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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 judgement.
• 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 decision already taken on location, capacity, facility,
manufacturing method and material handling techniques..

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Factors to be considered in plant layout
Factors to be considered in plant
layout
Building
Men Machinery Materials Movement
Waiting time
Services &
changes

z 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 option & then machinery will be brought inside.
 Continuous system:-Arrange machine 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 )
 Physics of worker ( ex.height)

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3) machinery
 Types of machine:
 General purpose machine:- compact in size & requires less space.
 Special purpose machine (SPM) :- large in size, complicated, high level of
automation.
 Number of machine:
 Level of automation ( semi / fully automated)
 Higher complexity wider space.

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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.

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5) Movement
 Movement of people / machine / 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

z 7) Services & 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 extinguisher- water sprinkler

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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)

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1) Functional layout ( process layout)
 Also called process layout.
 Its best suited for intermittent types of operation.
 Machines on layout are called as general purpose machines.
 It involves a grouping of like machines in one section / dept.
 EXAMPLES:-
 Machines performing grinding operation are installed in
grinding dept.
 Machines performing drilling operations are installed in
drilling dept.
 Heat Treatment / painting etc.

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 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

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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.

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 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 requirements.
 Use of special purpose machine (SPM), automatic or semi automatic.
 Easy production control.
 Disadvantages:-
 Heavy capital investment.
 Non flexible layout.
 Risk of total production line shutdown.

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3) Static product layout ( fixed position )
This type of layout involves the movement of men & machines to
the product which remains stationary .

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 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.

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4) Group layout ( cellular layout)
In cellular manufacturing layout the arrangement of facility so that
equipment used to make similar parts of families of parts is grouped
together.
The group of equipment is called “ cell”
The arrangement of cells is called a “ cellular layout”

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5) Combination layout ( Hybrid layout)
 It is a combination of product & process layout with an emphasis
on either.
 In Industries plant 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 -----Process layout
 Assembly of parts -------Product layout
 Ex : soap manufacturing machines-----product line
 Process layout----Functional basis----Ancillary services---
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 Heating / Manu of glycerin / power house / water treatment

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F.P : forging press. G.c : gear cutting
H.t : heat Treatment. G.g : gear grinding machine

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Factors influencing layout
1)Factory Building:
The nature & size of building the floor 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 the 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/ Equipment 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 product employees from harmful fumes etc. Adequate safety arrangement should be made.

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Symptoms of poor Layout
 A good layout results in
 Comfort,
 Convenience,
 Safety,
 Efficiency,
 Compactness,
 Finally in profits to the organization
 A poor layout results in
 Congestion,
 Wastes,
 Frustration,
 Inefficiency and
 Finally lower profit or loss to an organization.

z Plant layout tools & techniques
 1) Process chart
 Operations process chart
 Flow process chart
 2).Process Flow Diagrams
 3) Machine Data cards
 4) Visualization of layout
 Two dimensional plan or template
 Three dimensional plan or machine models

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