2. What is a Plant layout?
In simple words, plant layout means
allocation of space and arrangement
of equipments in such a manner that
overall operating costs are minimized.
3. Objectives of Plant layout:
Minimize material handling cost.
Effective utilization of men, equipment and
space.
Make effective utilization of cubic space.
Provide for employee convenience- safety
& comfort.
Minimize investment in equipment.
Minimize overall production time.
4. Principles of Plant layout:
1. Principle of minimum movement.
2. Principle of space utilization.
3. Principle of flexibility.
4. Principle of interdependence.
5. Principle of safety
6. Principle of smooth flow
7. Principle of supervision
8. Principle of satisfaction
5. Factors affecting Plant layout:
1. Policies of management
2. Plant location
3. Nature of product
4. Availability of floor space
5. Volume of production
6. Types of Plant layout:
1. Product layout
2. Fixed layout
3. Process layout
4. Combination layout
7. Product or Line layout:
Machines & equipments are arranged in one
line depending upon the sequence of operations
required for the products. The materials move
from one work station to another sequentially
without any back-tracking. Under this, machines
are grouped in one sequence therefore
materials are fed into the first machine &
finished goods travel automatically from
machine to machine. The output of one machine
becomes the input of the next.
For example, in a paper mill, bamboos are fed
into the paper mill at one end & paper comes
out from the other end.
8. Required general
principles:
1. All the machine tools or other items of
equipment must be placed at the point
demanded by the sequence of
operations.
2. There should be no point where one
line crosses another line.
3. Materials maybe fed where they are
required for assembly but not
necessarily at one point.
4. All the operations including assembly,
testing, packing must be included in the
line.
9. Juice processing flow-chart (with respect
to FIL industry):
Raw material
Blending
Homogenization
De-aeration
Sterilization
Rinsing
Storage
11. Advantages of Product Layout:
Low cost of material handling
Smooth operations
Continuous flow of work
Optimum use of floor space
Shorter processing time
12. Disadvantages of Product layout:
High initial capital investment in
special purpose machine.
Breakdown of one machine will
hamper the whole production process.
Heavy overhead charges.
13. Fixed layout:
In this type of layout, the major product being
produced is fixed at one location. Equipments,
labor and material are moved to that location. All
facilities are brought and arranged around one
work center. This type of layout is not relevant for
small scale entrepreneurs.
Material
Labou
r
Equipment
Finished product
Rambagh flyover
14. Advantages of fixed layout:
It saves time and cost.
The layout is flexible.
It is economical.
15. Disadvantages of fixed layout:
Production period being very long,
capital investment is very heavy.
Very large spaces required.
There's a possibility of confusion and
conflicts among different work groups.
16. Process layout:
In this type of layout machines of a similar
type and performing similar operations are
arranged together at one place.
In this type of layout the work has to be
allocated to each area in such a way that
no machines are chosen to do as many
different jobs as possible, i.e. Emphasis is
on the general purpose machine.
17. Advantages of Process layout:
1. Lower initial capital investment.
2. Lower overhead costs.
3. Change in output design can be adopted to the output of
variety of products.
4. Breakdown of one machine doesn’t lead to complete
stoppage.
5. Effective supervision.
6. Great flexibility.
Disadvantages:
1. Higher material handling costs.
2. More skilled labour is required which further increases the
cost.
3. Time gap in production is higher.
4. Work in progress inventory is high, leading to greater storage
space.
18. Combined layout:
Certain manufacturing units may require all three processes,
namely intermittent processes (job shops), the continuous
process ( mass production shops), and the representative
process combined process ( miscellaneous shops).
In most of industries, only a product layout or process layout
or fixed location layout does not exist. Thus in manufacturing
concerns where several products are produced in repeated
number with no likelihood of continuous production, combined
layout is followed. Generally a combination or product &
process layout or other combination is followed in practice.
19. Plant layout and production
layout of DANONE:
DANONE is a French food product
multinational corporation that produces
fermented dairy products like yoghurt &
curd.
Quality check of milk tanker
Weighing of milk tanker
Milk in Mix Tank (according to plan)
Quality check & release of recipe
20. Weighing Of recipe from warehouse
Mixing of ingredient & Hydration for 30min
Pasteurization (95°C for 5 mins) &
Homogenization at 300 bar
Inoculation Tank {2.5kl, 6KL &Tote (700ltr)}
Hot culturing: for stirred products at 38-400
C Cold culturing: for set products at 4-60 C
Reheater (40-42°C)
Packaging (Hassia, Zhongia Pouch filling
machine)
21. Printing & Weighing
Incubation (42°C till it achieves desired pH)
Cold Storage (4-6°C)
Dispatch to Market (in refrigerated trucks)
22. Production involves mainly 6
processes & equipments:
Tri blender
Pasteurizer
Sterilizer
Homogenizer
Reheater
