2. Introduction
As a part of such decisions, it becomes
important to decide where to place
machinery, where to locate the stores, heat
chambers, tool rooms, toilet, canteen and
other equipments.
The flow of production depends upon how
well these facilities have been placed or
arranged in the plant or factory.
3. In a properly or well designed plant, the
material move in forward direction from
raw material stage to the completion of
finished product.
The material and other resources do not
move in backward or zig zag direction
because this would make the production
process longer and costly.
Layout differs from firm to firm and
industry to Industry, changes take place in
the product design, volume of production,
production method which also requirs
change in plant layout.
4. A plant layout is appropriate arrangement of
machinery, equipment and other industrial
facilities such as receiving and shipping
department, tool rooms, maintains room etc..
The main purpose of plant layout is to
achieve fastest and smoothest production at
minimum cost.
So plant layout is a floor plan which to
decide and organise the machinery and
equipment, whether established or
anticipated, at the best possible place in a
way that aids the smoothest flow of material,
at the least cost and with a very little amount
of handling in processing the product from
the raw material to the finished product
5. Definitions
Knowles and Thomson says that a plant
layout involves
Planning and arranging manufacturing
machinery, equipment and services for the
first time in completely new plants;
The improvement in layouts already in
use in order to introduce new methods and
improvements in manufacturing procedure
6. Plant layout is the arrangement of
machinery, work areas and service areas
within a factory.
- G.R.Terry
Plant layout involves the development of
physical relationship among building,
equipment and production operations
which will enable the manufacturing
process to be carried out efficiency.
-M.E.Hurley
7. Factors affecting plant layout
Factors affecting plant layout are as follows
1. Type of labor
2. Location
3. Type of machinery
4. Type of production
5. Possibility of future expansion
6. Maintenance
7. Safety
8. Types of industry
9. Managerial policies
8. Objectives of an ideal plant
layout
Provide enough capacity by providing for
flexibility of volume and product
Maximum utilization of floor area
Maximum reduction of internal transport
from one operation to the next and
reducing material handling cost
Appropriate lighting and ventilating areas
Lowering cost of scrap and waste
9. Minimizing possibility of accident
Minimizing production delays
Providing space for future expansion
Ensuring safety of personal and equipment
Avoiding unnecessary change
Saving cost
Providing easy for supervision
Neatness
Providing proper production control
Eliminating waste efforts for spending up
production
Increase employee moral
10. Types of plant layout
Types of plant layout are different-
different types and they are as follows..
1. Production layout / straight line layout
2. Process layout / functional layout
3. Static layout / fixed position layout
4. Cellular layout
5. Combined layout / hybrid layout
6. Service facility layout
11. Product layout / straight line
layout
This layout requires machines to be
arranged in sequence as needed by the
particular product. All machines that is
required needed to arrange in order. This
known as a production line layout. In this
arrangement the product goes through all
the machines in the sequence for its
manufacture. Production of motor car is
the best example for this layout.
12. In contrast to process layout, the production is
given primary important im relation to the
process. In industries with few items of
production which require a continuous flow of
production for production this is the most
suitable layout.
The arrangement of machine in this layout
doesn’t require frequant changes.
Materials are fed into the first machine and
finished goods travel from one to another
machine. In this process there are many lines of
machines and hence they are special purpose
machine. The machine are arranged either in
U,L,Z,S,O,V,C or such other forms. It is
advantageous for mass scale production of
standardized goods
13. Advantages of product layout
Material handling cost is reduced because of
straight line production flow
In it effective production planning and control in
product layout as compared to process layout.
Due to shorter and fast movement of materials the
operating cycle is much shorter.
Bottlenecks and idle capacity are removed due to
line balancing.
Quality control can be done effectively as it
doesn’t regular change in the set up of machine.
Relatively easy to control
Less floor space is required per unit of production
14. Disadvantages of product
layout
Highly inflexible system since production flow is
regulated through the straight line sequence and
fixed rated capacity.
Can not avail benefit of specialized supervision.
The entire production flow can be interrupted by
the failure of single machine in the line.
It is difficult to implement the individual incentive
scheme as entire production is the result of the
joint efforts of all operations in the line.
Investment made in the duplication of machine
and equipments at times results in idle capacity
15. Process layout / functional
layout
This layout is also known as functional layout. In
it all machines performing similar type of
operations are grouped at one location. So in the
engineering area all lathes, milling machine etc
will placed together.
All foreign machines are placed in one area and
all lathes in another
The machine groups are generally arranged in
sequential form. This arrangement done on the
basis of labor operations.
The product take second place and is moved to the
machine which are kept at particular point
16. Operations vary from product to product in
such a layout and so it is more beneficial to
arrange the machines on the basis of process
rather than on the basis of products
In every department a partly finished good
would be waiting for operation or for further
processing. The machine are general purpose
machines.
This type of layout is more suitable for
intermittent production system or job order
type of production
17.
