m



MEANING & DEFINITION

V Physical arrangement of production facilities.

V Moore:- ³ plant layout is a plan of an optimum arrangement of

facilities including personnel, operating equipment, storage space,
material handling equipment & all other supporting services along
with the design of best structure to contain all these facilities.´

V Overall objective :- to design a physical arrangement that meets

the requirement of output quantity & quality.
 PLANT LAYOUT

ï Problems of plant layout:-

V Everyone in the organization is associated with plant layout.

V Reasons for change of plant layout:-

V Change in product design or launch of new product.

V Change in volume of demand for the company¶s product.
V High rate of accidents due existing plant layout.
V Outdated plant & machinery, need for salvage.
V Poor working environment affecting efficiency & productivity.
V Change in location or market.
V Minimizing cost through effective facilities planning.
 PLANT LAYOUT

ï Objectives of plant layout:-

V Primary objective :- to maximize profit by arrangement of all

facilities to the best suitability of manufacturing.

V Streamline flow of material through plant.

V Facilitate manufacturing process.
V Maintain high turnover of in- process inventory.
V Minimize material handling.
V Effective utilization of men, machine & space.
V Effective cubic space utilization
V Flexibility of manufacturing.
V Provision of employee safety, convenience & comfort.
 PRINCIPLES OF PLANT LAYOUT
ï PRINCIPLE OF INTEGRATTION :- A GOOD LAYOUT INTEGRATES ALL
RESOURCES- MEN,MACHINE,MATERIAL IN ORDER TO GET
OPTIMUM UTILISATION & MAXIMUM EFFECTIVENESS.

ï PRINCIPLE OF MINIMUM DISTANCE:- MINIMUM TRAVEL WITH MEN

& MATERIAL. FACILITIES SHOULD BE ARRANGED IN SUCH A WAY
THAT TOTAL DISTANCE TRAVELLED BY MEN, MATERIAL &
EQUPMENT SHOULD BE MINIMUM & IN STRAIGHT LINE.

ï PRINCIPLE OF CUBIC SPACE UTILIZSATION :- A GOOD LAYOUT IS

ONE WHICH USES BOTH HORIZONTAL & VERTICAL SPACE.
EFFECTIVE USE OF HEIGHT DIMENSION ALONG WITH FLOOR SPACE
.
 PRINCIPLES OF PLANT LAYOUT

ï Principle of flow:- material should move in forward direction

towards completion without backtracking.

ï Principle of maximum flexibility:- a good layout is one that can be

altered without much efforts & cost. Future expansion should be
taken into consideration.

ï Principle of safety, security & satisfaction:- give due consideration

to workers safety & satisfaction, safeguard of plant & machinery
against fire, theft etc.

ï Principle of minimum handling:- material handling reduced to

minimum.
 ADVANTAGES OF GOOD PLANT LAYOUT

V Advantages to workers:-
- reduced efforts of workers in travel.
- Minimizes material handling
- Provides convenient & comfortable working conditions
- Minimizes accidents.

V Advantages in manufacturing: -
- reduced material travel distance & time.
- Avoidance of bottlenecks in production.
- Less delay in production ; reduced cycle time
- Increased productivity.
 PLANT LAYOUT
Ñ Advantages in production control:-
- Uniform & uninterrupted flow of material
- Production completed without excess man &
material travel & material handling within
scheduled time.

Ñ Advantages to management:-
- Reduced labour cost.
- Reduced material handling cost.
- Economics in material handling.
- Effective land, space utilization.
- Effective man, machine utilization.
- Minimum capital investment.
- Reduced cost per unit
- Increase in market competitiveness
 PLANT LAYOUT

ï Factors influencing plant layout:-

V Type of production:- engineering / process industry

V Type of production system:- job/batch / mass
V Volume or scale of production
V Variety of product mix
V Available total area.
V Availability & arrangement of material handling system.
V Type of building:- single or multi-storey / shed.
V Scope or plans for future expansion or diversification.
V Types of production facilities- GPM or SPM.
 PLANT LAYOUT
Ñ Types of layout:-

Ñ 1) Block Layout :- arrangement of different production &

all other facilities within the premises of factory taken
as blocks. It includes production area, security, dispatch ,
canteen, maintenance, administration office etc.

Ñ 2) Shop Layout:- detailed arrangement of each facility

represented by block in block layout.

