Plant Layout Design and Facility Planning

KIOT
Plant Layout and Facility Design
Course code: Greg 4181
Target group: 4th year GED
Chapter four
Planning and installation of lay out
By: Endashaw Yohannes
Kombolcha/Ethiopia
Jan, 2019
1/29/2020 1

1. Planning the layout
The layout designer must interact with the product
designer, process designer and schedule designer.
While solving the layout problem the objective should be
used as a guide.
A number of procedures have been developed to facilitate
the design or planning of plant layouts
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General plant layout Procedure
1. Procure the basic data
2. Analyze the product and production
process
3. Make or buy part decision
4. Plan the material flow pattern
5. Consider general material handling plan
6. Calculate equipment requirement
7. Plan individual work stations
8. Select specific material handling
equipment
9. Coordinate groups of related equipment
10. Construct flow diagram for production
centers
11. Plan service and auxiliary activities
12. Determine space requirement
13. Allocate activity area and plot plan
14. Consider building types
15. Construct master layouts
16. Seek opinions and suggestions
17. Evaluate adjust and select the best
layout
18. Check final layout
19. Obtain official approval
20. Install the layout
21 Follow up the implantation of layout
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2. Economics by types of lay out
Product layout has higher investment in machinery and greater installation
charges, greater preventive maintenance cost that leads to higher fixed costs.
Process layout has lower fixed costs due to less machinery and less maintenance
cost.
Product layout has lower operating cost due to less material handling and less
skilled labor.
Process layout has higher operating costs due to high material handling and
skilled labor.
The total cost for process layout is stepper than product layout
Break even point is reached earlier for process layout than product layout.
Hence process layout is better for low production volumes as it yields better
profit than product layout.
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3. Evaluation of the layout
The best layout is the best compromise of all factors.
All considerations are not available in the form of data, there are some
consideration which can not be measured.
There are a lot of methods for evaluation, Example
Man hour evaluation
Space evaluation
List of pros and cons
Factor Ranking
Factor weighting system
Cost Comparison
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4. Installation of the lay out
Installing the layout may or may not be part of plant layout
The layout engineer is sometimes made responsible for
seeing the layout is properly installed.
Sometimes the layout engineer acts as an advisor and
coordinator while the actual supervision rests of the plant
engineer.
The layout engineer should submit all the required
documents ,diagrams and photographs.
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5. Organizing the installation
For planning purpose, the following seven stages are best for many
situation.
1. Plan: planning ahead of time the sequence of moves and actions
2. Provide: Get moving equipments and communications for adequate help
3. Prepare: Prepare new locations, foundation ,partitions ,painting
4. Move : keep move on schedule and Move as close as installation point
5. Install: Have installation crews accomplish daily
6. Start- up: Check the installation
7. Cleans Up: Inspect installation and set dead line for clean up.
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6. Coordinating the installation
When plans for installation are complete, conduct conference with
each section heads.
When installation involves construction of building, more
frequent meeting of the coordinating group is necessary.
This group should consist of the
o Layout engineer,
o The plant engineer and
o The building contractor.
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7. Factors influencing plant layout
For plant layout all the factors which are part of production activities
which are apparently important or not should be considered during the
initial stage of planning.
Factors ignored at initial stage may cost big way due to high production
cost or long movement of material or product.
Category of Factors influencing plant layout
o Material factor
o Machinery factor
o Man factor
o Movement factor
o Waiting factor
o Service factor
o Building factor
o Change factor
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Important Factors influencing plant layout
Type of industry
Volume of production
Type of process
Flexibility of layout
Machine requirement
Products
Work station Design
Storage space requirement
Materials
Movement Employees facility
Building
Expansion
Adaptability and versatility
