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Facility Layout
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Layout refers to the way in which

organizations position their
equipment, departments, or
work centres

”
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PLANT LAYOUT

▰ Techniques of locating different machines and plant services within

the factory so that the output can be available with high quality and
low cost
▰ According to Moore, facility layout is the plan of or the act of
planning an optimum arrangement of facilities, including
personnel, operating equipment, storage space, material handling
equipment, and all other supporting services along with the design
of the best structure to contain these facilities

▰ Locating machines / High quality products / Low cost

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RETAIL LAYOUT ……
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FACILITY LAYOUT

▰ Facility layout is an arrangement of different aspects of

manufacturing in an appropriate manner as to achieve desired
production results.
▰ Facility layout considers available space, final product, safety
of users and facility and convenience of operations.
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FACILITY LAYOUT OBJECTIVE

▰ To provide an ideal relationship between raw material, equipment,
manpower and final product at minimal cost under safe and comfortable
environment
▰ To provide optimum space to organize equipment and facilitate movement
of goods and to create safe and comfortable work environment.
▰ To promote order in production towards a single objective
▰ To reduce movement of workers, raw material and equipment
▰ To promote safety of plant as well as its workers
▰ To facilitate extension or change in the layout to accommodate new product
line or technology up gradation
▰ To increase production capacity of the organization
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Types Of Layouts

▰ Fixed Position Layout ▰ Other Common Layouts :

▰ A Process Layout (Functional), ▰ Office Layouts,
▰ A Product (Line) Layout, And ▰ Retail Layouts, And
▰ A Cellular Layout - Hybrid. ▰ Warehouse Layout.
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Fixed Position Layout

▰ When producing a product that is not easily able to be moved,

▰ it may require that the worker, their tools and equipment are brought to
the site where the production is taking place.
▰ This is a common layout in manufacturing a building, a ship or
performing repairs to major equipment.
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Fixed position layout – example

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Process Layout

▰ Departments, equipment, or work centres are arranged

according to their function and similarity
▰ This layout is also common in services.
▰ department store, similar goods are arranged together such as
footwear, jewelry, and house wares.
▰ Functional Layout
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EXAMPLE :
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ADVANTAGES

▰ equipment tends to be quite general-purpose

▰ If one particular piece of equipment breaks down, it
will not halt the entire process
▰ gives flexibility to handle a variety of products or
customers. It is ideal for job shops or small batch
manufacturing.
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DISADVANTAGE

▰ have to travel from department to department

▰ leads to lots of material handling and movement of
goods
▰ A flexible material-handling system is needed such as
forklifts
▰ inventory is queued.
▰ layout is generally very inefficient
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PRODUCT LAYOUT

▰ Assembly Line Layout

▰ very capital intensive 
▰ work station is located along the line and may consist of a
worker with equipment, or robots.
▰ not necessarily a straight line, often assembly lines zig zag or
are in a shape to use the maximum amount of space available.
▰ a large volume of product is produced
▰ very standardized
▰ layout is very efficient.
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▰ less variability in the work performed

▰ no build up of inventory, and no waiting. 
▰ job automatically moves to the next workstation.
▰ may be susceptible to shut downs - high probability
of failures
▰ Training and job rotation are critical activities
▰ Process Layout
▰ Job shop layout
▰ Carpentry /Tailoring
▰ Very low scale of production
▰ Very low standardization
▰ Highly customized
▰ Labour intensive
▰ Product Layout
▰ Assembly Layout
▰ Car / Newspaper manufacturing
▰ Very high scale of production
▰ Highly standardisation
▰ rarely customized
▰ Capital intensive
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Cellular Layout

▰ Cellular layouts are considered a “hybrid”

▰ both a Process layout and a product (line) layout.
▰ Machines are grouped into work cell
▰ became popular beginning in the late 1980s
▰ products which need same machines are grouped together and
manufactured in a cell.
▰ Each work cell will contain a unique set of equipment to
manufacture this family of parts in an assembly line type of
layout. 
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MERITS

▰ Reduced set up times

▰ Speed is greatly enhanced
▰ Inventory investment is reduced
▰ Quality is enhanced
▰ Employee morale is improved.
▰ Less floor space is required
▰ Improved performance

CELLULAR LAYOUT
▰ ADVANTAGES
▰ Low WIP
▰ Reduces material handling
cost
▰ Shorter flow of times
▰ Improved visual control
▰ Fewer tooling changes
▰ Improved quality
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▰ DISADVANTAGES
▰ Reduces manufacturing
flexibility
▰ Increased machine downtime
▰ Duplicated pieces may be
needed
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“
Lets do
some
activity!
”
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Our college wishes to build a new campus A Lecture Building

with 6 different buildings .
B Library
The college wants to Layout the facility to
reduce the amount of students / staffs travel
C Study Hall

distance between the buildings . D Office

1 3
E Canteen

F Seminar

2 4
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OTHER LAYOUT

▰ Office Layouts,
▰ Retail Layouts, And
▰ Warehouse Layout.
 Types of Retail layout
1. GRID
2. FREE FORM
3. RACE TRACK LAYOUT
4. STORED LAYOUT
 GRID
• The grid layout is the most common store layout you’re going to find in retail.
• Used in supermarkets, drug stores, and many big box retail stores,
• it’s used when stores carry a lot of products (particularly different kinds of products),
• or when a retail location needs to maximize space.
RACE TRACK LAYOUT
• If the product that people want is to browse, touch
and look at, then the racetrack, or loop, layout is
one to consider.
• Customers follow a prescribed path through the
merchandise and experience it the way the retailer
wants it to be seen.
• the retailer doesn’t really need to influence traffic
flow, because traffic can really only move one way.
• The retailer knows where the shopper is going to
look next, and promotions are arranged accordingly
– eye level and a little to the right.
 Free form
Mixed or Free Flow Layout

• This layout can be anything the retailer wants it to be, in

any shape or place.
• Customer behavior is the only consistent aspect of this
kind of layout
• Traffic flow can easily be disrupted
• if there isn’t some logic to how items are displayed in the
store, and if that logic doesn’t exist, it’ll create shopper
confusion. Confused shoppers exit the store nearly
immediately and usually without purchasing anything.
• Retailers can control traffic flow by placing promotions
and visual displays as “speed bumps” can entice the
shopper from one merchandise
STORED LAYOUT
• layout is efficient, simple to plan, and capable of creating
individual spaces for the customer.
• Plus, a basic straight design helps pull customers towards
featured merchandise in the back of the store.
• Merchandise displays and signage is used to keep customers
moving and interested
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OTHER LAYOUT >>>>

▰ SERVICE LAYOUT
╺ Hospital M1
╺ Education

M2
 Horizontal / Vertical Layout
╺ Take an example of Talcum powder
╺ Newspaper M3

MI M2 M3
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Factors affecting Facility Layout

▰ Material ▰ Availability of floor space 

▰ Product ▰ Nature of manufacturing process
▰ Worker ▰ Repairs and maintenance
▰ Machinery ▰ Volume of production
▰ Location
▰ Policies
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PRINCIPLES OF LAYOUT

▰ Minimum travel
▰ Sequence
▰ Usage
▰ Compactness
▰ Safety and satisfaction
▰ Flexibility
▰ Minimum investment
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REVISION OF LAYOUT

▰ Improvement of Plant Layout

▰ Expansion in production capacity
╺ due to permanent increase in demand 
╺ provisions of new physical facilities to increase the output of
the product.
▰ Adoption of technological innovations and improvements
╺ enhance the competitive standing of the firm
▰ revised as the part of work-simplification for betterment of
production techniques