CHPTER FIVE

Plant Layout and Plant (facility) Design

Contents To Be Covered
1. Basics Of Plant Layout
2. Study of Plant Layout;
3. Ergonomics and
4. Industrial Safety
  Plant Layout
 Plant layout is defined as a plan of, or the act of planning an
optimum arrangement of industrial facilities, including
 Personnel,
 Materials handling equipment
 Operating equipment,  All other supporting services along
 Storage space, with the design of the best structure
to contain these facilities
 Facility: is something created to serve a particular functions
such as:
 Facility can be used when:
to start a new product,  the market demand changes,
to change the product  the plant, the product, the
design, building become obsolete,
to reduce the cost;  accidents occur frequently,
 the working environment is poor.
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 Study of Plant Layout
The objective of plant layout study is to:
Ensure effective space utilization,
Minimize the cost of material handling (internal
transports),
Foresee future developments of the plant
according to a rational master plan,
Improve workers convenience as well as safety,
Create job satisfaction, and
Avoid unnecessary capital investment.
Types of Layout
1. Product Layout
2. Process layout/cellular manufacturing layout
3. Fixed-Position Layout
4. Combination or Hybrid layout
1. Product Layout:
 In this type of layout, only one product or one
type of product is produced in a given area.
 The product must be standardized and
manufactured in large quantities in order to
justify the product layout.
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2. Process Layout
 In this case, Similar equipment and similar
operations are grouped together in the process or
functional layout.
 It is particularly useful where low volume is required.
 3. Fixed-Position Layout
In this type of layout, the material or major
component remains in a fixed location, and
tools, machinery, men as well as other pieces of
material are brought to this location.
Typical examples are ship building,
construction industries, aircraft building and
bench work exercises.
This type of layout is not frequently used in
industrial enterprises. For this reason we are
not going to look into its advantage and
disadvantages.
Cellular manufacturing layout
  Ergonomics
 It is Derived from two Greek words:
 Ergo” meaning work “Nomoics” meaning natural laws
 Ergonomics is a science concerned with the design of
workplaces, tools, and tasks that match the
physiological, anatomical, and psychological
characteristics and capabilities of the worker.
 The Goal of ergonomics is to ‘fit the job to the person,’
rather than making the person fit the job.”
 “If it hurts when you are doing something, don’t do it.”
 Ergonomics makes the job safer by preventing injury
and illness, Makes the job easier by adjusting the job to
the worker, Makes the job more pleasant by reducing
physical and mental stress and Saves money.
Ergonomic Factors
 There are Two Categories of Ergonomic Factors
1. Environmental 2. Physical
1. Environmental factors : may affect:
Hearing, Vision, General comfort and health
Some examples of ergonomic environmental
problems that affect the work area are:
– Sick Building Syndrome
– Excessive noise
– Improper lighting
– Temperature extremes
 2. Physical factors:
 Are physical stressors that place pressure or stress on parts of the
body such as on a Joints, muscles, nerves, tendons, bones.
 Sometimes these injuries are referred to as “Cumulative Trauma
Disorders” (CTDs) or “Repetitive Strain Injuries” (RSIs)
 Cumulative = occurring gradually over a period of weeks,
months, or years
 Trauma = bodily injury to nerves, tissues, tendons, or joints
 Disorders = physical ailments or abnormal conditions
 Examples of Cumulative Trauma Disorders include:
 Carpal Tunnel Syndrome
 Epicondylitis
 Tenosynovitis
 Bursitis
  Three Main Ergonomic Principles
1. Work activities should permit worker to adopt
several different healthy and safe postures.
2. Muscle forces should be done by the largest
appropriate muscle groups available
3. Work activities should be performed with
joints at about mid-point of their (esp. head,
trunk,)
  Industrial Safety
• Industry; is the place where raw materials and customer
demand are accepted as well as goods and services produced,
shipped or hand over to the customer.
• Safety ; the condition of being protected from or unlikely to
cause danger, risk, or injury or denoting something designed to
prevent injury or damager: a safety barrier a safety helmet
• “Safety is the state of being “safe” (from French sauf), the
condition of being protected against physical, social, spiritual,
financial, political, emotional, occupational, psychological,
educational or other types or consequences of failure, damage,
error, accidents, harm or any other event which could be
considered non-desirable. Safety can also be defined to be the
control of recognized hazards to achieve an acceptable level of
risk. This can take the form of being protected from the event or
from exposure to something that causes health or economical
 Safety
 Safety means keeping yourself and others free from
harm or dangerous hazards.
 It means taking care from any injury and accident.
 It also means to avoid accidents by being careful with
what you are doing.
 Keeping safety is different according different
professions the way of keeping safety in hospital is
different from safety that takes care in industry.
Industrial hazards:
It can be defined as any condition produced by
industries that may cause injury or death to
personal or loss of product or property.
 Physical

Pollution Chemical

HAZARDS

Electrical Biological

Mechanical
 Industrial safety
 Is keeping the working place or the
company from any industrial hazards
that may cause injury or death to
personal or loss of product or property.
 That is taking any preventive action
before the hazards are occur and taking
decisive corrective action unfortunately if
the accident is happen.