PLANT LAYOUT- (Telsang)

DEFINITION

Plant layout refers to the physical arrangement of production facilities. It is the configuration of
departments, work centres and equipment in the conversion process.

According to Moore "Plant layout is a plan of an optimum arrangement of facilities including

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

The overall objective of plant layout is to design a physical arrangement that meets the required
output quality and quantity most economically.

2. Need of PLANT LAYOUT

The need for the plant layout change arise because of the following reasons:

1. Changes in the product design or introduction of the new product.

2. Changes in the volume of demand for the company's product.

3. Increasing frequency of accidents because of existing layout.

4. Plant and machinery becomes outdated and is to be replaced by new one. 5. Poor working
environment affecting worker efficiency and productivity.

6. Change in the location or markets.

7. Minimising the cost through effective facilities location.

3. OBJECTIVES OF PLANT LAYOUT

The primary goal of the plant layout is to maximise the profit by arrangement of all the plant
facilities to the best advantage total manufacturing of the product.

The objectives of plant layout are:

1. Streamlined the flow of materials through the plant.

2. Facilitate the manufacturing process.
3. Maintain high turnover of in process inventory
4. Minimise materials handling.
5. Effective utilisation of men. Equipment and space.
6. Make effective utilisation of cubic space.
7. Flexibility of manufacturing operations and arrangements.
8. Provide for employee convenience, safety and comfort.be

4. PRINCIPLES OF PLANT LAYOUT

1. Principle of integration: A good layout is one that integrates men, materials, machines and
supporting services and others in order to get the optimum utilisation of resources and
maximum effectiveness.

2. Principle of minimum distance: This principle is concerned with the minimum travel (or
movement) of man and materials. The facilities should be arranged such that, the total distance
travelled by the men and materials should be minimum and as far as possible straight line
movement should be preferred.

3. Principle of cubic space utilisation: The good layout is one that utilise both horizontal and
vertical space. It is not only enough if only the floor space is utilised optimally but the third
dimension, i.e., the height is also to be utilised effectively.

4. Principle of flow: A good layout is one that makes the materials to move in forward direction
towards the completion stage, i.e., there should not be any backtracking.

5. Principle of maximum flexibility: The good layout is one that can be altered without much
cost and time, i.e., future requirements should be taken into account while designing the
present layout.

6. Principle of safety and security and satisfaction: A good layout is one that gives due
consideration to workers safety and satisfaction and safeguards the plant and machinery against
fire, theft, etc.

7. Principle of minimum handling: A good layout is one that reduces the material handling to
the minimum.

5. ADVANTAGES OF PLANT LAYOUT

1. Advantages to the worker: A good layout will reduce the effort of the workers and minimises
the manual material handling. It reduces the number of accidents and provide better working
conditions.
2. Advantages to the management: Effective plant layout reduce the labour costs and enhances
the productivity thus ultimately reducing the cost per unit. This helps the management to gain
competitiveness in manufacturing.

3. Advantages to manufacturing: Minimises the movement between work centres and also
results in reduced manufacturing cycle.

4. Advantages to production control: A good layout facilitates production through uniform and
uninterrupted flow of materials and helps to carry out production activities within the
predetermined time period and with effectiveness.

6. FACTORS INFLUENCING PLANT LAYOUT

1. Type of production Engineering industry, process industry.

3. Scale of production.
2. Production system-job shop, batch production, mass production.
4. Availability of the total area.
5. Arrangement of material handling system.
6. Type of building single storey or multi-storey.
7. Future expansion plan.
8. Type of production facilities-dedicated or general purpose.

7. TYPES OF MANUFACTURING SYSTEMS

1. Make to stock production: In this type, the products are manufactured and placed in stock
before the customers order is received. The product is despatched to the customer "Off the
shelf" from finished goods inventory after receipt of customer order.

Examples-Manufactures of standard items like bearings, nut and bolts, etc., produce and keep
the finished goods inventory.

2. Make to order production: Some companies make the product to order and manufactures
the product after receipt of customer order. Here the lead time to deliver the item to the
customer will be more as the production activity starts only after the receipt of firm order.

Types of Production

According to volume and standardisation of the production of the products the manufacturing
systems are classified as:

(a) Job type production,

(b) Batch production, and

(c) Continuous production.

A. Job Type Production

It is characterised by manufacturing of one or few quantities of products designed and

produced as per the specifications of the customers within the prefixed time and cost, i.e., this
type of production is distinguished by high variety and low volume.

Characteristics of Job Type Production

1. High variety and low volume.

2. General purpose machines and equipment to perform wider range of operations.

3. The flow of materials and components different work station is highly discontinuous due to
imbalance in work content.

4. Manufacturing cycle time is more.

5. Highly skilled workforce is required.

6. Highly competent and qualified supervisors are required.

7. Very large work-in-process inventory.

8. Flexible material handling system with a capability to move objects of various sizes and
shapes along widely varying paths.

9. Difficulty in planning, scheduling and coordinating the productions of numerous components

of wide variety.

