the must be planned.
intensity of the existing interactions between the different
productive activities, auxiliary means, the systems of
manipulation and the different services of the plant.
The construction requirements must be considered at this stage,
environmental, safety and hygiene, handling systems
necessary, the energy supply and the evacuation of the
waste, the organization of labor, the control systems of
proceso, los sistemas de información, etc.
Reasons for the closeness between departments
Example
 SLP exercise
A small plant will produce five products in eight.
departments. The routes that are followed for their preparation and the
The expected monthly demand is shown in the following table:

Monthly demand in
Product Route
homogeneous units
1 A-B-C-D-E-D-F-G-H 400
2 B-C-A-D-F-C-D-H 600
3 A-C-D-F-D-E-F-G-H 400
4 C-D-A-E-F-G-H 800
5 A-C-D-C-F-E-G-H 600
 Of A B C D E F G H I

A
A
B
C
D
E
F
G
H
I
FLOW ACTIVITIES % CLASSIFICATION
ON

A= 10%-15%
E=10%-15%
I = Difference
O= 40%
It Doesn't Matter
X= No Matter
 Possible reasons
Material flow
Need for personal contact
Use of the same equipment
They share the same staff
Supervision or control
Contact frequency
Urgency of the service
Personal conveniences
Avoid Noise
Others
Assignment
Quadratic
The location of a single facility
despite the complexity that as it has been
visa may present, it is just a
particular case of the problem of
location.
 Characteristics

Assignment Minimum Circulation Security Flexibility

Reach the Search for the Ensure the The distribution in

integration of all traveled routes security plant will need,
the elements or for the material and satisfaction and from largest to smallest
involved factors men of comfort of adapt frequency
in the unit operation to personal under circumstances
productive, so that operation and between achieving this way the ones that are carried out
if it works like departments are a decrease in operations that
a unit of optimal those which the index of make it advisable
objectives requires economy accidents and a adoption of
of movements, improvement in the distributions
teams and space. work environment flexible.
 3.4. Automated methods to generate alternatives.

CORELAP ALDEP CRAFT

Computerized Relationship Layout Planning Created in 1967 (Automated Layout Design CRAFT stands for 'Computerized Relative'
Procedure: automated design process of Allocation of Technical Facilities (Relative Location)
Developed by Lee and Moore in 1967. Use the table Computerized Facilities). It is the first
of relationships between departments as input, the plant distribution was the first model for
multiple floors. It is a construction procedure program for creating distributions in
The user is the one who assigns the weights for each of the
what calculates the total proximity ratio (TCR in English plant, by means of a computer, appears in 1963. In
relationships. The distribution is built through his first moment was presented by Armour,
calculation of the Total Proximity Ratio (TCR) for each total closeness rating) for each department. The
TCR is the sum of numerical values assigned to the Buffa and subsequently verified and perfected
department. by Armour, Buffa, and Vollman (1967). The algorithm
proximity relationships in the relationship graph
through the coefficients A, E, I, O, U, X, as follows employee minimizes the associated maintenance cost
It was explained in the SLP system in the previous section. the layout design, starting from an initial layout
These numerical weights are called Closeness and trying, through successive exchanges of
Rating (CR) 'Proximity needs.' pair activities, reduce transportation costs.
3.5. Models used for order, organization
and cleanliness within the industry (5S, ANDON and
Control Visual
5s

Promote good habits

of order and cleanliness that
establish the bases more
consistent and appreciable
for the buildings and
Andon
application of many of
Lean tools.
This with the purpose of
comply with the factor of
Quality
Control
Visual
 Method developed by Hiroyuki Hirano, can
The 5s to define oneself as the pillar or beginning of any other
improvement tool.
Andon
"Andon" is a Japanese word.
used to refer to lanterns or
paper-covered lamps, their main
a characteristic is to emit light and
highlight a text, design, image...
In some cases, the light gives enough
information for the operator
solve the problem without the need for
warn other people integrated into
the process.
Visual Control
Visual Control is an effective way to bring to light
the anomalies so that everyone understands what
it is happening in the work area, in such a way that
make it easier for everyone to respect the
established standards.
It consists of establishing visual systems that
allow easy management of the level reached in
organization, order and cleanliness
 Examples
Alarms
Colored lamps
Lessons from a point
Information boards
Marks on the floor
Workstation Marking
Scoreboard
Security Pyramid