Type of machine and
equipment
Effect of location /Sit on
layout
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1. Type of industry
Major Classification of Industries
1. Primary industries – cultivate and exploit natural resources
Examples: agriculture, mining
2. Secondary industries – convert output of primary industries into
products
Examples: manufacturing, power generation, construction
2. Tertiary industries – service sector
Examples: banking, education, government, legal services, retail trade,
transportation
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2. Type Of Manufacturing process
Classification of manufacturing industry based of manufacturing process
A. Processing industries : A material may undergo a change in physical state,
chemical composition, volume or mass, in creating a product more useful to man. e.g.
Steel making is one of the example. It change state during process.
B. Fabricating industries: Fabricating involves a change in the physical form but
not the state of the raw materials used.
o Fabricating is basically the assembly of finished or semi-finished product from
other primary or secondary manufacturing industries
Examples : the manufacture of automobiles, airplanes, ships, all other types of
machinery, furniture, and garment
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4. Flexibility of Layout
o When change in product design ,methods of operation, the type of product or
production qualities then the machine and departments may also have to be
rearranged outs to .
o To design layouts to reduce the effect of subsequent alteration of production
process
Flexibility in layout can be secured in the following ways
o Keep enough unobstructed(free) floor areas
o Separate electric motors can be allowed
o Mobile machinery be used, where possible
o Equipment be placed on rubber footings instead of being fixed
permanently
o Portable conveyer units may be employed
o Make use of portable jigs and fixtures
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5. Type and quantity of Machine requirement
o In order to prepare a layout for a plant, the type & number of machines
required for each operation should be known.
o Machine may be either general purpose or specific purpose
o Machine requirement may be different in terms of space, speed and
material handling process.
6. Products
For effective layout the following aspects a product must be considered
A) Product design
B) Product Specification
C) Quantity and variety of products ( product Mix)
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7. Work Station Design
o Work station or work place is defined as the floor space occupied by
the worker and the machine or group of machines.
o It has been established that comfortable work-place will keep
workers more satisfied and more will be the productivity.
o Ergonomics combines the knowledge obtained from the study of
 Anatomy,
 Physiology,
 Psychology etc. To reduce the stress (like fatigue, eye strain,
mental and muscular fatigue) on the worker in his work-area.
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7. Work Station Design cont..
Important elements which are related to the work-Station Design.
A. Cleanliness
o As cleanliness affects on the workers' efficiency
o hence the working place must be clean.
o Work-area must be clean and well painted.
B. Proper illumination.
o Work-place must be properly illuminated (illumination of proper
intensity) so to avoid eye strain.
o Care must be taken to avoid glaring, flickering. Color of light
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C. Noise.
o A work-place must be selected so as to have as less noise as possible.
o Experiments have shown that reduction in noise result in the increase of
efficiency with lesser fatigue.
D. Location for Tools and Materials.
o To reduce the distance travelled, all tools and materials required by a
worker must be located within the normal grasp area and as far as
possible in front of the worker.
o For the assembly work, it is advisable to provide such arrangement so that
the components can slide along the smooth surface and the worker picks
them up. It will greatly reduce the time and effort.
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E. Proper Chairs.
o Chairs permitting proper posture for the workers must be provided.
o The height of chair and of the work bench must be arranged in such a way
so that the worker may not feel any difficult while working.
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F. Work Bench
o Experiments have shown that a semi-circular table having a radius of 20"
or 50 cm from a point at 4" or 10 cm back as shown in the following
diagram, follows a most comfortable position.
o The work bench must be so desired so that both hands can be used
simultaneously.
Fig: The human body related to the
vertical plane1/29/2020 21

