Chapter two

BASICS OF PLANT LAYOUT

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 Material
Material Method

Management

Machine
Man
Management
Machine
Man

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Plant design example
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Plant layout
 Plant layout has been defined as a plan of, or the act of
planning an optimum arrangement of industrial facilities,
including
 personnel,
 operating equipment,
 storage space,
 materials handling equipment and
 all other supporting services along with the design of the
best structure to contain these facilities
Basic of plant/facilities/ layout

 Plant layout:- un economical arrangement of

equipment and manufacturing processes in
conjunction with plant service
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Plant layout definition

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Plant layout

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Objective of Plant layout
 Minimize material handling and waste
 Facilitate manufacturing processes
 Flexibility of arrangement
 Maximum utilization of equipment and space
 Increases production capacity
 Efficient utilization of equipment
 Better and safe workplace
 Easy supervision
 Minimize capital investment
 Improve customer service
Basic of plant layout
 Plant location:-means deciding a suitable location, area,
place where the plant/ factory start operation
 Plat design:- planning of finance and plant location

Plant design

Capital Plant Plant

Product Sales Plant
acquisiti size location
design planning layout
on

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Consideration of plant layout

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Plant location selection
Cont..

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Factor influencing plant location

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Controllable factor
Proximity to the market
Supply of raw material
Transportation
Infrastructure availability
Labor and wages

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Uncontrolled factor
 Government policy
 Climate condition

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Location factor for manufacturing
organization
 Dominant factor
 Favorable labor climate
 Proximity to market
 Quality of life
 Good school, social and recreational facility
 proximity to suppliers and resources
 Utilities, Tax, and real state costs
 Secondary factor
 Room for expansion
 Construction cost
 Accessibility to multiple mode of transportation
 Community attitude and facilities

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Plant Location
 The geographical location of the final plant can
have a strong influence on the success of an
industrial enterprise.
 The plant should be located where the minimum
cost of production and distribution can be
obtained.
 The choice of the final site should first be based
on a complete survey of the advantages and
disadvantages of various geographical areas.
 An approximate idea for the plant location should
be obtained before a design project reaches the
detailed estimate stage.
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 Raw Materials
 The source of raw materials is one of the most important
factors influencing the selection because location near
the raw materials source leads to reduction in
transportation and storage charges.
 Attention should be given to the;
purchased price of the raw materials
distance from the source of supply
freight or transportation expenses
availability and reliability of supply
purity of raw materials
storage requirements
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Markets
 The location of markets or intermediate
distribution centers affects the cost of product
distribution and the time required for shipping.
 It should be noted that markets are needed for by-
products and end products as well as for major
final products.

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Energy Availability
Power and steam requirements are high in
most industrial plants and the fuel is
ordinarily required to supply these utilities.
Consequently, power and fuel can be
combined as one major factor in the choice of
a plant site.
In addition, the presence and cost of
electricity is an important consideration for
plant location.
In industrial areas the cost, voltage and
availability of electricity is different than in
living areas.
Climate
 Excessive humidity or extremes of hot or cold
weather can have a serious effect on economic
operation of a plant and these factors should
be examined when selecting a plant site.

