Relationship between plant layout and material handling

There is a close connection between the concepts of plant layout and material handling. A good plant structure can ascertain the least material handling process and inexpensive material handling equipment. The material handling factors to be considered while designing the plant layout are:

1) Excessive material movement damages the materials and causes loss of valuable man-hours in shifting materials. A layout should be designed such that it suits the manufacturing requirement of the products and reduces the material handling to minimum.

2) If the workers are compelled to search through the entire workshop for a particular material, their productive time is bound to go wasted. For maximum utilization of their time the plant should be equipped with:
a) Clearly identified and well-named functional areas.
b) Distinct areas for raw materials, tools, work-in-process, inspection and finished goods.

3) For an effective and speedy movement of materials there should be an effective use of:
a) Bins, trolleys, racks and trays to keep materials instead of placing them on floors
b) Proper packaging techniques before dispatching
c) Conveyors, chutes, inclined planes and gravity feed bins to automate, materials
movement.

4) Public utilities should be located at easily accessible distances and should not
require distant walks on part of the workers

5) Economical use of space should be aimed. Machines and equipments should be
placed in such a way that there is a minimal or no wastage of space and yet there
should be optimum choice for expansion.

6) Maximum opportunity for greater width of aisles, heights of ceilings and other
areas of storage so the need of later alterations will be reduced

A good plant layout thus facilitates an efficient material handling system. It offers minimum material handling by making material movements shorter, faster and economical. Overcrowding is prevented. Delays in supplying are avoided due smooth manufacturing activity and hence it is generally desirable to adopt a good plant layout that facilities minimum handling.