The physical relationships between hand and eye movement.
1/29/2020 22

Workstation layout, Office 1 and 2
Office 2
Office1
1/29/2020 23

8. Materials
o Because of its physical and chemical characteristics materials to be used
for products influences plant layout.
o The shape ,size, weight and the state of material affects the choice of
layout, material handling equipment and storage facilities.
9. Movement
o Material flow should be in straight line with out back tracking or cross
flow.
o It should move with out delay
o A good layout also provides for easy and safe movement of production
workers.
o It should provide safe and easy movement of production workers, indirect
workers and supervisors.
1/29/2020 24

10. Employees' Facility
Good layout provides satisfaction and safety for employees at factory.
Industrial acts also demand services like medical facilities ,canteen, locker
rooms, and lavatories as essential services.
Noise ,heat ,light and ventilation etc. also contributes to employees
working conditions.
11. Expansion
Expansion plans should be given at initial stage of planning the layout.
Additional facilities and departments in added or located anywhere in this
space available results confusion in the flow of material and production
cost.
1/29/2020 25

12. Adaptability and versatility
Layout should handle the emergencies and variations with out any difficulty.
Versatility of any design is measured by its ability to handle a variety of
products.
13. Building
Building should be an integral part of layout
Building is basically the shell that houses and protects the man, material,
machinery and supporting activities necessary for production.
In case of new building layout engineer is free to plan production layout and
auxiliary activities in the most economical way and design the building to
house these facilities.
When the building is already existence ,building influences the layout ,as in
this case building factors become a limitation.
1/29/2020 26

14. Landscape
The region and the particular place selected for plant determines the
arrangement of the receiving and shipping layout and the material handling
method.
Landscape design is also influenced by the size and shape of the plant
climatic conditions and laws of the area.
15. Industrial building
Industrial building should be designed considering purpose, location,
products, manufacturing methods, flexibility and material handling
Factory building is a important consideration because once it has been
erected it can not be replaced easily.
1/29/2020 27

Classification of Industrial buildings
Buildings can be classified as
1. Single-storey and
2. multi–storey buildings
1. Single storey is better when heavy plants and machinery are used and
bulky work is performed such as locomotives, air craft etc.
2. Multi storey building is better when the land available is limited and the
manufacturing process involves the gravity flow
1/29/2020 28

Advantage of single storey buildings
Vibration are less
Machinery and equipment change is easy
Easier to handle goods and use cranes
Saving in floor space because there is no upstairs ,lifts or support columns
No risk of articles falling down.
Better natural lighting through glass roofs
Less danger of fire
Enough space for future expansion by converting to multi-storey building
Low construction cost per square meter
Building can be erected quickly
Operation and supervision is easy
Requires lighter foundation
1/29/2020 29

Advantage of multi-storey buildings
Economical in the cost of land specially in big cities
More efficient use of available land
Cost of heating and ventilation is less
Small ground runs are required for drainage purpose.
Material handling distance required are reduced by gravity flow.
Lay out is more compact
Makes use of overhead storage which is much safer from theft.
1/29/2020 30

1. Nature of manufacturing process
2. Flexibility
3. Lighting
4. Ventilating
5. Material handling
6. Future expansion
7. Employee facility
8. Good appearance
9. Noise and vibration
10. Strength, durability, safety and Security
11. Types of building construction
Factors considered in building design
1/29/2020 31

1. Roof Structures, types of roof structures
Features of factory buildings
1/29/2020 32

2. Shape of Buildings
Shape of the building depend on the contour and perimeter of the land
available.
Commonly used buildings are of I,F,E,H,T,C,Y,U square, circle and triangle
shapes.
When operations produce dust, odor or vibration these should be
segregated in separate building
1/29/2020 33

3 . Walls
o In industrial plants exterior walls are load bearing walls ,while interior walls are
carried by the columns.
o Inside partitions are not load bearing and ,are easily movable to provide
flexibility in the layout.
4. Windows
Windows help in ventilating and lighting, but windows are not preferred in the
following situations
o In underground
o When direct sunlight gives brightness or glare
o When direct sun rays produce heat
o When climate is subject to extreme heat and cold
o Work is subjected to dust, dirt, and contamination
o Workers are affected by external noise
1/29/2020 34

5. Aisles
o Aisles are the ways over which materials and personnel travel.
o Width of the aisles should be sufficient so that the material and men can move
easily and smoothly.
o Width of aisle depend on the size of the trucks and loads , the speed of travel
permitted ,the frequency of their trip , the pedestrian traffic and whether
the traffic is one way or both way.
o Aisles should only used for moving men and material nor for temporary storage.
6. Floor
Floor should have the following two main characteristics.
o Floor should be strong enough to support equipment and product.
o Floor level should be constant through out the building and other buildings as
they may be connected some day with each other by passages.
1/29/2020 35

7. Elevators and stairs
o While designing the building ,provision should be made for the elevator
and stair cases at different parts of the building
o Sufficient space is provided at the entrance and exist of elevators and
staircase to avoid traffic jams.
o For safest, staircase should not be slippery and rise of steps should not
be more than 15cm.
8. Fire protection
o Fire laws and regulations should be strictly followed.
o Inflammable materials must be kept in separate store
1/29/2020 36

9. Plant protection and security
o Permit only authorized personnel to enter the plant
o To avoid theft and pilferage use watchmen, high fencing,
flood lighting, patrolling
10. Parking lots
o Adequate parking spaces should be located with in short
walking distance of the plant.
o Parking lots must be integrated with the street and high
way system to permit smooth handling of traffic.
1/29/2020 37

