 Civic amenities for workers.
PLANT LOCATION, LAYOUT
AND FACILITIES PLANNING
PLANT LOCATION- is the function of
determining where the plant is to be located, for
maximum operating economy and effectiveness.
Plant is a place where men, materials, money,
machines and equipment are brought together for
manufacturing products.
Factors effecting the location of the plant:
 Proximity to source of supply: Reduce
transportation costs of perishable or bulky
raw materials
 Proximity to customers: E.g.: high
population areas
  Proximity to labor: Local wage rates,
attitude toward unions, availability of special
skills (e.g.: silicon valley
 Community considerations: Local
community’s attitude toward the facility
(e.g.: prisons, utility plants, etc.)
  Site considerations: Local zoning & taxes,
access to utilities, etc.
  Quality-of-life issues: Climate, cultural
attractions, commuting time, etc.
 Other considerations: Options for future
expansion, local competition, etc.
Steps of Location Selection    Local market is accessible.
Various Factors
1. Deciding on Domestic / International location -
The choice of particular country depends on
factors like political stability, export and import
quotas, currency exchange rate, cultural and
economic peculiarities, natural and physical
conditions.
2. Selection of Region:
 Availability of raw materials.
  Nearness to the market.
  Availability of power.
 Transportation facilities.
 Suitability of climate.
  Government policy
  Competition between states
3. Selection of community:
 Availability of Labor
 Existence of complementary ad competing

industries
 Finance and research facilities.
  Availability of water/fire-fighting facility.
  Local taxes and restrictions.
 Personal factors.
4. Selection of sites:
 Soil, size and topography.
 Disposal of wastes.
  Rural, suburban, city sites.
 Decide optimum sites.
The plant location may be in the: city, village, or
a suburban.
Village site:
  Land is available at cheaper rates.
 The rates and taxes are less.
 Low wages and less labor troubles
Disadvantages of country sites:
  Lack of supply of skill workers.
 Lack of civic amenities.
  Poor transportation.
City Sites
Advantages are:
 Transportation facilities are adequate.
 Civic facilities are available.
 Technical and commercial institution is
available.
 Advertising value is present.
Disadvantages are:
 The cost of land and labor is high.
  Labor unrest is frequent.
 Congestion is prevalent in most of the
factory.
  Several restrictions could be imposed by
government and society.
Suburban Site: They offer a compromise between
the city and village sites.  They have advantages of
both.
LOCATION MODELS (Procedures for evaluation
location alternatives)
Analysis of location alternative should consider
both objective factors such as availability of
proper transport facilities, availability of suitable
labor, tax consideration and subjective factors like
civic amenities, weather conditions, etc.
Factor rating methods.
There are many factors to be considered both
quantitative and qualitative in choosing the
location. Managers use weightings to make the
decisions process.
Eg. A firm has to choose between two locations A
and B..
Point Rating method
Location Break-even analysis.
This is drawn for different location to have
comparison at a glance. Fixed costs, variable
costs, output is calculated
Qualitative Factor Analysis Method
The entrepreneur who is making a choice
between different sites has to consider intangible
factors in additions to costs factors. Intangible
factors which cannot be measured quantitatively
can be expressed as significant, good, and bad.
The total contributions of intangibles for each
location are evaluated.
PLANT LAYOUT
Plant - the arrangement and location of different
departments and of the machinery within a
department so that optimum utilization of space
is achieved.
- the overall arrangement of machines,
men, materials, materials handling and services
facilities and passage required to facilitate
efficient operations of Plant layout involves:
Planning and arranging manufacturing machinery,
equipment, and services for the first time in
completely new plants;
The improvements in layouts already in use in
order to introduce new methods and
improvements in manufacturing procedures.”