18. Advantages of process layout
It facilitates more flexible in production then a line
layout because different product can be made without
the changes in the arrangement of machine.
It is possible to have specialization in supervision.
It is possible to develop individual incentive scheme.
It eliminates the duplication of machine and facilitates
the most favorable use of installed capacity.
There is reduced investment in machine since they are
general purpose machine.
There is scope for expansion as the capacity of
different production lines can be increased
19. Disadvantages of process
layout
Due to long routine and back tracking between the
process the cost of material handling increase
The group incentive scheme is possible to
implement on the basis of quantity of the products
manufacturing.
More number of supervisors are required at each
process unit due to which the cost of supervision
increase.
This layout needs more floor space to ensure
storage every where.
It is very difficult to maintain line balancing in
production. Hence, waiting and idle time
increasing
20. Static layout / fixed position
layout
In this layout movement of men, machine and
materials is necessary. Static layout also called
fixed layout refers to the movement of men and
machine to the product which us stationary.
Where the product is huge the layout will be
static.
For example, aircraft, ship building,
manufacturing of dams, bridges, buildings etc.
In this type of layout materials and other major
components remain in fixed location but tools,
men, machines are brought to the location.
The cost of moving men and machine would be
less than cost of moving the product because the
product is bulky.
21.
22. Advantages of static layout /
fixed position layout
This layout is simple and easy to understand
The laborers in this type of layout can be
fully utilized.
Frequent adjustment can be made
Material handling is less
Men and machine are used for a variety of
operations producing different products.
Cost of transportation bulky product is
avoided.
Worker take pride when the work is
complete
23. Disadvantages of static layout
/ fixed position layout
Heavy machines, equipments and tools take
time to reach the work place.
It is heavy expensive since highly skilled
worker are needed.
This kind of layout is suitable only for
special types of project and producing small
quantity of items
24. Cellular layout
This layout is an attempt to bring some
benefits of a line layout in circumstances
where a pure line layout is not practicable. In
thus layout machines are placed in groups
that make a family of parts which requires
the same treatment in each cell.
It offers more control than a static process
layout and is more flexible than a line layout
Flexible manufacturing system was first
installed in 1968 in England
25. Since customization is the call of the day
there is an attempt made to bring in an
element of flexible into the manufacturing
system with regards to the batch size
variations and the differing operations
sequence
It is a manufacturing system in which there
is some amount of flexibility that allows the
system to respond in the case of change,
whether predicted or unpredicted.
26. Advantages of cellular layout
In this type if layout the work can be done
with lot of speed
Specialization can be used for the work in
this type of layout
Production cost decrease and delivery
time shortens.
Reduced material handling cost
Quick set up
Low stock of inventories needed
27. Disadvantages of cellular
layout
Capital requirement is needed in this type
of layout because of duplication of an
equipment
In cellular type of layout the cost is
increase
More space needed
There are chance of idle capacity in
cellular layout
28. Combined layout / hybrid
layout
It is difficult to find process or pure layout
in practic. They are both manually
exclusive. A good compromise from
which it is possible to benefit from both
the layout is possible to some extent.
So efforts must be made to have the
combined layout which including
advantages of the process and product
layout
29. A combined layout is developed to expand
the production with a vision to tap the idle
capacity of the product layout
Generally combined layout developed where,
Product layout is used for main product
Process layout used for by products or joint
products
E.g in soap manufacturing unit
manufacturing soap is arranged on line
layout whereas manufacturing glycerine is
on functional layout
30. Advantages and
disadvantages of combined
layout / hybrid layout
Advantages
Optimum utilization of resources can be
done in this layout
Disadvantages
Combined layout is time consuming
More investment is needed in this layout
More space is utilized in it
31. Service facility layout
The major difference between service
facility and manufacturing facility layout
is that a variety of service facilities exist
to forge link between customers and
service
Some of the requirement of service
facility layouts are well organized and
adequately lighted parking area as well as
designed walkways to and from parking
area.
32. Customer contract two extremely different
type of layout. One is that type of layout that is
totally designed around the customer receiving
service function and the other is the one that is
designed around technology, processing of
physical materials and product efficiency.
hospitals are the best example for service
facility layout that focus more on technology
or physical materials processing and
production efficiency while banks are good
example of layout designed around customers.
There are other facilities that strike balance
between these extremes and a restaurant is a
good example where attention is directed both
at customer receiving and servicing as well as
on processing and preparation of food
33. Principles of an ideal layout
Principle of maximum flexibility
Principle of maximum co-ordinations
Principle of maximum visibility
Principle of maximum accessibility
Maximum use of space
Principle of maximum safety and satisfaction
Principle of minimum travel
Principle of minimum investment
Minimum handling
Minimum discomfort
Principle of sequence
34. Characteristics of a good
layout
1. Sufficient space
2. Satisfactory safety and security to
worker
3. Minimum material handling
4. Suitable storage facility
5. Simple supervision
6. flexibility
