PLANT LAYOUT

THE PLANT
Refers to the physical components of the
manufacturing process of the product

Required both in terms of buildings and

equipments

Accounts for the bulk of the fixed assets of

the organization
 THE LAYOUT
‘Layout’ refers to the physical disposition of
the plant and various parts of the plant.

Plant Layout is very important in a production

manager’s responsibility since it is very
difficult and uneconomical to relocate the
plant once it is put in place.
 THE PLANT LAYOUT

“Planning and arranging manufacturing

machinery, equipments 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 procedure.
 THE PLANT LAYOUT
Refers to the arrangement of machinery,
equipments and other manufacturing facilities.
For the purpose of achieving the quickest and
smoothest production at the least cost.
 How to prepare a layout?
Information required
 Type and quantity of labour.
 Dimensional plan of the space to be laid out.
 The volume of work to be produced from the space.
 The operations to be undertaken, their descriptions, sequence and
standard times.
 The equipments needed to carry out the operations.
 The number of movements of material from one work centre to another
during a representative working period.
 The volume of main stores and finished part stores required.
 What lines of consumption and fire exists are required.
 What special requirements are imposed by the local authority or by the
company’s insurer.
 What special inspection requirement exist.
 What special geographical requirements must be met.
 If any spare plant will need to be stored in the space under consideration.
SUGGESTED PROCEDURES
 Prepare model
 Study operations sequence
 Choose ‘key’ operations
 Locate ‘key’ operations in plant
 Locate main gangways
 Locate remaining work areas
 Locate minor gangways
 Plan individual areas in detail
 Locate subsidiary equipment
 Test completed layout against principles of good layout
 Verify layout on floor
 Check against company policy
OBJECTIVES OF PLANT LAYOUT
Economies of handling
Effective use of available area
Minimization of production delays
Improved quality control
Minimum equipment investment
Avoidance of bottlenecks
Better supervision
Improved utilization of labour
Improved employee morale
Avoidance of unnecessary and costly changes
FEATURES OF A GOOD PLANT LAYOUT
Maximum Flexibility
Maximum Co-ordination
Maximum use of Volume
Maximum Visibility
Maximum Accessibility
Maximum Security
FEATURES OF A GOOD PLANT LAYOUT
Maximum Flexibility
Maximum Co-ordination
Maximum use of Volume
Maximum Visibility
Maximum Accessibility
Maximum Security
FEATURES OF A GOOD PLANT LAYOUT
Maximum Flexibility
Maximum Co-ordination
Maximum use of Volume
Maximum Visibility
Maximum Accessibility
Maximum Security
FEATURES OF A GOOD PLANT LAYOUT
Maximum Flexibility
Maximum Co-ordination
Maximum use of Volume
Maximum Visibility
Maximum Accessibility
Maximum Security
FEATURES OF A GOOD PLANT LAYOUT
Maximum Flexibility
Maximum Co-ordination
Maximum use of Volume
Maximum Visibility
Maximum Accessibility
Maximum Security
FEATURES OF A GOOD PLANT LAYOUT
Maximum Flexibility
Maximum Co-ordination
Maximum use of Volume
Maximum Visibility
Maximum Accessibility
Maximum Security
FEATURES OF A GOOD PLANT LAYOUT
Minimum Distance
Minimum Handling
Minimum Discomfort
Inherent Safety
Unidirectional Flow
Visible Routes
Identification
FEATURES OF A GOOD PLANT LAYOUT
Minimum Distance
Minimum Handling
Minimum Discomfort
Inherent Safety
Unidirectional Flow
Visible Routes
Identification
FEATURES OF A GOOD PLANT LAYOUT
Minimum Distance
Minimum Handling
Minimum Discomfort
Inherent Safety
Unidirectional Flow
Visible Routes
Identification
FEATURES OF A GOOD PLANT LAYOUT
Minimum Distance
Minimum Handling
Minimum Discomfort
Inherent Safety
Unidirectional Flow
Visible Routes
Identification
FEATURES OF A GOOD PLANT LAYOUT
Minimum Distance
Minimum Handling
Minimum Discomfort
Inherent Safety
Unidirectional Flow
Visible Routes
Identification
FEATURES OF A GOOD PLANT LAYOUT
Minimum Distance
Minimum Handling
Minimum Discomfort
Inherent Safety
Unidirectional Flow
Visible Routes
Identification
FEATURES OF A GOOD PLANT LAYOUT
Minimum Distance
Minimum Handling
Minimum Discomfort
Inherent Safety
Unidirectional Flow
Visible Routes
Identification
PRINCIPLES OF A GOOD PLANT LAYOUT
The Principle of Minimum Travel
The Principle of Sequence

