IntermediateTopic 37 of 102Manufacturing, Robotics & Systems
Plant layout and material handling
Arrange equipment and flow to minimise movement.
In depth
Layouts: product (assembly line), process (job shop), cell (group technology), fixed position. Objectives: minimise handling, ensure safety and flexibility. Tools: from-to charts, systematic layout planning, simulation. Material handling: conveyors, AGVs, forklifts, cranes, ASRS; unit load principle.
Key points
- Flow analysis
- Space utilisation
- Ergonomics
ExampleA U-shaped cell reduces walking distance for operators.
What is Plant layout and material handling?
Arrange equipment and flow to minimise movement.
Why is it important to understand plant layout and material handling?
Plant layout affects how materials move and how long products spend in the factory, so layout directly controls cost and throughput.
What is a process layout?
An arrangement where similar machines are grouped together, which suits varied products but can create long material flows.
What is a product layout?
An arrangement where machines follow the sequence needed for one product, which suits high volume production.
How is Plant layout and material handling used in practice?
Typical applications include arranging machines in cells to reduce the distance parts travel, placing a store close to the assembly line to cut handling and designing a warehouse to reduce picking time for orders.
What should I learn before Plant layout and material handling?
Study "Process capability" first (topic 36 of 102 in Manufacturing, Robotics & Systems). It covers the groundwork this topic builds on.
What are the key points of Plant layout and material handling?
Flow analysis. Space utilisation. Ergonomics.
Can you give an example of Plant layout and material handling?
A U-shaped cell reduces walking distance for operators.
What comes after Plant layout and material handling?
The next topic is "Production planning and scheduling", which builds directly on this one.
How difficult is Plant layout and material handling?
It is classed as Intermediate in Manufacturing, Robotics & Systems (topic 37 of 102). It is an intermediate topic. Work through the beginner topics in Manufacturing, Robotics & Systems first.