Plant Layout

By: Shobhit Kumar

 Objectives
 Provide enough production capacity.
 Improve productivity
 Reduce accidents
 Full utilization of resources
 Smooth supervision
 Minimize material handling and transportation
 Optimum utilization of men, machine, space and equipment.
 Smooth flow of material towards plant.
 Effective Planning and Control over equipments and process.
 Provide health and safety for the employee.
 Principles of Plant Layout
 Principle of Minimum Travel.
 Principle of Sequence.
 Principle of Usage
 Principle Of Flexibility
 Principle of Safety and satisfaction.
 Principle of Minimum Investment.
 Principle of Compactness
Factors Affecting Plant Layout
 Material
 Machines
 Equipments
 Human
 Manufacturing Process
 Characteristics of Building
 Transportation
Types Of Layout
 Product Layout
 Also called as straight line layout, layout for serialized
manufacture
 If the nature of layout depends upon the type of product
and quantity of production then the layout is known as
Product Layout.
 In this type of layout the machines are arranged in a
straight line, depending upon the sequence of the
operations.
 In this layout the output of the one machine becomes the
input of the other machines.
 This layout is suitable for the continuous production.
 It is used for the mass production of a single product.
 Special purpose machines can be used
Application of Product Layout
 Automobiles, Chemical industries
 Bottling Plant, Petroleum products
 Paper Industries, Cement factories
 Sugar Industries, Rolling mills
Advantages of Product Layout
 Better utilization of machines
 Avoid bottle neck production
 Shorter processing time
 Cost of production is less
 Production control is simple and easier
 Early detection of mistakes
 Greater incentives to the workers to raise their
level of performance.
 Effective coordination can be achieved
 Disadvantages of Product
Layout
 Expensive
 Inflexible
 Difficulty in supervision
 Expansion is difficult
 Not suitable for variety if the products
 Breakdown can stop the whole production system.
 Requires trained workers
 Factor of absenteeism in labors
 Process Layout
 Also called as functional layout, batch production layout,
Job shop layout.
 It involves a grouping together of like or same machines
in one department.
 In this type of layout machines which are performing
same types of operations are installed at one place.
 In other words we can say that in this type of layout
machines are arranged in a systematic manner so that
similar jobs can be perform at a particular work station.
 This type of layout is used in engineering industries,
furniture industries, television industries, garment
industries, shoe making industries.
 Advantages of Process
Layout
 Greater flexibility in production
 Scope of expansion
 Full utilization of equipment
 Easy to handle the break downs
 General purpose machines are used
 Greater incentives to the individual workers
 Variety of the products can be made.
 Workers become specialized in the performance and
they know the equipments and the operations
 Effective supervision
 Economical to produce the variety of products
 Disadvantages of Process
Layout
 Movement of material is difficult.
 Requires much floor space
 Difficulty in production control
 Routing and Scheduling are difficult
 Highly skilled labor is required
 More frequent inspection
 Material handling and transportation cost are high
due to manual handling.
 Fixed Position Layout
 Also called as static layout, stationary layout.
 As the position of the job is fixed that’s why it is called fixed
layout.
 In this layout complete job is done at a fixed place with men,
materials, machines.
 It involves the movement of men, machines, materials to the
product which remains fixed.
 This type of layout is used for complex products.
 In this the movement of men, machines, material to the product is
advisable because the cost of moving them would be low rather
than the cost of moving a bulky product.
 The main stress is on the principle of motion economy and
principle of minimum distance travelled
 Application of Fixed Plant
Layout
 Locomotives
 Ships
 Aircrafts
 Boilers
 Generators
 Submarines
 Turbines
 Advantages Of Fixed plant
Layout
 Better utilization of space
 Better Economy of motion
 Investment is small
 Production control is easier, faster and cheaper.
 Application of variety of job production
 Workers identify themselves with the product and
takes pride when the work is completed.
Disadvantages Of Fixed plant
Layout
 Movement of machines and equipment to
the production center may be costly and
time consuming.
 Highly skilled workers are required
 Can be used for limited quantity of jobs.
 Very costly, sophisticated jigs and fixtures
required.
 Fixed Position Layout

All the resources are moving toward a specific place

Material

Labour PRODUCT Equipment

Services
 Process Layout

Turning Grinding Fitting Inspection

Office
Stores Tools Store Stock Room Labeling Packing
 Product Layout
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