The Principle of Compactness

The Principle of Usage

The Principle of Safety & Satisfaction

The Principle of Flexibility

The Principle of Minimum Investment

PRINCIPLES OF A GOOD PLANT LAYOUT
The Principle of Minimum Travel
The Principle of Sequence

The Principle of Compactness

The Principle of Usage

The Principle of Safety & Satisfaction

The Principle of Flexibility

The Principle of Minimum Investment

PRINCIPLES OF A GOOD PLANT LAYOUT
The Principle of Minimum Travel
The Principle of Sequence

The Principle of Compactness

The Principle of Usage

The Principle of Safety & Satisfaction

The Principle of Flexibility

The Principle of Minimum Investment

PRINCIPLES OF A GOOD PLANT LAYOUT
The Principle of Minimum Travel
The Principle of Sequence

The Principle of Compactness

The Principle of Usage

The Principle of Safety & Satisfaction

The Principle of Flexibility

The Principle of Minimum Investment

PRINCIPLES OF A GOOD PLANT LAYOUT
The Principle of Minimum Travel
The Principle of Sequence

The Principle of Compactness

The Principle of Usage

The Principle of Safety & Satisfaction

The Principle of Flexibility

The Principle of Minimum Investment

PRINCIPLES OF A GOOD PLANT LAYOUT
The Principle of Minimum Travel
The Principle of Sequence

The Principle of Compactness

The Principle of Usage

The Principle of Safety & Satisfaction

The Principle of Flexibility

The Principle of Minimum Investment

PRINCIPLES OF A GOOD PLANT LAYOUT
The Principle of Minimum Travel
The Principle of Sequence

The Principle of Compactness

The Principle of Usage

The Principle of Safety & Satisfaction

The Principle of Flexibility

The Principle of Minimum Investment

 TYPES OF PLANT LAYOUT
PLANT LAYOUT

PROCESS LAYOUT

FIXED POSITION
PRODUCT LAYOUT
LAYOUT
 TYPES OF PLANT LAYOUT
PLANT LAYOUT

PROCESS LAYOUT

FIXED POSITION
PRODUCT LAYOUT
LAYOUT
TYPES OF PLANT LAYOUT
PLANT LAYOUT

PROCESS LAYOUT

FIXED POSITION
PRODUCT LAYOUT
LAYOUT
TYPES OF PLANT LAYOUT
PLANT LAYOUT

PROCESS LAYOUT

FIXED POSITION
PRODUCT LAYOUT
LAYOUT
 TYPES OF PLANT LAYOUT
PLANT LAYOUT

PROCESS LAYOUT

FIXED POSITION
PRODUCT LAYOUT
LAYOUT
 PRODUCT LAYOUT
RECEIVING RAW PACKING AND SHIPPING
MATERIALS
STORAGE FINISHED GOODS STORAGE

