FOOD PLANT

LAYOUT &
DESIGN

FD-411

LECTURE 9
 PLANT LAYOUT
• Objective of Layout Strategy
• Strategic Importance of Layout decision
• Plant Layout Definition
• Objective & Advantage of Plant Layout
• Types of Plant layout Problems
• Basic Flow patterns of Plant Layout
• Types of Plant Layout
• Plant layout Factors
• Layout Design Procedure
• General Guidance for Plant Layout
 Objective of Layout Strategy

• The Objective of Layout Strategy is to develop an effective and

efficient layout that will meet the firm’s competitive requirement
Strategic Importance of Layout decision
• Layout is one of the key decisions that determines
the long-run efficiency of operations.
• Layout has numerous strategic implications
because it establishes an organization’s competitive
priorities in regard to capacity, processes ,
flexibility and cost as well as the quality of work
life, customer contact and image.
Strategic Importance of Layout decision
In all Cases, Layout design must consider how to achieve
the following :
• Higher Utilization of space, equipment and people
• Improved flow of information, materials or people
• Improved employee morale and safer working
conditions
• Improved customer/Client interaction
• Flexibility (Whatever the layout is now, it will need to
change).
 Plant Layout Definition
• Plant Layout refers to an optimum arrangement of different facilities
including human resource, plant and machinery, material etc
• Plant layout is a strategic decision
• It is crucial function that has to be performed both at the time of initial
design of any facility and during its growth, development and
diversification
• The problem of plant layout should be seen in relation to overall plant
design which includes many other functions such as product design,
sales planning, selection of the production process, plant size, plant
location, building etc.
 Objective & Advantage of Plant Layout
Some of the important objectives of a good plant layout are as follows:
• Overall Simplification of production process
• Overall integration of man, materials, machinery, supporting activities
and any other considerations.
• Minimization of material handling cost
• Saving in floor space
• Increases output and reduced in-process inventories
• Worker convenience
• Better working environment
• Minimization of waste
• Higher flexibility and adaptability
 Plant Layout
The Layout problem occurs because of many developments including.
• Change in product design
• Introduction of new product
• Changes in demand
• Market changes
• Competitive cost reduction
• Frequent accidents
• Adoption of new safety standards
• Decision to build a new plant
 Plant Layout
• Plant Layout problem is defined by Moore (1962) as
follows:

Plant Layout is a plan of or the act of planning, an optimum

arrangement of facilities, including personnel, operating
equipment, storage space, materials handling equipment,
and all other supporting services, along with the design of
the best structure to contain these facilities
 Types of Plant layout Problems
The plant Layout problems can be classified into four types
as follows:

• Planning completely new facility

• Expanding or relocating an existing layout
• Rearrangement of existing layout
• Minor modification in present layout
 Basic Flow patterns of Plant Layout
The Basic types of flow patterns that are employed in
designing the layout are
• I –Flow
• L- Flow
• U- Flow
• S Flow
• O- Flow
 I –Flow
• I Flow Separate receiving and shipping area.

Simple form of arrangement when we have

horizontal space available in it reviving
area is separated from raw material flow
 L–Flow
• L – Flow: When Straight line flow chart is to be accommodated

Space availability is
less or it’s square type
 U–Flow
• U Flow very Popular as a combination of receiving and dispatch.

It’s very popular Bec process length is more

and space is less so we can bend by u shape o
shape or s shape in o Flow the difference
between two lines is less as compared to u
Flow o Flow is not preferred in industries
 S–Flow
• S- Flow: when the production line is long.
 O–Flow
• O – Flow when it is desired to terminate the flow where it is
originated