Ñ 3) Workplace layout:- in a shop, the detailed arrangement

of each workstation, storage area, material in & outflow
area near work station ,arrangement of tools, jigs, dies
fixtures, components, subassemblies etc. is elaborated
in workplace layout.
 PLANT LAYOUT

V Types of plant layout:-

V 1) layout by fixed position:-

V Also called project layout.
V Material, major components remain in a fixed location, and tools,
machinery, men & other material are brought to the location of
job.
V Suitability:- for project jobs such as :- ship vessels, pressure
vessels, huge air crafts. TOOLS

RAW
MACHINES PRODUCT
MATERIAL

MANPOWER
 PLANT LAYOUT
V Advantages:-

V Minimum capital investment in plant layout

V Less material movement
V Continuity of operations
V Less total production cost
V Greater flexibility
V Job enlargement & upgrades skill of operators
V Sense of attachment with job

V Disadvantages:-

V Machines, tools take more time to reach workplace.

V Highly skilled workers are required
V Complicated jigs/fixtures are required.
 PLANT LAYOUT
V 2) Functional Layout( Process Layout) :-

V Recommended for batch / lot production.

V Each department is responsible for carrying out a particular
process /function on the job and not for a particular product.
V All machines/equipment performing similar type of operations are
grouped at one location forming a section.
V Machines are placed on a functional basis .
V For ex.:- All lathes, milling m/c are grouped in the shop will be
clustered together.
V The flow of material from a workstation to other varies from
product to product.
V Usually material travel paths are long with backtracking.
 PLANT LAYOUT
V PROCESS TYPE LAYOUT

MILLING LATHE HEAT ASSEMBLY

SECTION SECTION TREATMENT SHOP
SHOP

WELDING INSPECTION PAINTING

GRINDER
SECTION DEPT. SHOP
SECTION

RECEIVING SHIPPING
AREA DEPT.
 PLANT LAYOUT

V PROCESS LAYOUT FOR MULTIPRODUCTS:-

¦
 ¦ ¦ 




  


  ¦  

 PLANT LAYOUT

V Advantages:-

V Flexibility of equipment & personnel.

V Comparatively less no. of GPM, low plant cost ;
V Less capital investment in plant layout .
V Higher utilization of production facilities.
V Greater flexibility as regards to work distribution of men &
machine& also volume of production.
V Succession of operations is not suffered due to breakdown of one
machine.
V Variety of jobs make the job challenging & interesting.
V Supervisors are knowledgeable & workers are skilled.
 PLANT LAYOUT

V Disadvantages:-

V Long material movements may occur as per product functional or

process requirement.
V Backtracking of material may occur as per job process.
V Thus material handling efficiency is reduced.
V Process cycle time is prolonged.
V Production planning & control is difficult.
V More in process inventory; less inventory turn over.
V More set-up time; low productivity.
V Requires more space due to lack of automate material handling.
V More time in inspection as it is necessary after each process
 PLANT LAYOUT
V Product Layout ( Line Layout):-
V Machines are arranged as per the sequence required by the
product.
V Special purpose machines are used for quick, specific & reliable
operation on the job.
V Mostly used in mass production.
V Ex.:- Sequence of operation required is turning, milling, drilling,
assembly, inspection ,packing & dispatch.
RAW
MATERIAL LATHE MILLING DRILLING ASSEMBLY

INSPECTION

PRODUCT PACKAGE &

DESPATCH
 PLANT LAYOUT
V PRODUCT LAYOUT FOR MULTIPRODUCTS:-

 




  

 
 PLANT LAYOUT
V Advantages:-

V Mechanized or automated material handling.

V Less material travel distance as machines are closely spaced & in
sequence of operations.
V Less material handling time & cost.
V Perfect balancing offline is done which eliminates bottlenecks &
idleness.
V Forward & simplified material flow towards completion.
V No backtracking.
V Simplified production planning & control.
V Less work in process inventory; more inventory turnover.
V Unskilled workers can manage production.
V Cycle time is reduced ; productivity is increased.
 PLANT LAYOUT

V Disadvantages:-

V Lack of flexibility as layout is for specific product with spms laid

down in order to fulfill required sequence of operations for that
particular product.

V Large capital investment as cost of SPMs is high.

V Breakdown of any machine can stop the production line.