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Transportation Facilities
 The common means of transportation used by
major industrial concerns are roads, highways,
railroads and water.
 For selection careful attention should be given to
“freight rates”.
 In food industry, raw materials and food products
are in huge amounts and not very durable.
 Therefore, transportation should be done with a
great care and should be fast.
Water Supply
 The process industries use large quantities of
water for cooling, washing, steam generation,
immobilized conveying and as a raw material.
 Therefore, the plant must be located where a
dependable supply of water is available.
 Water sources can be tab water, rivers, lakes, deep
wells and artesian wells.
 If own sources are to be used the level of existing
water, seasonal fluctuations, chemical,
bacteriological content and cost for supply and
purification must be considered. 26
Waste Disposal
 The site selected for a plant should have adequate capacity
and facilities for correct waste disposal.
 In recent years many legal restrictions have been placed on
the methods for disposing of waste materials from the
process industries.
 In choosing a plant site, the permissible tolerance levels for
various methods of waste disposal should be considered
carefully and attention should be given to potential
requirements for additional waste treatment facilities.
Labor Supply
 The type and supply of labor available in the
vicinity of a proposed plant site must be
examined.
 Consideration should be given to prevailing pay
rates, restrictions on number of hours worked per
week, competing industries that can cause
dissatisfaction or high turnover rates among the
workers, the ethnic distribution and variations in
the skill and intelligence of workers.
Taxation and Legal Restrictions
 Tax rates, health insurance rates and property tax
rates do not change depending on position in our
country.
 However, being a governmental policy some
places are promoted for the development (as
reduced tax and interest rates). I
 n industrial regions permissions to be taken are
important in cost and time delays.
 For the abroad enterprises local tax rates and
promotions should be considered.

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Site Characteristics
 The characteristics of the land at a proposed plant
site should be examined carefully (topography and
soil structure).
 The cost of land is important as well as local
building costs and living conditions. Future
changes may make it desirable or necessary to
expand the plant facilities.
 The buildings that are constructed as a result
detailed land analysis, soil analysis and structural
calculations are very resistant to aging as well as
natural disasters like earthquakes. 30
Flood and Fire Protection
 Before choosing a plant site, the regional
history of natural events like floods or
hurricanes should be examined.
 Protection from losses by fire is another
important factor for selection of plant location.
In case of a major fire, assistance from outside
fire departments should also be available as
well as fire protection systems.

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Community Factors
 The character and facilities of a community can
have effects on the location of the plant.
 Cultural facilities as schools, shops, mosques,
cafeterias, kindergartens, cinemas are important
for a progressive community.
 If these facilities are not present it becomes for
the plant as a necessity to provide such facilities.

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Approximate region determination for
preliminary survey

raw materials

markets

energy supply

climate

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 Reduction in possible areas

transportation facilities water supply

raw materials

markets

energy supply

climate

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Final selection

waste disposal

labor

taxes and legal restrictions

site characteristics

flood and fire protection

community factors

raw materials, markets, energy supply, climate,

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transportation facilities and water supply
Consideration in plant layout
 Major consideration
Department of organization
Location of production department
Position of service department
Size of site/building
Type of construction
Ventilation and air conditioning
Lighting
Appearance
Provision for future expansion

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Type of plant layout

1. Manufacturing unit
2. Service establishment

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Symptom of good and bad plant layout
Types of plant layout: manufacturing unit
 There are four types of plant layout
Product/line layout
Process/ functional layout
Fixed position layout
Combined layout

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Types of Layout
 Product Layout:
 all the machines are arranged in the sequence, as required to
produce a specific product.
 It is called line layout because machines are arrange in a straight
line.
 The raw materials are fed at one end and taken out as finished
product to the other end.
 For example

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Product/line Layout is Used When:
 One or few standard products are to be produced,
 large volume of production of each item over a
considerable time is needed,
 minimum of inspection is required during sequence of
operations,
 minimum of very heavy equipment or equipment
requiring special facilities are needed,
 materials and products permit bulk or continuous
handling of mechanical means and
 one machine is always used for one purpose.
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Advantages of Product Layout
 lower total material handling cost,
 lower total production time,
 Short manufacturing cycle due to uninterrupted flow of
materials
 greater incentive for groups of workers to raise level of
performance,
 less floor area required per unit of production and
 greater simplicity of production control, fewer control
records needed and lower accounting cost.

