PLANT LAYOUT

Presented by
•Rahul Chakraborty
•Sourabh Banargee
•Partha Chatterjee
•Debadrita Dey
•Debashree Chatterjee
 Definition
Plant layout refers to the arrangement of
physical facilities such as machines,
equipment, tools, furniture etc. in such a
manner so as to have quickest flow of
material at the lowest cost and with the least
amount of handling in processing the
product from the receipt of raw material to
the delivery of the final product.
Objectives Of Good Plant Layout
 Proper and efficient utilization of available floor space
 Transportation of work from one point to another point without any
delay
 Proper utilization of production capacity
 Reduce material handling costs
 Utilize labour efficiently
 Reduce accidents
 Provide for volume and product flexibility
 Provide ease of supervision and control
 Provide for employee safety and health
 Allow easy maintenance of machines and plant.
 Improve productivity
 Types Of Layout
Product or line layout
Process or functional layout
Fixed position or location layout
Combined or group layout
Cellular layout
Product Or Line Layout
In this type of layout the machines and
equipments are arranged in one line depending
upon the sequence of operations required for the
product. It is also called as line layout. The
material moves one machine to another machine
sequentially without any backtracking or deviation
i.e. the output of one machine becomes input of
the next machine. It requires a very little material
handling. It is used for mass production of
standardized products.
Advantages of Product layout
Low cost of material handling, due to straight and
short route and absence of backtracking.
Smooth and continuous operations
Continuous flow of work
Lesser inventory and work in progress
Simple and effective inspection of work and
simplified production control Optimum use of
floor space
Lower manufacturing cost per unit
Disadvantages of Product layout
Higher Initial capital investment in special
purpose machine (SPM)
High overhead charges
Breakdown of one machine will disturb the
production process.
Lesser flexibility of physical resources.
 Ford Motor Company (1908-1915)

The assembly line developed for the Ford Model T had

immense influence on the world. What was worked out
at Ford was the practice of moving the work from one
worker to another until it became a complete unit, then
arranging the flow of these units at the right time and
the right place to a moving final assembly line from
which came a finished product. Regardless of earlier
uses of some of these principles, the direct line of
succession of mass production and its intensification
into automation stems directly from what we worked
out at Ford Motor Company between 1908 and 1913.
 Process Layout

In this type of layout the machines of a

similar type are arranged together at
one place. This type of layout is used
for batch production. It is preferred
when the product is not standardized
and the quantity produced is very
small.
Advantages Of Process Layout
 Lower initial capital investment is required.
 There is high degree of machine utilization, as a machine is
not blocked for a single product
 The overhead costs are relatively low
 Breakdown of one machine does not disturb the
production process.
 Supervision can be more effective and specialized.
 Greater flexibility of resources.
Disadvantages Of Process Layout
Material handling costs are high due to
backtracking
More skilled labour is required
resulting in higher cost.
Work in progress inventory is high
needing greater storage space
 Combined Layout
A combination of process layout &
product layout is known as combined
layout.
Manufacturing concerns where
several products are produced in
repeated numbers with no likelihood
of continuous production.
 Fixed Position Or Location Layout
Fixed position layout involves the
movement of manpower and machines to
the product which remains stationary. The
movement of men and machines is advisable
as the cost of moving them would be lesser.
This type of layout is preferred where the
size of the job is bulky and heavy. Example
of such type of layout is locomotives, ships,
boilers, generators, wagon building, aircraft
manufacturing, etc.
 Advantages Of Fixed Position Layout
The investment on layout is very small.
The layout is flexible as change in job
design and operation sequence can be
easily incorporated.
Adjustments can be made to meet
shortage of materials or absence of
workers by changing the sequence of
operations.
 Disadvantages Of Fixed Position Layout
As the production period being very long so the
capital investment is very high.
Very large space is required for storage of material and
equipment near the product.
As several operations are often carried out
simultaneously so there is possibility of confusion and
conflicts among different workgroups.
 Cellular Layout
Cellular manufacturing is a type of layout where machines are
grouped according to the process requirements for a set of similar
items (part families) that require similar processing. These groups are
called cells. Therefore, a cellular layout is an equipment layout
configured to support cellular manufacturing. Processes are grouped
into cells using a technique known as group technology (GT).
Workers in cellular layouts are cross-trained so that they can operate
all the equipment within the cell and take responsibility for its output.
Sometimes the cells feed into an assembly line that produces the final
product. An automated version of cellular manufacturing is the
flexible manufacturing system (FMS). With an FMS, a computer
controls the transfer of parts to the various processes, enabling
manufacturers to achieve some of the benefits of product layouts
while maintaining the flexibility of small batch production.
 Advantages Of Cellular Layout
Cost. Cellular manufacturing provides for faster processing
time, less material handling, less work-in-process inventory,
and reduced setup time, all of which reduce costs.
Flexibility. Cellular manufacturing allows for the production
of small batches, which provides some degree of increased
flexibility. This aspect is greatly enhanced with FMSs.
Motivation. Since workers are cross-trained to run every
machine in the cell, boredom is less of a factor. Also, since
workers are responsible for their cells' output, more
autonomy and job ownership is present.
 Royal Enfield's manufacturing operations go through
a series of modernization and improvement efforts,
with a number of automated processes. The Company
has put in place modern manufacturing practices like
Cellular layouts, Statistical process controls and
Flexible manufacturing systems. The Chennai
manufacturing facility has received the ISO 9001
certification and for managing its operations in a
clean and safe environment, it has obtained the ISO
14001-quality certification.
Thank you