B. Batch production

Batch production is characterised by manufacture of limited number of products produced at

regular intervals and stocked at warehouses awaiting sales Examples-Pharmaceutical industry,
chemical industry, assembly shops such as machine tools. subcontractors who take component
for processing from large manufacturer.

Characteristics of Batch Production

1. Short production runs.

2. The plant and machineries set up is used for limited number of parts and then it is used to
make different product.

3. More number of set-ups.

4. The workers are expected to possess skill in one particular manufacturing operation.

5. The amount of supervision required is less compared to job type.

6. Plant and machineries are flexible.

7. Manufacturing cycle time is comparatively lower than job production.

8. Large work-in-process inventory.

9. Flexible material handling system.

C. Repetitive Production

This is characterised by high volume and low variety. This manufactures several standard
products produced and stocked in the warehouses as finished goods awaiting to be despatched.
Examples of mass production are plastic goods, manufacture and assembly shops of
automobiles. etc.

Characteristics

1. Flow of material is continuous.

2. Special purpose machines are used.
3. Material handing system is mechanised most of the time by conveyers, etc.
4. Relatively lower skilled persons can manage work.
5. Shorter cycle time.
6. Work-in-process is comparatively low because of line balancing.
7. Higher inventory of raw materials.
8. Less flexibility of equipment and machines.

The types of Manufacturing Systems are shown in Fig. 8.1.

8.8. TYPES OF LAYOUT

1. Functional Layout (Process Layout)

This layout is recommended for batch production. All machines performing similar type of
operations are grouped at one location in the process layout e. g., all lathes, milling machines,
etc.. are grouped in the shop will be clustered in like groups. Thus, in process layout the
arrangement of are grouped together according to their functions

A typical process layout is shown in Fig. 8.2. The flow paths of material through the facilities
from one functional area to another vary from product to product. Usually, the paths are long
and there will be possibility of backtracking. Refer Fig 8.2

Advantages

1. Flexibility of equipment and personnel.

2. Lower investment on account of comparatively a smaller number of machines and lower cost
of general-purpose machines.
3. Higher utilisation of production facilities.
4. Greater flexibility with regards to work distribution to machineries and workers.
5. Variety of job makes the job challenging and interesting.
6. Supervisors will become highly knowledgeable about the functions under their department.

Disadvantages

1. Backtracking and long movements may occur in the handling of materials thus reducing
material handling efficiency.
2. Material handling cannot be mechanised which adds to cost.
3. Process time is prolonged which reduce the inventory turnover and increases the investment
in inventories.
4. Production planning and control is difficult.
5. More space is required.
6. Lowered productivity due to number of set-ups.

2. LINE Layout (Product Layout)

In this type of layout, the machines are arranged in the sequence as required by the product. If
the volume of production of one or more products is large, the facilities can be arranged to
achieve efficient flow of materials and lower cost per unit. Special purpose machines are used
which perform the required function quickly and reliably. The equipment is closely placed along
the sequence in which the item is processed. The Product Type Layout is shown in Fig. 8.3.

Advantages

1. Reduced material handling cost due to mechanised handling systems and straight flow.

2. Perfect line balancing which eliminates bottlenecks and idle capacity. 3. Manufacturing cycle
is short due to uninterrupted flow of materials.

4. Simplified production, planning and control,

5. Small amount of work-in-process inventory.

6. Unskilled workers can learn and manage the production.

Disadvantages

1. Lack of flexibility-A change in product may require the facility modification.

2. Large capital investment.

3. Dedicated or special purpose machines.

4. Dependence of the whole activity on each part. Breakdown of any one machine in the
sequence may result in stoppage of production.

4. Fixed Position Layout (PROJECT LAYOUT)

This is also called the project type of layout.

In this type of layout, the material, or major components remain in a fixed location and tools,
machinery, men and other materials are brought to this location. This type of layout is suitable
when one or few pieces of identical heavy products are to be manufactured and when the
assembly consists of large number of heavy parts, the cost of transportation of these parts is
very high.

Advantages:
1. Helps in job enlargement and upgrades the skills of the operators.
2. The workers identify themselves with a product in which they take interest and pride in doing
the job.
3. Greater flexibility with this type of layout.
4. Layout capital investment is lower.

Comparison between Product and Process Layout

Refer Table 8.1,

8.9. MATERIAL FLOW PATTERNS (refer fig 8.4)

Classified based on availability of floor space

1. Horizontal flow system: Usually devised for a single-story building when the flat floor area is
available.

2. Vertical flow system: This system is used in case of multi-storey buildings and limited area is
available.

Characteristics of different Flow Patterns

(a) Straight line

1. Shortest route and must have roads on both sides.

2. Plant area has long length and narrow width.

3. Unsuitable for longer production lines.

(b) U-type

1. Less difficulty in returning empty containers.

2. Suitable for longer production lines.

4. Requires square like floor area.

5. One side road link will be required.

(c) Serpentine (Inverted S-Shape)

QUESTIONS for TW

1. Define plant layout. What are the objectives of good plant layout?
2. What are the various types of layout? Explain the application of each.
3. Compare product layout and process layout.
4. What are the principles of plant layout?
5. What are the factors that influence the plant layout?

Note – Draw figures where spaces are provided