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 utilization 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 . Principal of Cubic Space Utilization:
• The good layout is one that utilize both horizontal and vertical space. It is not only enough if
only the floor space is utilized optimally but the third dimension, i.e., the height is also to be
utilized effectively

4 . Principal 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(back down)

5 . Principal 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, 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
NEED FOR PLANT LAYOUT:
• There are design changes in the product
• There is an expansion of the enterprise
• Some new product is to be added to the existing line
• Some new department is to be added to the enterprise and there is reallocation
of the existing department
• A new plant is to be set up

BENEFITS OF PLANT LAYOUT:

• Reduction in number of accidents, loss of man-hours and wastage of equipment
• Better provision for maintenance and inspection of the production capacity, work
in process and the work completed
• Reduction in cost of supervision
• Better utilisation of available floor space
CASE STUDY: PEPSI CO
INTRODUCTION:
• Since the creation of its iconic Pepsi-Cola soft drink in 1898, PepsiCo has grown into a global consumer products leader
offering a vast portfolio of food and beverage brands. One of its divisions, Pepsi Beverages Company (PBC),
manufactures, sells, and distributes some of the company’s most recognized beverages – including Pepsi, SoBe,
Gatorade, and Mountain Dew – in the United States, Canada, and Mexico
•  As part of consolidation strategies, the company decided to relocate a beverage filling line from an Oklahoma(US)
facility to an existing 50,000 square foot facility in Dallas(US) where it was currently operating three other filling lines for
the Gatorade and other 3 beverages
CHALLENGE:
• Pepsi did not want to relocate any of the original platforms that were around the existing line. “We wanted to put this
new line in a completely different configuration,” said Ken Graham, project lead and senior principal engineer for PBC.
Because safety is first in everything they do, PepsiCo needed to make sure the platform design would meet
OSHA’s(Occupational Safety and Health Administration) safe work standards. The platforms would be supporting
conveyor and other equipment over an open product zone, so they also had to make sure the platforms met – and
exceeded all the company’s strict food grade standard
SOLUTION:
• To aid in this effort, Graham and his team chose Cubic Designs to design, manufacture and install these new 18-foot-tall
food grade platforms that would span a total of about 4,000 square feet between two separate areas of the filling line.
The platform’s structures had to be made of galvanized steel to keep them corrosion resistant. “The hot-fill process
involves pasteurizing the product, resulting in a very humid atmosphere, “ explains Graham. Along the edges of the
platform, a 4-inch and 6-inch kick plate prevents particles from falling onto the open bottle area on the bottom level
 RESULT:
•  Fabrication of the structure took about 6 to 8 weeks to complete. Installation was even quicker than regular, non-
food grade platforms. “Cubic Designs uses a pre-built structure, which they design in their plant, and then just
bolt together at the customer’s site,” says Graham. “This greatly reduces the amount of metal fabrication, metal
shavings, etc. on the production floor. This also allows for quicker assembly and less down time needed for
installation.” A few months later, Pepsi hired an independent auditor to inspect the new line (including the new
platforms). They received very favorable comments and a passing grade