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Disadvantage
 Lack of flexibility of operations,
layout cannot be adapted to the manufacture of any other
type of product
 The manufacturing cost increases with a fall in
volume of production.
 If one or two lines are running light, there is a
considerable machine idleness.
 A single machine break down may shut down the
whole production line.
 Specialized and strict supervision is essential
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Process/functional Layout
 Process Layout: Similar equipment and similar
operations are grouped together in the process or
functional layout.
 It is particularly useful where low volume is required.
 In this type of layout, the machines and not arranged
according to the sequence of operations but are arranged
according to the nature or type of the operations. This
layout is commonly suitable for non repetitive jobs

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Process Layout is Used when
 many types or styles of products are on special order ,
 relatively low volume of production on individual items
is needed,
 many inspections are required during a sequence of
operations,
 high proportion of very heavy equipment or equipment
requiring special treatment exist,
 materials or products become too large or too heavy to
permit bulk or continuous flow and
 one machine is used for different operations. 49
Some of the Advantages of Process Layout

 less duplication of equipment, hence lower investment

cost,
 greater flexibility of production,
 better and more efficient supervision,
 greater incentive for individual workers to raise level of
performance,
 better control of complicated or precision processes,
 easier to handle breakdowns of equipment by
transferring work to another machine or station.
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Disadvantage
There are long material flow lines and hence the expensive
handling is required.
Total production cycle time is more owing to long distances and
waiting at various points.
Since more work is in queue and waiting for further operation
hence bottle necks occur.
Generally, more floor area is required.
Since work does not flow through definite lines, counting and
scheduling is more tedious.
Specialization creates monotony and there will be difficult for the
laid workers to find job in other industries.

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Fixed-Position Layout
 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.
 is appropriate for a product that is too large or too heavy
to move
 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. 52
 Developing Simulating Layout Problems
Product Market
Design New Obsolete Poor
Market Cost
Demand Worker
Change product Facility Relocation Reduction
Change Environment

Move to Rearrange Minor

Build New Existing changes
existing
Plant Plant
Plant

Class of layout problems

Relation between causes and classes of layout problems

Cause and result occur very frequently

Cause and result occur less frequently
Cause and result occur occasionally
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Advantage of fixed position layout
 Material movement is reduced
 Capital investment is minimized.
 The task is usually done by gang of operators,
hence continuity of operations is ensured
 Production centers are independent of each other.
Hence, effective planning and loading can be
made. Thus, total production cost will be reduced.
 It offers greater flexibility and allows change in
product design, product mix and production
volume.
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Limitations of Fixed Position Layout:
 Highly skilled man power is required.
 Movement of machines equipment’s to production
center may be time consuming.
 Complicated fixtures may be required for
positioning of jobs and tools. This may increase
the cost of production.

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PLANT LAYOUT DECISION
 The solution of any size and type of plant layout
problems could be facilitated by using a systematic and
logical approach.
 An early pioneer in this area was Richard Muther,
developer of the Systematic Layout Planning (SLP)
methodology.

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The Simple load distance method

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 Ergonomics and
industrial safety

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 Ergonomics is defined as the study of people’s
efficiency in their working environment, but in
the world of health and safety, it tends to denote
fitting a job or a task to a person

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A hazard is any source of potential damage, harm or adverse health
effects on something or someone.
 Harm – physical injury or damage to health.
 Hazard – a potential source of harm to a worker.
 Basically, a hazard is the potential for harm or an adverse effect

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TYPES OF HAZARDS:
 A common way to classify hazards is by category:
 Biological – bacteria, viruses, insects, plants, birds, animals, and humans,
etc.,
 Chemical – depends on the physical, chemical and toxic
properties of the chemical,
 Ergonomic – repetitive movements, improper set up of
workstation, poor design of equipment, workstation design,
(postural) or workflow, manual handling, repetitive
movement.etc.,
 Physical – Slippery floors, objects in walkways, unsafe or
misused machinery, excessive noise, poor lighting, fire.
radiation, magnetic fields, pressure extremes (high pressure or
vacuum), noise, etc.,
 Psychological – Shift work, workload, dealing with the public,
harassment, discrimination, threat of danger, constant low-level
noise, stress.stress, violence, etc., 63
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