Proceedings of 2014 RAECS UIET Panjab University Chandigarh, 06 – 08 March, 2014 978-1-4799-2291-8/14/$31.00 ©2014 IEEE Improving Employee & Manpower Productivity by Plant Layout Improvement Abstract—This research aims to improve the plant layout of flour mill industry to eliminate obstructions in material flow and thus obtain maximum productivity of employee as well as plant. The efficiency of production depends on how well the various machines; production facilities and employee’s amenities are located in a plant. Only the properly laid out plant can ensure the smooth and rapid movement of material, from the raw material to the end product. Plant layout encompasses new layout as well as improvement in the existing plant layout. Plant layout is an important decision as it represents long-term commitment. An ideal plant layout should provide the optimum relationship among output, floor area and manufacturing process. It facilitates the production process, minimizes material handling, time and cost, and allows flexibility of operations, easy production flow, makes economic use of the building, promotes effective utilization of manpower, and provides for employee’s convenience, safety, comfort at work, maximum exposure to natural light and ventilation. It is also important because it affects the flow of material and processes, labor efficiency, supervision and control, use of space and expansion possibilities etc. Keywords—Plant-layout, employee productivity, plant productivity, machining process. I. INTRODUCTION A plant layout can be defined as follows: “Plant layout refers to the arrangement of physical facilities such as machinery, equipment, furniture etc. within the factory building in such a manner so as to have quickest flow of material at the lowest cost and with the least amount of handling in processing the product from the receipt of material to the shipment of the finished product.” It may be defined as a technique of locating machines, processes and plant services within the factory so as to achieve the right quantity and quality of output at the lowest possible cost of manufacturing. It involves a judicious arrangement of production facilities so that workflow is direct. As far as small business is concerned, it requires a smaller area or space and can be located in any kind of building as long as the space is available and it is convenient. Plant layout for Small Scale business is closely linked with the factory building and built up area. From the point of view of plant layout, we can classify small business or unit into three categories as Manufacturing units, Traders and Service Establishments. The overall objective of plant layout is to design a physical arrangement to meets the required output – quantity and quality most economically or Plant layout ideally involves allocation of space and arrangement of equipment in such a manner that overall operating costs are ‘minimized. The objective of this research paper is- • To use available floor space efficiently & properly. • To ensure that work proceeds from one point to another point without any delay. • To reduce hazards to personnel. • To reduce accidents. • To provide ease of supervision and control. • To provide for employee safety and health. • To increase employee morale. In addition to these objectives, a good plant layout has the following objectives also as: • Reduce material handling costs. • Utilize labor efficiently. • Provide for volume and product flexibility. • Allow ease of maintenance. • Allow high machine or equipment utilization. • Improve productivity. II. INTRODUCTION OF TIRUPTI FLOUR MILL TIRUPATI FLOUR MILL INDUSTRIES is a small scale manufacturing plant of flour machines. It was established in year 1996 and since then, it is working in the field of manufacturing flour machines in Banmore industrial area in Morena district, Madhya Pradesh. The unit is owned by Mr. HARIOM JHA, Mr. PRADEEP JHA and Mr. RAVINDRA JHA since it was established. It operates its plant in process such as casting, machining, painting and packaging. It is spread in area of 5610 ft 2 with well-organized structure. Fig.1: Existing Plant It has a production of 10 to 15 machines per day, which leads it to a 4500 to 5000 machines per year of different sizes, with its small man power. This unit have yearly turnover of nearly 2 cores which are most likely figure of small scale industry. It has single distributor in every district and now this unit is able to fulfill the demand of Gwalior division only. III. LITERATURE REVIEW In the present, there are several methods for plant layout design such as systematic layout planning (SLP) [1,2], algorithms [3,4], and arena simulation [5] can apply to design plant. Plant layout analysis and design for multiproduct line production has been studied [5]. The detailed plant layout problem includes machine layout problems such as space distribution for different machines and cellular manufacturing design problems are critical factors [6]. The unequal-area Abhishek Jain PhD Research Scholar, PTU, Jalandhar Punjab, India , abhi_mpct@rediffmail.com Harwinder Singh Mechanical Engineering Department, GNDEC, Ludhiana, Punjab, India harwin75@rediffmail.com RajbirBhatti Mechanical Engineering Department, SBSSTC, Firozepur, Punjab, India rajbirbhatti@gmail.com