Plant Layout and its Types

Layout?
“Plant layout ideally involves allocation of space and
arrangement of equipment in such a manner that
overall operating costs are minimized”.

Dr. Zargari
 Objectives of Layout
1. Efficient utilization of available floor space
2. To ensure that work proceeds from one
point to another point without any delay
3. Provide enough production capacity.
4. Reduce material handling costs
5. Reduce hazards to personnel
6. Utilize labor efficiently
7. Increase employee moral.

Dr. Zargari
 Objectives of Layout….Cont..

1. Reduce accidents
2. Provide for volume and product flexibility
3. Provide ease of supervision and control
4. Provide for employee safety and health
5. Allow ease of maintenance
6. Allow high machine or equipment
utilization
7. Improve productivity

Dr. Zargari
 Types of Layout

o Manufacturing units
a. Product;
b. Process;
c. Fixed Position
d. Combined

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 1.Manufacturing Layout
a. Product layout(line Layout):
 The materials move form one workstation to
another sequentially without any backtracking or
deviation.
 Materials are fed into 1st machine and semi-
finished goods travel automatically from machine
to machine.
 The output of one machine becoming input of the
next.

Eg: Food Processing Unit; Paper mill

Dr. Zargari
 1.Manufacturing Layout
a. Product layout(line Layout):
Eg: Paper mill

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 1.Manufacturing Layout
a. Product layout(line Layout):
Advantage Disadvantage

1.Low material 1.Initial cost is very

handling cost high
2.Continuous work 2.Repetitive
3.Optimum floor process
space

Dr. Zargari
 1.Manufacturing Layout
b. Process (functional)layout:

 In this type of layout machines of a similar type

are arranged together at one place.
 The work has to be allocated to each
department in such a way that no machines
are chosen to do as many different job as
possible.

Eg: Process oriented layout for an hospital

Dr. Zargari
 b. Process (functional)layout:
E g : P r o c e s s o r ie n t e d la y o u t f o r
a n h o s p it a l

Patient A - broken leg

ER
triage Emergency room admissions
room Patient B - erratic heart
pacemaker
Surgery

Laboratories

Radiology ER Beds Pharmacy Billing/exit

Dr. Zargari
 1.Manufacturing Layout
b. Process layout:
Advantage Disadvantage

1.Low capital 1.High material

2.Overhead cost handling cost
are relatively low. 2.Time lag is higher
3.Effective
supervision

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 1.Manufacturing Layout
c. Fixed (position) layout:
 Here, Major products being produced is fixed
at one location.
 All other facilities are brought and arranged
around the work center.

Eg: Ship building, Dam construction, flyover

construction.

Dr. Zargari
 1.Manufacturing Layout
c. Fixed (position) layout:
E g : S h ip b u ild in g , D a m & f ly o v e r
c o n s t r u c t io n .

Dr. Zargari
 1.Manufacturing Layout
c. Fixed (position) layout:
Advantage Disadvantage

1.Save cost, as 1.Lengthy

customization is production period,
necessary heavy investment
cost
2.Several
operations are
carried out
simultaniously.

Dr. Zargari
 1.Manufacturing Layout
d. Combined layout:

 In many manufacturing units, several products

are produced in repeated numbers with no
likelihood of continuous production, combined
layout is followed.

Eg: Soap industry, all inputs are almost

manufactured in separate units viz
glycerin, water treatment, fragrance etc.

Dr. Zargari
 1.Manufacturing Layout
d.Combined layout:
Eg: S oaps

Dr. Zargari