Optimizing Industrial Plant Layout and Process Flow

Process Flow Diagrams

Process flow diagrams are used to describe and improve the process of becoming a productive system. They can be qualitative or quantitative.

Provision of Machinery

• By Process: Groups all machines or processes of the same type.
• By Product: Groups all machines or processes in order to make the same product or a series of products.

Process Layout: Advantages and Disadvantages

• The manufacturing cycle is flexible.
• Investment in equipment is minimal.
• It occupies more space than product distribution.
• Machines remain active as long as possible.
• There are no fixed lines for work travel.

Product Layout: Advantages and Disadvantages

• The course of work eliminates waiting and reduces material handling.
• Total production time is kept low.
• Production costs are low when volume is large.
• It is easier to train inexperienced workers.
• The failure of one machine can stop the entire production line.

Plant Distribution

In distribution, a plant is determined by where each activity or piece of equipment is located.

Reasons for Changing Plant Distribution

• Incorporation of a new product.
• Changes in product demand.
• Replacement of obsolete equipment.
• Reducing costs.

Principles for Designing Plant Distributions

• Design the building after finalizing the plant distribution.
• Start with a diagram of general areas and drill down into the details.
• Seek diverse perspectives.

Area Requirements for the Plant

Consider the following when planning space:

• Receiving volume, maneuver materials, and receive frequency.
• Type of material.
• Storage (raw material, finished product, production department).
• Quality control, utilities, maintenance offices, restrooms, reception, circulation, and parking.

Precautions

• Implement a ventilation system.
• Isolate hazardous areas.

Organization

An organization chart is the graphic representation of an institution's structure or its administrative units, showing the relationships between constituent bodies.

• Provides knowledge of hierarchical relationships.
• Should be as simple as possible to represent structures clearly.
• Homogenize nomenclature (lines, shapes, and composition) to facilitate interpretation.
• To preserve technical validity, keep charts updated. It is recommended to list the responsible unit and date of approval in the lower right corner.

Project Control Networks

Common methods include:

• CPM (Critical Path Method): Developed in 1957.
• PERT: Developed by the U.S. Navy in 1957.
• MDP and TERG.

Steps in Network Elaboration

1. Planning and project scheduling.
2. Estimating time and resources.
3. Development of basic identification card.
4. Network restructuring.
5. Resource allocation.
6. Project control.