WC1 WC2 WC3 TEST

 PRODUCT LAYOUT
RECEIVING RAW PACKING AND SHIPPING
MATERIALS
STORAGE FINISHED GOODS STORAGE

WC1 WC2 WC3 TEST

 PRODUCT LAYOUT
RECEIVING RAW PACKING AND SHIPPING
MATERIALS
STORAGE FINISHED GOODS STORAGE

WC1 WC2 WC3 TEST

 PRODUCT LAYOUT
RECEIVING RAW PACKING AND SHIPPING
MATERIALS
STORAGE FINISHED GOODS STORAGE

WC1 WC2 WC3 TEST

 PRODUCT LAYOUT
RECEIVING RAW PACKING AND SHIPPING
MATERIALS
STORAGE FINISHED GOODS STORAGE

WC1 WC2 WC3 TEST

 PRODUCT LAYOUT
RECEIVING RAW PACKING AND SHIPPING
MATERIALS
STORAGE FINISHED GOODS STORAGE

WC1 WC2 WC3 TEST

 PRODUCT LAYOUT
RECEIVING RAW PACKING AND SHIPPING
MATERIALS
STORAGE FINISHED GOODS STORAGE

WC1 WC2 WC3 TEST

 PRODUCT LAYOUT
RECEIVING RAW PACKING AND SHIPPING
MATERIALS
STORAGE FINISHED GOODS STORAGE

WC1 WC2 WC3 TEST

PRODUCT LAYOUT
 PRODUCT LAYOUT
SEQUENTIAL
 PRODUCT LAYOUT
SEQUENTIAL
USED ESPECIALLY FOR ASEMBLING
OPERATIONS
 PRODUCT LAYOUT
SEQUENTIAL
USED ESPECIALLY FOR ASEMBLING
OPERATIONS
MORE EQUIPMENTS REQUIRED
 PRODUCT LAYOUT
SEQUENTIAL
USED ESPECIALLY FOR ASEMBLING
OPERATIONS
MORE EQUIPMENTS REQUIRED
ALSO CALLED “LINE LAYOUT”
 PRODUCT LAYOUT
SEQUENTIAL
USED ESPECIALLY FOR ASEMBLING
OPERATIONS
MORE EQUIPMENTS REQUIRED
ALSO CALLED LINE LAYOUT
CATERS ONLY TO ONE PRODUCT
 PROCESS LAYOUT
PLANNERS AUTOMATIC GRINDERS
INWARD S
GOODS STORED CENTRAL
INSPECTION
AREA
MILLING HEAT
MACHINES TREATMENT

RAW MATERIAL DRILLING ELECTROPL

STORED SHOPS ATING ASSEMBLY
SHOPS
TURNING SHOPS PAINTIING FINISHED
GOODS
PROCESS LAYOUT
EQUIPMENTS PERFORMING SIMILAR
OPERATIONS GROUPED TOGETHER
PREFERRED WHEN VOLUME IS LOW,
VARIETY IS HIGH
JOB-SHOP TYPE OF PRODUCTION
FLEXIBILITY IN SEQUENCE OF
OPERATIONS
FIXED POSITION LAYOUT
FIXED POSITION LAYOUT
Material remains in a fixed position
FIXED POSITION LAYOUT
Material remains in a fixed position
Preferred when equipment, and
machinery are small in no. and workers
skilled
COMPARISON OF PRODUCT AND
PROCESS LAYOUT
COMPARISON OF PRODUCT AND
PROCESS LAYOUT
Characteristics Product Process
Layout Layout
1. Mechanizations of Materials 
Handling
2. Avoidance of Bottlenecks
3. Economy in Manufacturing Time
4. Minimization of Investment in
Work in-process
5. Better Production control
6. Early Detection of bad
workmanship
7. Greater incentive to a group of
workers
COMPARISON OF PRODUCT AND
PROCESS LAYOUT
Characteristics Product Process
Layout Layout
1. Mechanizations of Materials 
Handling

2. Avoidance of Bottlenecks
3. Economy in Manufacturing Time
4. Minimization of Investment in
Work in-process
5. Better Production control
6. Early Detection of bad
workmanship
7. Greater incentive to a group of
workers
COMPARISON OF PRODUCT AND
PROCESS LAYOUT
Characteristics Product Process
Layout Layout
1. Mechanizations of Materials 
Handling

2. Avoidance of Bottlenecks
3. Economy in Manufacturing Time 
4. Minimization of Investment in
Work in-process
5. Better Production control
6. Early Detection of bad
workmanship
7. Greater incentive to a group of
workers
COMPARISON OF PRODUCT AND
PROCESS LAYOUT
Characteristics Product Process
Layout Layout
1. Mechanizations of Materials 
Handling

2. Avoidance of Bottlenecks
3. Economy in Manufacturing Time 
4. Minimization of Investment in 
Work in-process
5. Better Production control
6. Early Detection of bad
workmanship
7. Greater incentive to a group of
workers
COMPARISON OF PRODUCT AND
PROCESS LAYOUT
Characteristics Product Process
Layout Layout
1. Mechanizations of Materials 
Handling

2. Avoidance of Bottlenecks
3. Economy in Manufacturing Time 
4. Minimization of Investment in 
Work in-process
5. Better Production control 
6. Early Detection of bad
workmanship
7. Greater incentive to a group of
workers
COMPARISON OF PRODUCT AND
PROCESS LAYOUT
Characteristics Product Process
Layout Layout
1. Mechanizations of Materials 
Handling

2. Avoidance of Bottlenecks
3. Economy in Manufacturing Time 
4. Minimization of Investment in 
Work in-process
5. Better Production control 
6. Early Detection of bad 
workmanship
7. Greater incentive to a group of
workers
COMPARISON OF PRODUCT AND
PROCESS LAYOUT
Characteristics Product Process
Layout Layout
1. Mechanizations of Materials 
Handling