V Operators are not skilled , they learn specific operation to be

performed on a certain machine.
 PLANT LAYOUT
V COMPARISON BETWEEN PRODUCT & PROCESS LAYOUT:-

SR.NO. CHARACTERISTIC PRODUCT LAYOUT PROCESS LAYOUT

1 NATURE SEQUENCE OF GROUPING OF
MACHINES MACHINES
2 APPLICATION HIGH VOLUME, HIGH VOLUME &
FEW PRODUCTS VARIETY
3 PRODUCT STANDARDISED DIVERSIFIED
4 WORKFLOW STRAIGHTLINE VARIABLE
5 MATERIAL MECHANISED NON AUTOMATED
HANDLING
6 INVENTORY LOW WIP HIGH WIP
7 BREAKDOWNS STOPS PRODUCTION CAN BE TOLERATED
8 PRODUCION CENTRE SIMPLE COMPLEX
9 FLEXIBILITY LOW HIGH
10 SPACE UTILISATION EFFICIENT LOW
11 PRODUCT COST HIGH FIXED COST , LOW FIXED COST,
LOW VARIABLE COST HIGH VARIABLE COST
 PLANT LAYOUT
V COMBINATION / HYBRI D LAYOUT:-

V Mixed type in which process layout is combined with product

layout.

V Various components are produced by process layout.

V Assembly of finished components is by product layout.

V Combines merits of both types.

V Ex.:- Manufacture of refrigerator. Functional layout to

produce various operations like stamping, welding, heat
treatment at various workstations & final assembly is done by
product layout.
 PLANT LAYOUT
V COMBINATION LAYOUT (HYBRID / MIXED LAYOUT)
V Pure product or process layout is not seen in industries.
V A process layout is combined with product layout
V Ex.:-1) a plant involving fabrication & assembly of parts.
V Fabrication is in process layout & assembly in product.
V Refrigerator , washing machine manufacturing.
V Soap manufacturing ± processing all ingredients is by process layout. Mixing of
ingredients, molding of soap, packing are in product layout.

ROTOR PROCESS
LAYOUT
MOTOR PROCESS
HOUSING LAYOUT
BEARING PROCESS
MOTOR
HOUSINGS LAYOUT ASSEMBLY
LINE
BEARING PROCESS
COVERS LAYOUT PRODUCT
END PROCESS LAYOUT
COVERS LAYOUT
 PLANT LAYOUT
Ñ Group Technology (GT) Layout:-
Ñ Trend to bring element of flexibility in manufacturing system as
regards to variation in batch size & sequence of operations.
Ñ Grouping of equipment performing a sequence of operations on a
family of similar components / products is essential.
Ñ Items are grouped into families.

Ñ Family :- Components which undergo same sequence of

operations ( follow same path)

Ñ Two basic steps:- 1) Determine component families.

2) Arrange equipment to process each family of
components.

Ñ Represents plant within plant.

Ñ Reduces planning time, set-up time for jobs.

 PLANT LAYOUT

Ñ Types of gt layout:-

1) Group GT Layout:-
Ñ All machine tools required for processing all components in a
family are arranged in a cell.
Ñ All components may not be processed on all machines but
complete processing is achieved in a cell.
Ñ All components do not follow exactly identical path.
Ñ Example:- gear box housing cell
 PLANT LAYOUT
GROUP GT LAYOUT:-

V All components do not follow exactly identical path.

CELL RAW RAW RAW

HOUSING A HOUSING B HOUSING C
M/C. 1 M/C. 1 M/C. 1 M/C. 1
2 2 5 2
3 3 4 3
4 4 3 5
5 5 2 4
CELL FINISHED FINISHED FINISHED
PRODUCT HOUSING A HOUSING B HOUSING C
 PLANT LAYOUT
GROUP GT LAYOUT:-

V All components may not be processed on all machines.

CELL RAW RAW RAW

HOUSING A HOUSING B HOUSING C
M/C. 1 M/C. 1 M/C. 1 M/C. 1
2 2 -- --
3 3 3 --
4 -- 4 4
5 -- -- 5
CELL FINISHED FINISHED FINISHED
PRODUCT HOUSING A HOUSING B HOUSING C
 PLANT LAYOUT

2) Line GT Layout:-
Ñ All machine tools required for processing all components in a
family are arranged in a cell.

