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Plant Layout
Learnito Study Series for Business Students
Find notes, QnA and case studies at
www.learnito.com/catalog
Production and
Operations Management

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Contents
• Meaning of Plant Layout
• Principles of Plant Layout
• Types of Plant Layout
• Tools in Plant Layout
• Building, Lighting and Ventilation
• Air-conditioning, Noise and Safety
• Assessment
• Case let : General Electric

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Meaning of Plant Layout
• Layout refers to the configuration of
departments, work center and equipments with
particular emphasis on movement of
work(customers or materials) through the
system.
• How important are Layout decisions ?
- they require substantial investments
- Involve long term commitments
- Have significant impact on the cost and efficiency of
operations.

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Principles of Plant Layout
• Principle of Minimum Travel
• Principle of Sequence
• Principle of Usage
• Principle of Compactness
• Principle of Safety and Satisfaction
• Principle of Flexibility
• Principle of Minimum Investment

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Types of Plant Layout
A. Process Layout: also called as functional
layout. It is designed for a “lot job” which
involves grouping together of like machines in a
single department.
B. Product Layout: also called as “Straight line
layout”, typically used for serialized
manufacture. This involves arrangement of
machines in one line, depending upon the
sequence of operations.

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Types of Plant Layout
C. Fixed Position Layout: Also called as “Static
Layout”. This is followed in the manufacture of
bulky and heavy products such as locomotives,
ships, boilers and generators.
D. Cellular Manufacturing Layout: is a layout in
which facilities are so arranged, that the
equipment used to make similar parts or
families of parts are grouped together.

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Types of Plant Layout
E. Combined Layout: A combination of product
and process layouts with emphasis on the either
is noticed in most industrial establishments.
F. Service Facility Layout: This type of layout
typically exists to bring together, customer and
services. Service facility layouts ideally provide
for easy entrance to these facilities from
freeways and busy thoroughfares.

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Tools & Techniques in Plant layout
1. Template: General patterns and sealed representation of
physical object in a layout.
2. Operations and Sequence Analysis: It helps in graphically
analyzing the sequence issue and confirming the layout.
3. Line Balancing: this technique looks into the work that needs to
be divided among the workers required on a assembly line is
minimized.
Layouts using computers:
- ALDEP : Automated Layout Design Programs
- CORELap: Computerized relationship planning
- CRAFT : Computerized relative allocation of facilities technique

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Building, Lighting and Ventilation
Features of Building
• Functional smoothness
• Flexibility and Safety
• Ease of material handling
• Proper flow of lighting and ventilation
Type of Building Materials
• Wood Frame building
• Steel frame buildings
• Reinforced cement concrete

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Building, Lighting and Ventilation
Type of Buildings
• Single Storied buildings
• Multi storied buildings
• High bay or Monitor type of buildings
• Lighting
Importance of Good Illumination are as follows
• Ease of seeing
• Reduced eye strain
• Better floor utilization
• Good House keeping
• Improved productivity and better supervision

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Building, Lighting and Ventilation
• Sources of Lighting can be classified as
– Natural lighting which is the Sun light and
– Artificial lighting.
• Artificial illumination or lighting are classified into
– General lighting and
– Niche lighting or supplementary lighting.
• Types of light sources are:
– Filament or incandescent lamps
– Discharge or fluorscent lamp
– Electro luminescence lamp
• Ventilation is the free movement of air inside out and vice versa.
Ventilation is of two types.
– General ventilation and
– Exhaust ventilation

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Air-conditioning, Noise and Safety
• Conditioners of Air was first invented in 1904 in
the USA
• Objectives of Air conditioning are:
– Protect workers health
– Improve quality of products
– Product preservation
– Reduce maintenance
• Noise Control is important to protect the hearing capacity
of employees resulting in headaches and other ailments

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Air-conditioning, Noise and Safety
• Noise Control Methods
– Control at Source (Overhauling, Noise producing items such
as machines, bearings, gears and spindles)
– Control by enclosure to machines
– Control by absorption
– Control through ear protection
• Safety means freedom from occurrence of accidents risking
injury or loss of life. Accidents are of many types, namely, major,
minor, temporary, permanent, disability, fatal, etc.

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Assess yourself !!
• Do you understand what is Layout of plant?
• Why is the layout so important in the present context?
• What are the principles behind the behind layout?
• When and why you should go with a particular layout?
• What are the types of buildings?
• Why is Air conditioning and Safety important?

15.
www.company.com
Plant Layout
Learnito Study Series for Business Students
Find notes, QnA and case studies at
www.learnito.com/catalog
Production and
Operations Management