Design of Production System

Factory Building and

Plant Layout
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 Factory Building and Plant
Layout
 Introduction
 Factors affecting the factory building
 Type of Manufacturing Process
 Plant Location
 Material Handling
 Factory Layout
 Provision of facilities
 Future Expansion
 Safety and Security
 Employee Facilities
 Flexibility 2

 Appearance
Factory Building and Plant
Layout

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 Factory Building and Plant
Layout

 Types of Factory Buildings

 Single Storey or Horizontal Buildings -
Advantages
 Greater flexibility in layout
 Cheaper and efficient material handling
 Efficient supervision
 Facilities Expansion
 Effective utilization of floor space
 Reduced fire hazards
 Use of natural light and ventilation 4
 Factory Building and Plant
Layout

 Disadvantages
 High cost of land
 Non – availability of gravitational flow
 Cost of heating is high

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 Factory Building and Plant
Layout

 Multi- storey building - Advantages

 Use of gravity flow
 Low cost of land
 Lower heating cost
 More storage space
 Compact layout
 Upper stories free from noise
 Safe storage

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 Factory Building and Plant
Layout

 Disadvantages
 High cost of construction
 Wastage of floor space
 Poor natural lighting
 Rigid layout
 High cost of supervision
 Difficulty in material handling
 Low load bearing capacity
 Difficulty in expansion

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 Factory Building and Plant
Layout
 Types of Construction of Factory Building
 Wood frame construction
 Brick Construction
 Steel Construction
 Reinforced Concrete Construction
 Pre-cast concrete Construction

 Specific Parts of Factory Building

 Roof
 Walls
 Floor

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Factory Building and Plant
Layout

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 Factory Building and Plant
Layout
 Plant Layout
 A technique of locating machines, processes and
plant services within the factory in order to secure the
greatest possible output of high quality at the lowest
possible total cost of production.

 Objectives of a good Plant Layout

 A good layout is one which allows materials rapidly
and directly for processing. This reduces transport
handling, clerical and other costs down per unit,
space requirements are minimized and it reduces idle
machine and idle man time.
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 Factory Building and Plant
Layout
 Objectives of a good plant layout
 Integrate the production centers
 Reduce material handling
 Effective utilization of available space
 Worker Convenience and Job satisfaction
 Flexibility
 Removal of bottlenecks
 Quick disposal of work
 Avoids industrial accidents

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 Factory Building and Plant
Layout

 Situation in which layout problem may arise

 When starting a new plant
 Changes in the product design
 Necessity of introducing a new product
 Changes in the volume of production
 Poor Working Conditions
 Frequent accidents
 Changes in the location of industries

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 Factory Building and Plant
Layout
 Factors influencing Plant Layout
 Management Policy
 Manufacturing Process
 Nature of Product
 Volume of Production
 Type of Equipment
 Type of building
 Availability of total floor area
 Arrangement of material handling equipment
 Service facilities
 Possible of future expansion
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 Factory Building and Plant
Layout
 Principles of Plant Layout
 Principle of overall integration
 Principle of minimum movement
 Principle of smooth and continuous flow
 Principle of satisfaction and safety
 Principle of flexibility

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 Factory Building and Plant
Layout
 Techniques used in Plant Layout
 Operation Process Chart
 Flow Process Chart
 Flow Diagrams
 Machine Data Cards
 Templates
 Three Dimensional Models

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Factory Building and Plant
Layout

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 Factory Building and Plant
Layout

 Types of Plant Layout

 Process Layout
 Product Layout
 Combination Layout
 Fixed Position Layout

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Factory Building and Plant
Layout

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Layout

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Factory Building and Plant
Layout

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 Factory Building and Plant
Layout
 Flow Patterns
 Horizontal Flow System
 I – Flow
 L – Flow
 U – Flow
 S – Flow
 O – Flow
 Combination of I and U
 Combination of I and S
 Combination of I and O

 Vertical Flow System

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Layout

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Layout

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Layout

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Layout

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Factory Building and Plant
Layout

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Layout

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 Factory Building and Plant
Layout

References:
Industrial Engineering and Production
Management – M. Mahajan, Dhanpat Rai & Co.,
New Delhi, 2002

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QUESTIONS?
THANK YOU!

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