   --  Knowles and Thomson
Factors influencing Layout choices:
Layout of a plant is influenced by the relationship
among materials, machines and men.
a)Materials: includes provisions for storage and
handling of raw-materials, supplies and
components used
b) Product: type of product. E.g. light, heavy, big,
small, liquid, influences the plant layout.
c) Workers: the gender of employees, position of
employees, employees facilities such as locker
rooms, canteens etc.
d) Machinery and equipment: type of product,
volume of production, type of process,
management policies, determine the type of
machines and equipment.
f) Location: Type of building influences layout
design, and location determines the mode of
transport of materials.
g) Managerial policies: regarding volume of
production, provisions for future expansion,
extent of automation, speed of declining goods to
customers, inventory policies, personnel policies
influence plant layout.
h) Manufacturing process
i)  Disposable of waste and dangerous gases
PRINCIPLES OF PLANT LAYOUT
While accepting the selected layout the layout
engineers should be guided by certain principles,
the layout selected in confining with layout
principles should be an ideal one.
1.  Principle of minimum travel: men and
materials should travel the shortest distance
between operations.
2.  Principle of sequence: machinery and
operation should be arranged in a sequential
order.
3.  Principle of usage: every unit of available
space should be effectively utilized.
4.  Principle of compactness: There should be
harmonious fusion of all the related factors so
that the final layout looks well integrated and
compact.
5. Principle of safety and satisfaction: Layout
should build in provision for safety for the
workers.
6.  Principle of flexibility: Layout should permit
revisions with least difficulty and at minimum
costs.
7.  Principle of minimum investment: Layout
should result in saving in fixed capital investment.
Importance of Plant Layout
 Economies in Handling:  Long distance
movement should be avoided and specific
handling operations must be eliminated.
  Effective use of available areas
   Minimization of production Delays
  Improved Quality Control
   Minimum Equipment Investment:
  Avoidance of Bottlenecks
   Better Production Control
   Better Supervision
   Improved Utilization of Labor
    Improved employee Morale
   Avoidance of Unnecessary and costly
changes
TYPES OF PLANT LAYOUT
The methods of grouping of Layout are:
✓Process layout/functional/job shop layout
- Also known as "Functional Layout"
- Process layouts are facility configurations in
which operations of a similar nature or function
are grouped together.
ADVANTAGES:
 Best use of specialization of   machines &
employees
 Flexible – variety of products
 General purpose machines – less costly
 Ability to follow diverse paths
 Less vulnerable to shutdowns
 Machine breakdown less of problem
 Small batch product economy
 Suitable for incentive pay
DISADVANTAGES:
  General purpose machines slower
   Work routing, scheduling difficult
 Material handling costs high
 Material moves slowly
 Partially finished inventory high – large
storage space
 Communication difficult
 Some limit to size of parts
✓ Product layout/straight line processing/flow-
line layout
- Also called " Special Purpose Machine" or "Line
Layout".
- It involves arrangement of machinery in one line,
depending upon the sequence of operations.
ADVANTAGES
 Best for products made in large quantities
  Low cost per unit
 Low storage & inventory
 Simplified training of new workers
 Fewer personnel
 It facilities better production control.
 Work-in-progress is reduced. An automatic
material handling is quite common, materials
handling costs is less
DISADVANTAGES:
 Large initial investment
  Vulnerable to stoppage
 Inflexible – new designs not introduced
  Parts must fit exact – no   rework along line
   Not suitable for incentive pay
 Absenteeism hard to handle
 All stations must take same time
✓ Fixed position/static layout
- The movement of men & machines to the
product which remains stationary.The job is
stationary as it is heavy.
- The movement of men, materials is available
because the cost of moving the job is heavy. It is
used when product is large
ADVANTAGES:
1. Men and machines can be used for a wide
variety of operations.
2. Investment on layout is small.
DISADVANTAGES:
1. Costly and high precisions tooling involved.
2.  Skilled labor is required.
✓ Combination / hybrid layout
- Combine elements of both product & process
layouts. - Also called hybrid layouts or  group
technology layout
Features of Good layout
   Smooth flow of production.
 Maximum utilizations of available spare.
 Minimum materials handling.
 Smooth movement of men, materials,
machines from place to place.
 Good working conditions-lighting,
ventilations, temperature, humidity.
 Flexibility for change of layout: Expansion,
change in production design.