Ñ All components are processed on each machines & follow exactly

identical path

Ñ Complete processing is achieved in a cell.

Ñ Example:- Gear box housing cell

 PLANT LAYOUT

CELL RAW RAW RAW

HOUSING A HOUSING B HOUSING C
M/C.1 M/C.1 M/C.1 M/C.1
2 2 2 2
3 3 3 3
4 4 4 4
5 5 5 5
CELL FINISHED FINISHED FINISHED
PRODUCT HOUSING A HOUSING B HOUSING C
 PLANT LAYOUT
Example :- 3 motor models A,B &C
Main families :- Shaft/Rotor, Motor Housing,
Bearing Housings, Bearing Covers, end covers.
BEARING BEARING END
ROTOR HOUSING HOUSING COVER COVER
CELL CELL CELL CELL CELL

COMPONENTS
OF A,B,C

MOTOR
ASSLY

TESTING,STORAGE
& DESPATCH
 PLANT LAYOUT

V Advantages:-

V Brings out element of flexibility in manufacturing system as

regards to batch size and sequence of operation.

V Technique very useful for companies that produce variety of

parts in small batches to ensure uninterrupted assembly.

V Reduces production planning for jobs

V Reduces set up time.

 PLANT LAYOUT
Ñ Material Flow Patterns:- coordinated material movement from
start to finish.
Ñ Types:- 1)Horizontal:- for single storey building , flat floor space
Ñ is available.
2) vertical:-for multistoried plant building .
cubic space utilization.
A) PRODUCTION LINE FLOW PATTERNS:-
1) STRAIGHT LINE ( I) FLOW PATTERN:-
Ñ Simplest of all .Plant area has longer length & shorter width.
Not suitable for long production lines. Total handling distance is
minimum. Convenient for ³I ´ shaped buildings.
Ex.:- Automobile plants.
START FINISH
 PLANT LAYOUT
2) I-Flow Pattern:-
V Recommended where i patterns are not suitable.
V For longer production line.
V Occupies less space.

3) U-Flow Pattern:-
V Suitable for longer production lines.
V Requires square floor area.
V Permits receiving & shipment on same side of plant.
V Better security checks.

4) S-Flow Pattern:- (Inverted S or Serpentine)

V Suitable if line length longer than building length.
V Compact arrangement.
V Easy supervision
V Receiving & shipment on opposite sides.
 PLANT LAYOUT
5) O ±Flow Pattern :- Suitable for operations are performed on
rotary table. Component traverses circular path as it moves from
one workstation to other & leaves as finished product.
V Ex.:- Manufacture of electric bulbs.

L-FLOW LINE U-FLOW LINE

S-FLOW LINE
 PLANT LAYOUT
B) Assembly Line Flow Pattern:-
1) Comb Pattern:-
Ñ Feed to main assembly line is from no. Of sub assembly lines
located on one side of main assembly line.
Ñ Main assembly line is on wall side or along aisle.
2) Tree Pattern:-
Ñ Sub assembly lines located on both sides of main assembly line
give feed to main assembly line.
Ñ Shorter than comb pattern for same no. Of sub assembly lines.
3) Dendritic Pattern:-
Ñ Parts combine to form subassemblies.
Ñ Subassemblies combine with other subassemblies or parts to
form progressive assemblies which leads to final main assembly.
 PLANT LAYOUT
5) Overhead Flow Pattern:-
V The flow starts from upper floors to ground floor.
V For multistoried plants.
V Final main assembly is on ground floor.

COMB PATTERN TREE PATTERN

DENDRITIC
PATTERN
 PLANT LAYOUT
Ñ C) Machine Arrangements Patterns:-
1) Straight Line Arrangement:-
Ñ Axis of machines is parallel to adjacent aisle.
Ñ Normally two rows of machine on each side of aisle .
2) Diagonal Arrangement:-
Ñ Axis of machines is inclined to the aisle.
Ñ More no. Of machines accommodated in given area.
Ñ Narrow aisle is sufficient.
Ñ Material receipt & removal are from either sides of m/c.
3) Circular Arrangement:-
Ñ When one operator operates more than one machine.
Ñ Operator at centre & workstations at circumference.
4) Odd Angle Arrangement :- Convenient feed to m/c.
 PLANT LAYOUT