2. Avoidance of Bottlenecks
3. Economy in Manufacturing Time 
4. Minimization of Investment in 
Work in-process
5. Better Production control 
6. Early Detection of bad 
workmanship
7. Greater incentive to a group of 
workers
COMPARISON OF PRODUCT AND
PROCESS LAYOUT
Characteristics Product Process
Layout Layout
8. Reduced investment on 
machines
9. Flexibility in production
10. Scope for expansion
11. Handling of breakdowns is easy
12. Greater incentive to individual
workers
13. Better utilization of workers and
equipment
14. Specialization in supervision
COMPARISON OF PRODUCT AND
PROCESS LAYOUT
Characteristics Product Process
Layout Layout
8. Reduced investment on 
machines 
9. Flexibility in production
10. Scope for expansion
11. Handling of breakdowns is easy
12. Greater incentive to individual
workers
13. Better utilization of workers and
equipment
14. Specialization in supervision
COMPARISON OF PRODUCT AND
PROCESS LAYOUT
Characteristics Product Process
Layout Layout
8. Reduced investment on 
machines 
9. Flexibility in production

10. Scope for expansion
11. Handling of breakdowns is easy
12. Greater incentive to individual
workers
13. Better utilization of workers and
equipment
14. Specialization in supervision
COMPARISON OF PRODUCT AND
PROCESS LAYOUT
Characteristics Product Process
Layout Layout
8. Reduced investment on 
machines 
9. Flexibility in production

10. Scope for expansion
11. Handling of breakdowns is easy 
12. Greater incentive to individual
workers
13. Better utilization of workers and
equipment
14. Specialization in supervision
COMPARISON OF PRODUCT AND
PROCESS LAYOUT
Characteristics Product Process
Layout Layout
8. Reduced investment on 
machines 
9. Flexibility in production

10. Scope for expansion
11. Handling of breakdowns is easy 
12. Greater incentive to individual 
workers
13. Better utilization of workers and
equipment
14. Specialization in supervision
COMPARISON OF PRODUCT AND
PROCESS LAYOUT
Characteristics Product Process
Layout Layout
8. Reduced investment on 
machines 
9. Flexibility in production

10. Scope for expansion
11. Handling of breakdowns is easy 
12. Greater incentive to individual 
workers

13. Better utilization of workers and
equipment
14. Specialization in supervision
COMPARISON OF PRODUCT AND
PROCESS LAYOUT
Characteristics Product Process
Layout Layout
8. Reduced investment on 
machines 
9. Flexibility in production

10. Scope for expansion
11. Handling of breakdowns is easy 
12. Greater incentive to individual 
workers

13. Better utilization of workers and
equipment 
14. Specialization in supervision
 CIRCUMSTANCES WHEN PRODUCT
AND PROCESS LAYOUT CAN BE USED
Product Layout Process Layout
1. One or few “Standard” 1. Many types of products
products or emphasis on special
orders
2. Large volume of 2. Relatively low volume
production of production

3. Minimum inspection 3. More inspection

required required during an
operation
 CIRCUMSTANCES WHEN PRODUCT
AND PROCESS LAYOUT CAN BE USED
Product Layout
4. Materials and products 4.
permit bulk or
continuous handling by
mechanical means
5. Little or no occasion to 5.
use the same machine
or work station for more
than one operation
Process Layout
Materials and products
too bulky to permit bulk
or continuous handling
by mechanical means
Frequent need for using
the same machine or
work machine for two or
more different
operations
ADVANTAGES OF A PROCESS LAYOUT

Reduced investment on machines

Greater production facility
Specialization
Greater scope for expansion
Better utilization of men and machines
Easy handling of breakdown of equipment
Full utilization of equipment
Low investment as compared to Product Layout
DISADVANTAGES OF PROCESS LAYOUT

Difficulty in movement of materials

Requires more floor space
Difficulty in production control
More production time
Accumulation of work-in-progress
ADVANTAGES OF PRODUCT LAYOUT
Mechanization of materials handling
Avoids production bottlenecks
Economy in manufacturing time
Facilitation of better production control
Less floor per unit area of production
Reduction in materials handling cost
Reduced work-in-progress and investment
Early detection of mistakes or badly produced
items
DISADVANTAGES OF PRODUCT LAYOUT

Known for it’s inflexibility

Expansion of facilities is difficult

Breakdown of equipment can disrupt

the system