11. Exterior Appearance
o A pleasing appearance, good landscaping and cleanliness are now a days are
being considered as of primary importance, as it has greatly increase the
morale of workers and public.
12. Utility Supply
o Commonly supplied utilities in an industrial building are steam, fuel gas,
compressed air, electricity, fuel oil, hot and cold water etc. that can be
transported by pipe.
o Their layout should be properly planned and proper care should be taken
for their maintenance, expansion, flexibility ,easy use etc.
1/29/2020 38

13. Lighting
o Light provided in a factory should be adequate, properly
distributed ,employ simple and clean fittings and should
have not glare.
o Light should be uniformly distributed over working plane
1/29/2020 39

Illumination should be properly designed other wise it will
lead to
o Accident
o Poor performance- due to poor lighting performance of workers reduced
o Spoilage of work- leads to error.
o Reduction in speed of work
o Effect of health- causes eye strain & headache
o It affects human relations.
o Sufficient space is provided at the entrance and exist of elevators and
staircase to avoid traffic jams.
o For safety, staircase should not be slippery and rise of steps should not
be more than 15cm.
1/29/2020 40

Industrial Landscape
Though priority in industry is production and profit , it is important that a
conducive environment not only inside a plant but also in the landscape
leads to greater productivity
Major components of landscape design
1. Landscape for vehicular and pedestrian movement
A) Entrance zone
It should express corporate identity
Integrate with security structures
Associated with various kinds of parking
1/29/2020 41

Industrial Landscape cont…
1. Landscape for vehicular and pedestrian movement
B) Plant and Township road
The landscape respond to the functions and dimensions of various
kinds of road
C) pedestrian Networks
Especially in residential areas and zones associated with community
facility ,the design of foot paths and related landscape should be
responsive for residents need.
1/29/2020 42

2) Landscape Lighting
Landscape lighting is typically applicable to the illuminations of the internal
streets, parking lots, gardens and security in the plant.
lighting in an integral part of the landscape and it has both aesthetical and
functional aspects
New technology lamps in addition to being more efficient can produce
different colors.
The importance of color in lighting and its effective blending are necessary
for a good blending
Example, The yellow of the sodium vapor lamp is ideal for active areas, the blue
of mercury vapor create more relaxed environment and the white color of
halogen is suitable for flood lighting and security.
1/29/2020 43

3) Vegetative plants
Landscape plants have the following purposes
To create or reinforce the spaces
To provide shade
To provide color and form
To act as a noise baffle
For visual improvement of the environment
To use as a wind break
To hide undesirable features and areas like factory waste disposal areas
Facilitate s dilution and dispersal of unavoidable pollutants
Creates shady ,evergreen and flowering plants to add aesthetics value
1/29/2020 44

Factors for selecting plant material
o Function
o Visual effect
o Existing planting
o Soil
o Siting
o Ecology
Example of illustration for use of trees in landscape design
Form
o The general form of trees are broad, round ,square ,tapering and
columnar
1/29/2020 45

A) Broad and round
• With dense foliage used as focus or for total shade
• With light foliage for tracery effect
B) Tapering and columnar
• Normally used as avenue planting ,used as screens and to frame a
significant view.
Branching trees
1/29/2020 46

Visual aspects of trees
1/29/2020 47

PLOT-PLAN
This is a drawing/ or sketch showing the physical features, like buildings,
roads, parking etc. and other items to be placed on the property.
The plot-plan includes:
Building location.
Roads, access, gates etc.
Other transport facilities like rail etc. if any,
Parking areas, drive ways.
Other exterior facilities such as sheds, electric sub stations, stock yards,
security posts, residential colony (if any) etc.
1/29/2020 49

The objectives of the plot-plan are
1. To make best use of the land.
2. To place buildings etc. in their most effective positions.
3. To pre-plan for future expansion needs.
4. To relate internal to external material flow.
5. To ensure best orientation of buildings considering light,
wind, rain etc.
6. To plan pleasing appearance and arrangement landscape .
7. To meet parking requirements.
1/29/2020 50

Reading
Plant lay out and material handling
(S.C Sharma)
1) Chapter four – procedure for plant layout
2) Chapter five – Industrial Building
1/29/2020 51

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