2. Definition of Plant layout
๏ต A method of organizing the
elements of a production
process, in which similar
processes and functions are
grouped together.
๏ต Plant layout is the organization of physical
facilities like machinery , equipment & the
allocation of space for the various
activities of the plant & personnel working
in the plant.
3. Plant Layout
Characteristics
๏ต Provide space for machine / materials /
storage / etc.
๏ต Flexible for future changes in capacity /
Design / Process etc ( Cellular design).
๏ต Accommodate future expansion.
๏ต Deals with government rules &
regulations ( Municipal corporation /
Labor law & rules.
๏ต Safety of employees / visitors / vendors is
prime concern
๏ต Achieve economy in operation.
4. Plant Layout
Layout is a Fundamental of
every organization and
enterprise.
Kitchen, Retailers, offices,
service organization and all the
enterprises have a specific
layout.
Previously Layouts were based
on intuition, experience and
judgment.
With the complexities and
competition now scientific
methods are used.
The Layout comes in picture
after the location has been
finalized.
Development of good layout
depends on decisions already
taken on location, capacity,
facility, manufacturing method
and material handling
techniques.
7. 1. BUILDING & STRUCTURE :
Depend on type of production system
Intermittent system : building &
shades are constructed & layouts
done in shades with best possible
options & then machinery will be
brought inside.
Continuous system : arrange machines
first then construction around. It should
withstand & offer support to cranes /
hoists / trolleys etc.
2. MEN:
Number of people.
Unskilled ( more space ) / skilled ( less
space i.E. Computeroperator).
Physic of workers ( ex. Height ).
8. 3. Machinery :
Type of machine :
โข General purpose
machines : Compact in
size & requires less space.
โข Special Purpose machines (SPM) : Large in size , complicated,
high level of automation.
Number of machines :
Level of automation ( Semi / fully automated)
Higher complexity wider space.
9. 4. Material
Nature of material (
Flammable /
inflammable /
Hazardous & Non
Hazardous ,
Corrosive ,
Methalene , mercury
, oils , fuels)
Form of material (
Solid / Liquid /
Powder etc)
Quantity of material
to be handled.
Cycle Time :
Consumption of
material.
10. 5. Movement:
โข Movement of people / machines / cranes ( length &
frequency)
โข Purpose of movement ( With load / without load / Quantity
of load)
6. Waiting Time:
โข Cycle time for completeting each activity.
โข Intermittent โ
โข Uncertain & High.
โข More storage places between machines & facilities.
โข Continuous โ
โข Defined & low.
11. 7. Services & changes
Changes :
๏ต Production Volume
๏ต Product type & design
๏ต Process type
๏ต Varieties
๏ต Frequency of change ( Ex 5 years)
Services:
๏ต Electrical supply
๏ต Pneumatic supply ( Air supply)
๏ต Water supply
๏ต Chilling process โ Cooling Tower
๏ต Air ventilation โDucting
๏ต Fire extinguishers โ Water sprinklers
13. 1. Functional Layout ( Process Layout)
โข Also called as process layout.
โข Its best suited for intermittent type of operation.
โข Machines on layout are called as general purpose machines.
โข It involves a grouping together of similar machines in one section
/ dept.
Example :
โข โข
โข Machines performing grinding operation are installed in grinding
dept.
โข Machines performing drilling operation are installed in drilling
dept.
โข Heat Treatment / Painting etc.
14. Advantages :
Easy to handle machine breakdown by transfer
of to another machine.
Greater Scope for expansion.
Investment on equipment will be comparatively
low .
Full utilization of equipment.
Disadvantages :
Requires more floor space.
Difficulty in movement of material.
Production control is difficult.
High production time as material has to travel
from place to place.
15. 2. Line Layout
(Product Layout)
๏ต It involves the arrangement of machines in
one line , depending on operation
sequence.
๏ต Raw material will be fed in first machine
& finalproduct will come out of last
machine.
๏ต Output of one machine becomes input to
next machine.
๏ตExample :Sugar refineries / Paper mills /
Cement plants / Rolling mills.
16. Advantages:
โข Smooth & regular flow of finished goods.
โข Shorter processing time due to less travel , storage & inspection frequency.
โข Reduced material handling.
โข Low cost labors & lesser training requirement.
โข Use of special purpose machines (SPM) ,automatic or semi automatic.
โข Easy production control.
Disadvantages :
โข Heavy capital investment.
โข Non flexible layout .
โข Risk of total production line shutdown..
17. 3. Static Product Layout ( Fixed Position)
This type of layout involves the movement of men & machines to the
product which remains stationary
18. Advantages :
The investment on layout is very small.
The high cost & difficulty in transporting a
bulky product are avoided.
Disadvantages :
High cost of operation.
Very high duration of project.
Rework will be very costly.
19. 4. Group Layout( Cellular Layout)
In cellular manufacturing layout the arrangement of a facility so that
equipment used to make similar parts or families of parts is grouped
together
The group of equipment is called 'cellโ
The arrangement of cells is called a โCellular Layout'
20. 5. Combination layout ( Hybrid Layout)
It is a combination of product & process layout with an emphasis on either
In industries plants are never laid out in either pure form.
It is possible to have both types of layouts in an efficient combine form if
the products are somewhat similar & not complex.
Fabrication of parts ----Process Layout
Assembly of parts ----Product layout
Ex : Soap Manufacturing Machines ---- Product line
Process Layout ---------- Functional basis---Ancillary services ----
Heating / Manu of glycerin / power house / water treatment plant.
21. Factors Influencing Layouts
Factory Building : The nature & size of building determines the floor space available for layout
While designing the special requirements i.e. Air conditioning , dust control , Humidity control,
Noise proofing etc must be kept in mind.
Nature of product : Product layout is suitable for uniform products . Process layout is suitable
for custom made products.
Production process : In assembly line industries product layout is better. In job order or
intermittent manufacturing process layout is desirable.
Types of machinery : General purpose machines are arranged as per process layout, Special
purpose machines are arranged as per product layout.
22. Repairs & maintenance : machines / equipments must be arranged keeping in mind
the movement of operators & maintenance tools.
Human needs : adequate arrangement should be made for wash rooms, drinking water /
canteen & other employee facilities.
Plant environment : heat / noise / light / ventilation & other aspects should be duly
considered
23. A poor layout results in
โข Congestion,
โข Wastes,
โข Frustration,
โข Inefficiency and
โข Finally lower profit or loss
to an organization.
A good layout results in
โข Comfort,
โข Convenience,
โข Safety,
โข Efficiency,
โข Compactness and
โข Finally in profits to the
organization