 Proper location of storage areas, shipping
department, inspection.
 Facilities supervision and control.
 Provision for safety and reduction of provided for the process involved, and artificially
accidents. attractive and of such standard shape and design
which is flexible  its use and expansive units
RECENT TRENDS IN LAYOUT construction.
Plant layout is the art and science of bringing to
gather men, materials, methods and supporting Symptoms Of Poor Layout
facilities in the form of a given arrangements that A good layout results in
suits individuals industrial activity to have the  Comfort,
benefits of profits maximizations through  Convenience.
economy, efficiency, effectiveness and  Safety,
productivity.  Efficiency.
 Compactness and
The process of preparing layout is an art and well  Finally in profits to the organization.
as science. The recent trends in layout are as
follow: A poor layout results in
The use of computerized facilities design  Congestion.
The various techniques have been developed and  Wastes.
used in layout engineering such as:  Frustration,
 ALDEP (Automated layout design program)  Inefficiency and
 CORELAP (Computerized relationship layout  Finally lower profit or loss to an
planning) Organization.
 CRAFT (computerized related allocation of
facilities technique),  Factors in designing a Factory:
 CALP (computer Aided layout planning) etc.  Adaptability
  Expandability.
The use of various tools and techniques for  Product and equipment
planning the layout.  Employees facilities and services areas
The commonly used technique is use are  Materials handling
templates, model equipments, layout drawing etc.  Lighting, ventilation and air-conditioning.
 Templates: Is pattern which consists of thin  Fire protection.
plate of wood or metal which serves as  Security and services and maintenance.
gauge or guide in mechanical work.
  Model equipment: Model or three Types of Building:  
dimensional models represents machinery The decision on choosing a suitable type for a
installed in a factory. It is a replica or a particular firm depends among other things on
miniature prototype of machine and the manufacturing process, the area of land, and
equipment. the cost of construction.
  Layout drawing: Layout drawings are the The industrial building can be grouped under four
replica of a factory floor plan showing the types:
space management. It is blue print which  Single storey building - the reduced cost of
indicates the total square feet where all the land and extensive transport facilities have
equipment has to be arranged. encouraged single storey buildings in sub-
   Plot plan: Is a miniature of the entire urban areas.
factory building including the facilities of  High bay and monitor types- It is a single
workers. storey structures with roof trusses
 Line balance: is phase of assembly line study surrounded by a monitor, giving maximum
that equally divides then works to be done overhead space.
among workers so that the total number of  Multi-storey building- In big cities costs of
employees required is minimum land is high and has no much scope of
horizontal expansion which has given ways
FACTORY BUILDING to multi-storey.
A ideal plant building is the one which is built to   Special building- are needed for certain
house the most efficient layout that can be manufacturing processes.  Eg the aircraft
 industry needs a building with spans 300 to The light is provided uniformly over the whole
500 feet in length department in a sufficient intensity to satisfy the
requirement of the general manufacturing
conditions within it.
FACILITIES PLANNING: There are three types
PLANT UTILITIES of general lighting.
Plant utilities refer to such services as lighting, 1. Direct lighting. 
ventilation, air-conditioning etc. All these deserve 2. Indirect lighting
due consideration from operations management 3. Semi-direct lighting.
as they contribute to increased efficiency and
greater output. B. Supplementary lighting. involves the provision
of intense light at the point of work or in adjacent
The types of plant facilities and services are as areas to suit the worker particular requirement.
follow:
1.      Plant Lighting Types of light sources:
2.      Ventilation
3.      Air-conditioning 1.      Filament or incandescent lamps.
4.      Industrial Sanitation 2.      Discharge lamps or fluorescent lamps.
5.      Noise control 3.      Electro-luminescent lamps, mercury vapour
6.      Industrial safety lamps.
 
Plant lighting: C. Modification of both.
