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.
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 plant layout.
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.
Credit:ivythesis.typepad.com
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