V PROCEDURE OF PLANT LAYOUT:-

V Analysis of product to be produced.
V Determine process required & its sequence to manufacture the
product.
V Prepare layout planning chart s:- flow process charts,
Time estimation, machine selection & balancing , manpower etc.
V Determine type & no. of workstations / machines required .
V Determine storage area required for each workstation.
V Determine minimum aisle width.
V Determine office area required.
V Consider personnel facilities & services.
V Consider plant services.
V Make provision for future expansion.
 PLANT LAYOUT

Ñ DATA TO BE COLLECTED FOR DESIGN OF A GOOD LAYOUT:-

Ñ Processes of operation
Ñ Sequence of operations of each process
Ñ Material flow
Ñ Frequency of travel
Ñ Space required & available area.
Ñ Activities & their relation or dependence.
 PLANT LAYOUT

Ñ TECHNIQUES USED TO COLLECT & ANALYSE DATA:-

Ñ Process Charts :- 1) Operation Process Charts

2) Flow Process Charts
V Travel chart
Ñ REL chart
Ñ Templates
Ñ Models
Ñ Computer Aided Layout Planning (CALP)
Ñ Flow diagram
Ñ String diagram
 PLANT LAYOUT
V TRAVEL CHART :-
V It is a from ± to chart
V Records & indicates movement of material between two
workstations or departments.
V Helps to determine degree of closeness between two departments
or workstations.
V Basic tool in layout design
V Achieves principle of minimum travel & hence material handling
cost.
V Advantages:-
V Useful for movement analysis,
V Helpful to locate activities & backtracking
V For comparing alternative layout.
V Can be easily computerized.
 PLANT LAYOUT
V METHOD:-
V List departments both row & column wise in same sequence.
V Each intersecting square is called a cell.
V Note movement from one to other department in cell
V Ex.:- MBC ± movement from dept. B toCc
V Place entries on either side of diagonal in cell.

DEPT. A B C D E F
A
B MBC
C
D
E
F
 PLANT LAYOUT

V Relationship Chart (REL chart):-

V Displays relative importance of placing one department near
another.
V Each diamond shaped cell in the chart shows type of relationship
between two functional departments.
V There are two entries in each cell.
V The top letter indicates the degree of closeness between two
departments.
V The no. below indicates the reason for that relationship.
V The diagram explores relatedness of departments rather than
calculating exact flow and costs.
V This rating of required closeness of the department pairs is used to
develop a proposed layout
 PLANT LAYOUT

DEPT. 1
I
DEPT. 2 U
U A
DEPT. 3 E E
X E X
DEPT. 4 I I
O E
DEPT.5 U
U
DEPT. 6
VALUE DEGREE OF CLOSENESS
A ABSOLUTELY ESSENTIAL

1 4 E ESPECIALLY IMPORTANT

5 2 I IMPORTANT

3 6 O ORDINARY CLOSENESS
U UNIMPORTANT
X NOT DESIRABLE
 PLANT LAYOUT
V COMPUTER AIDED LAYOUT PLANNING:-
V Computerized layout analysis increases the speed and accuracy of evaluation of
various alternatives.
V CRAFT ( COMPUTERIZED RELATIVE ALLOCATION OF FACILITES):-
V Input:- Material flow per unit time, Cost per unit per unit
distance moved, Space requirements
V It is an improvement algorithm
V Limitations:- maximum 40 departments
V Considers exchange between locations repeatedly until no further
significant cost reductions are possible.
V Output:- in the form of facilities in a basic rectangular form with
lowest cost.
V Assumes that movement between department occurs along
straight line between centroids of the departments.
V Assumes that cost varies linearly with distance.
 PLANT LAYOUT
V COMPUTER AIDED LAYOUT PLANNING:-

V CORELAP ( COMPUTERIZED RELATIONSHIP LAYOUT PLANNING):-

V Uses A,E,I,O,U,X closeness ratings, Space requirements and
Maximum building length to width ratio to develop a layout.
V Input:-
V No. of departments and area requirements
V Relationship chart.
V Weightage for REL chart.
V Maximum building length to width ratio.

V ALDEP (AUTOMATED LAYOUT DESIGN PROGRAMME) :-

V Requires input data for building specifications.
V Preference matrix for location relationships.
V Capacity of laying out up to 63 departments.