Adequate lighting is necessary for a worker to
perform his job with ease and accuracy. According Contrast of Natural Lighting and
to all India General Standards a minimum of 14 to Artificial lighting:
18 lumens of illuminations is considered
adequate. Factor     
1. Cost 
Importance of Good illumination: 2. Dependability         
 Ease of seeing./reduced eye strain, 3. Maintenance
 Improved quality of work. 4. Health   
  Better utilization of floor space. 5. Distribution
  Good housekeeping. 6. Control   
  Fewer accidents. Natural                                 
 Improved employee morale/ better 1) Inexpensive  
supervision. 2) Less dependable 
 Flexible layout. 3) Of windows and glasses
4) Good and harmless
Sources of lighting: 5) Special efforts are needed
There are two major source of lighting: 6) Very less  
     Day light. Artificial
It is natural lighting which is received from the sun 1. Expensive  
through apertures in the building. 2. Dependable
Bowstring type 3. More maintenance
Saw tooth 4. Bulbs produce heat, glare
Glass blocks 5. Even distribution
6. Intensity can be controlled.
 Artificial lighting.
Lights refers to illumination secured through Ventilation
artificial means as bulbs and tubes. “Ventilation is concerned largely with engineering
Type of Artificial Lights techniques for controlling air currents within the
A. General lighting plant and for introducing outdoor air in a pattern
and on a scale that is just adequate to maintain
satisfactory air purity”
The importance of ventilation can be highlighted
as it meets requirements of
1.      Protection of the health of workers.   Impairs the hearing of employees.
2.      Preservation of quality of the product
3.      Meets legal requirement.
Types of ventilation:
General ventilation: is introduced to serve
 To keep the working conditions at acceptable
comforts level.
  To keep contaminants in the air within safe
limits.
General exhaust ventilation: is a system for
preventing the contamination of factory air by
withdrawing the contaminant at its source into a
duct system for discharge to the building exterior.
Sources of ventilation:
·         Natural ventilation
·         Mechanical ventilation
Air-conditioning:  Industrial air-conditioning is
requires control over temperatures, humidity,
dust, motion, purity and odors.
Objectives of air-conditioning:
 To protect worker’s health.
 To improve workers comfort level.
  To secure specified temperature conditions.
 To improve the quality of products.
  Product preservations.
  To reduce maintenance charges.
  To improve employer-employee relations
Industrial Sanitation: Sanitation refers to control
of the spread of infection and other insults to the
health of the employees.  Occupational disease
caused by the industrial process leads to
employee’s dissatisfaction and turnover.
Elements of sanitation:
1.      Supply of portable water.
2.      Disposal of waste and effluents.
3.      Provision of food which is free from
contamination.
4.      Elimination of insects and rodents.
5.      Provision of personal services.
6.      Good housekeeping.
Noise control:  performance in the working areas they
Noise is unwanted and unpleasant sound.
Vibration is accomplice of noise in the crime
against men and matter
Importance of noise control:
 Results in fatigue and nervousness.
 Vibration causes damage to machinery and
equipment's.
 Bad working environment
Noise control methods:
  Control at source.
 Control by enclosures.
 Control by absorptions.
 Control by ear protection.
Safety: Safety is freedom from occurrence or risk
of injury or loss. Industrial safety refers to
protection of the workers from the dangers of
industrial accidents.
Principles of safety programme:
An organization may be accident free, when it
adopts a safety programme for safety
management. Industrial safety signifies all those
measures to safeguard and protect the property
and personnel of a factory against the possible
theft; sabotage and other losses may be monetary
or non-monetary.
 
Significance of Industrial safety
 Prevention of personal injuries and deaths.
 A sound safety work works on reducing
production or operating in costs.
 Building up the employee morale.
 Building public-relations.
 Improvement in efficiency.
 Promote public safety.
 
Micheal Armstrong provides
five basic principles that must govern the
safety programme:
 Tracing out the factors responsible for
industrial accidents.
   Identify potential hazards, provide effective
safety facilities and equipment and to take
prompt remedial actions.
 The management and the supervision must
be made fully accountable for safety
control.
 Top management commitment in
determining policy, monitoring and taking
remedial actions.

 Create awareness among employees about

safety methods.