B Y S U J E E T TA M B E .

M M S ( O P E R AT I O N S )

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.

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 , Methalene , 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 completeting 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

Types of Plant layout

Functional Layout ( Process Layout)

Line Layout ( Product Layout)

Static Product Layout ( Fixed Position)

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.

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.

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

1. Aircraft Assembly

2. Flyover Bridge

3. Water Dam

Raw Material

Machine & equipment

Labors

Finished Product

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 “

1

5

2

4

3

1

Cell 1211 3 Cell 3

Cell 2 Cell 4

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.

F.P : Forging Press G.C : Gear Cutting H.T : Heat Treatment

G.G : Gear Grinding Machine

F.P

F.P

G.C

G.C

G.C

H.T

H.T

G.G

G.G

Process Layout

Product Layout

Raw material

Raw material

Finished Products (Gears)

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.

Factors Influencing Layouts

Symptoms Of Poor Layout

A good layout results in

• Comfort,

• Convenience,

• Safety,

• Efficiency,

• Compactness and

• Finally in profits to the organization

A poor layout results in

• Congestion,

• Wastes,

• Frustration,

• Inefficiency and

• Finally lower profit or loss to an Organization.

Plant Layout Tools & Techniques

1. Process Chart

i. Operations process chart

ii. Flow process chart

2. Process Flow Diagrams

3. Machine Data cards

4. Visualization of layout

i. Two dimensional plan or template

ii. Three dimensional plan or machine models

THANK

YOU