Plant Layout

Definitions of Plant Layout

• A method of organizing the elements of a production process, in
which similar processes and functions are grouped together.
• Plant Layout is the physical arrangement of equipment and
facilities within a plant.
• 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.
Plant Layout Characteristics
• Provide space for machine / materials / storage / etc.
• Flexible for future changes in capacity / Design / Process etc (
Cellular design).
• Accommodate future expansion.
• Deals with government rules & regulations ( Municipal
corporation / Labor law & rules.
• Safety of employees / visitors / vendors is prime concern
• Achieve economy in operation.
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.
ABC Drug Company Plant Layout
Objectives of Plant Layout
1. Efficient utilization of available floor space.
2. To ensure that work proceeds from one point to another point
without any delay.
3. Provide enough production capacity.
4. Reduce material handling costs.
5. Reduce hazards to personnel.
6. Utilize labor efficiently.
7. Increase employee moral.
 Factors to be considered in plant layout

Services &
Building Men Machinery Materials Movement Waiting time
Changes
Factors to be considered in Plant
Layout
1. Building & Structure : Depend on type of production system
(Intermittent/Continuous)
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. Computer operator).
Physic of workers (ex. height).
3)Machinery :

Type of machine :
• General purpose machines : Compact in size & requires less space.
• 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.
4) Material

Nature of material ( Flammable / inflammable / Hazardous & Non

Hazardous, Corrosive , Methylene , mercury , oils , fuels)
Form of material ( Solid / Liquid / Powder etc)
Quantity of material to be handled.
Cycle Time : Consumption of material.
5) Movement :

Movement of people / machines / cranes ( length & frequency)

Purpose of movement ( With load / without load / Quantity of load)

6)Waiting Time :

Cycle time for completing each activity.

Intermittent – • Uncertain & High.
More storage places between machines & facilities.
Continuous – • Defined & low.
7)Services and changes

Changes :
• Production Volume
• Product type & design
• Process type
• Varieties
• Frequency of change ( Ex 5 years)

Services:
• Electrical supply
• Pneumatic supply ( Air supply)
• Water supply
• Chilling process – Cooling Tower
• Air ventilation –Ducting
• Fire extinguishers – Water sprinklers
Importance of Plant layout
• Optimum use of resources
• Removes bottleneck
• Save handling cost
• Quick execution of orders
• Better quality control
• Improve production control
• Improve employee morale
• Limited investment
• Best use of labour
• Improves supervision
Principles of Plant Layout
• Principle of Minimum Movement
• Principle of Flexibility
• Principle of Low Investment
• Principle of Compactness
• Principle of sequence
• Principle of full utilization of available space
• Principle of safety and satisfaction of workers
• Principle of Integration
Features of a Good/Scientific layout
• Adequate space for free movement of workers
• Safety to workers
• Maximum flexibility
• Effective Production control
• Convenience in storing
• Adequate gangway space
• Minimum materials handling
• Minimum damage and spoilage of materials
Types of Plant layout

Functional Layout ( Process Layout)

Line Layout ( Product Layout)

Static Product Layout ( Fixed Position Layout)

Group Layout ( Cellular Layout)

Combination layout ( Hybrid Layout)

1) Functional Layout ( Process Layout)

• Also called as process layout.

• Its best suited for intermittent type of operation.
• Machines on layout are called as general purpose machines.
• It involves a grouping together of like machines in one section / dept.

Example :
• Machines performing grinding operation are installed in grinding dept.
• Machines performing drilling operation are installed in drilling dept.
• Heat Treatment / Painting etc.
Example: 1
Process oriented layout for an hospital
❑ 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.
2) Line Layout ( Product Layout)

• It involves the arrangement of machines in one line, depending

on operation sequence.
• Raw material will be fed in first machine & final product will come
out of last machine.
• Output of one machine becomes input to next machine.

Example : Sugar refineries / Paper mills / Cement plants / Rolling

mills
Product layout (example 1) of a Paper mill
 Advantages :

• Smooth & regular flow of finished goods.

• Shorter processing time due to less travel , storage & inspection frequency.
• Reduced material handling.
• Low cost labors & lesser training requirement.
• Use of special purpose machines (SPM) ,automatic or semi automatic.
• Easy production control.

Disadvantages :

• Heavy capital investment.

• Non flexible layout .
• Risk of total production line shutdown..
3) Static Product Layout ( Fixed Position)

• This type of layout involves the movement of men & machines to

the product which remains stationary
❑ 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.
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 “cell”
The arrangement of cells is called a “ cellular Layout “
 Group layout Example of soaps
A company may produce 500 different
products. However, if we analyze how each of
the products is manufactured, we may be able
to create groups of products—say, one group
of 150, another group of 100, and so on—that
are very similar in the way they are produced.
To be efficient, we could place all the
resources needed for each group in a
separate area, called a cell. The production of
a group, or family, of items would be done
very efficiently because all the resources
required would be in close proximity. This is
the goal of group technology.
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.
Factors influencing Layout
• 1. 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.
• 2. Nature of product : Product layout is suitable for uniform products . Process layout is
suitable for custom made products.
• 3. Production process : In assembly line industries product layout is better. In job order or
intermittent manufacturing process layout is desirable.
• 4.Types of machinery : General purpose machines are arranged as per process layout ,
Special purpose machines are arranged as per product layout.
• 5. Repairs & Maintenance : Machines/Equipments must be arranged keeping in mind the
movement of operators & maintenance tools.
• 6. Human Needs : Adequate arrangement should be made for Wash rooms, drinking water
/ Canteen & other employee facilities.
• 7.Plant Environment : Heat / Noise / Light / Ventilation & other aspects should be duly
considered e.g. Paint shop / Fabrication / Plating section should be located separately to
protect employees from harmful fumes etc. Adequate safety arrangement should be made.