session 8

PLANT LAYOUT

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

► House wife must arrange her kitchen.

► Retailer must arrange his counter and display the
products.
► Office management position the desks, tables and
other equipment.
► Organizations arrange their facilities, department
within the factory, stores etc to achieve smooth
flow


Layout identically involves the allocation of space



and the arrangement of equipment in such a manner

that overall operating costs are minimized.


Plant Layout is the method of allocating machines



and equipment, various production processes and

other necessary services involved in
transformation process of a product with the
available space of the factory so as to perform
various operations in the most efficient and
convenient manner providing output of high
quality and minimum cost.


Objectives of Plant Layout



► economies in materials, facilitate

manufacturing process
► proper and efficient utilization of
available floor space.
► To ensure that work proceeds from one point
to another point
► Provision of better supervision and control.
► Careful planning to avoid frequent changes
in layout.
► Meet the quality and capacity requirement.
► Provide efficient material handling system.
► To suggest improvements in production
process and work methods.


Types of
 Layout
1. Product Layout
2. Functional or Process Layout
3. Stationary Layout


Product Layout


► The postion of a particular machine is

determined at some definite stage where
the machine is required to perform some
operatin from a sequence of operations
designed to manufacture the product.
► Once a machine is in line, it cannot perform
any operation which is not designated in
the sequence of operations.


 Product Layout:

INPUT OUTPUT
Storage Storage
Machine A Machine B Machine C
  Product Layout

Advantages Disadvantages

oth and regular flow of material and finished goods.

onomy in materials and labor by minimizing waster.

ssing time ►Plant layout is of inflexible nature

►
erial Handling ►Vulnerability to production line shut
►
bor procurement and ►Supervision is more diffi
ng requirement.
►Requires heavy capital investment.
ection
is more production.
tion control
d for buffer stock


Functional Layout


► All operations of similar nature are

grouped together in the same department
or part of the factory.
► Machines performing same type of operations
are installed at one place.
► Example: furniture, Kitchen


 Functional Layout:
INPUT INPUT

P1 P2

Machine A

Machine D

Machine B

Machine C

OUTPUT
  Functional Layout

Advantages Disadvantages

r output of smaller quantities and with varying specifications.

e specific operation
►More
can be
material
used. handling
of the system works►independently
Longer Processing
. time
roduction facilities
►Requires substantial production planning and control
►Requires more floor space.
s not disrupt production
►Inspection
schedules
is .ore frequent and costlier.
ment ►Requires highly skilled labor creating difficulty in
ixed costs to total costs.


Stationary Layout


► This type of layout is used where Semi-

finished goods are of such a size and
weight that their movement from one
place to othe other is not possible.
► Men, equipment and the raw material is moved
to a place where all the manufacturing
activities are carried out.
► Example: Ship-building


 Stationary Layout: INPUT

INPUT

Men
Raw material

Building Construction
(Immovable product) INPUT

OUTPUT
Machinary
  Stationary Layout

Advantages Disadvantages

f frequent adjustments
►Heavy
both with
and sophisticated
respect to product
equipment
and the
cannot
process
be used
. i
►
ployed and remain busy
►This
throughtout
layout is
thesuitable
process for
in one
somework
special
or the
type
other
of .p


Techniques of Plant Layout: Information required for



proper planning
► Type and quantity of labor required.
► Dimensional plant of the space
► Volume of work (present and future)
► Description fo the operations, their sequence
► Nature of machines to perform operations
► Amount of material, buffer stock required at
each workstation.
► Size of finished and semi-finished products
inventory.
► Kind of communications and fire-exits.
► Special requirements to fulfil the local bye-


Plant Layout tools: Information required for proper



planning
I. Process Charts
i. Operations Process Charts
ii. Flow process Chart
II. Process Flow Diagrams
III. Machine data cards
IV . Visualization of Layout
i. Two-dimenstional plan
ii. Three-dimenstional Plan


Features of good Plant Layout:



I. Sufficient space for the worker as well as for

the equipment.
II. Provide adequate safety and security to
workers against accidents.
III. Sufficient gang-way space for materials,
workers and semi–finished goods.
IV . Arrangement of machines and equipment should
be such that minimmum material handling is
necessary for low cost processing.
V . Stores not far from the place of operations.
V I. Supervision, co-ordination and control of the
activity should be effectively and easily
executed.
V II. Sufficient scope for making adjustments and
modifications whenever need arises.