Plant Layout Principles and Types Guide

Production Plan
Plant Layout: Principles

and Types
IGCALINOS, Jay Mark D.

jaymarkigcalinos16@gmail.com
Contents of the Report
01 Principles of Plant
Layout 02 Types of Plant
Layout
Principle of Overall Integration Product Layout
Principle of Safety Process Layout
Principle of Smooth Flow Combination Layout
Principle of Economy Fixed Position Layout
Principle of Supervision
Principle of Satisfaction
PRODUCTIO
N PLAN
Principles of Plant
Layout
Principle of Plant Layout
V.
Principle of Overall Integration

All the plant facilities and services should be fully
integrated into a single operating unit; to minimize
cost of production.
VI
.
Principle of Safety
There should be in-built provision in the design of
layout, to provide for comfort and safety of workers.
VII.
Principle of Smooth Flow

The layout should be designed as to reduce work
bottlenecks and facilitate uninterrupted flow of work
throughout the plant.
VIII.
Principle of Economy
The layout should aim at effecting economy in
terms of investment in fixed assets.
IX
.
Principle of Supervision
A good layout should facilitate effective supervision
over workers.
X.
Principle of Satisfaction
A good layout should boost up employee morale,
by providing them with maximum work satisfaction.
PRODUCTIO
N PLAN
Types of Plant
Layout
Product Layout (or Line Layout)
All the machines are arranged

in the sequence, as required to
produce a specific product.
It is called line layout because

machines are arranged in a
straight line.
The raw materials are fed at

one end and taken out as
finished product to the other
end.
For example:
For a garment manufacturer, stations for sewing

cloth, sewing on buttons, inspecting seams,
wrapping finished garments and boxing them up
would all be located within close proximity for an
individual clothing item, allowing individual
garments to pass from one station to another
quickly.
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Advantages
01 02 03
Reduced Perfect line
material Short
balancing
handling cost manufacturing
which
due to cycle due to
mechanized eliminates
uninterrupted
handling bottlenecks
flow of
systems and and idle
materials.
straight flow. capacity.
Advantages
04 05 06
Simplified Lesser wage
production cost, as
planning and Small amount
unskilled
control; and of work-in-
simple and workers can
progress
effective learn and
inventory.
inspection of manage
work. production.
disadvantages
Large Dependence
Lack of of whole
flexibility of capital
investment activity on
operation each part.
01 02 03
disadvantages
Same machines Delicate

special
duplicated for
purpose
manufacture of
machines
different require costly
products. maintenance
/repairs.
04 05
Suitability of Product Layout
Product layout is suitable in the following cases:
01
Where one or few
standardized
products are
manufactured.
Where a large 02
volume of production
of each item has to
travel the production
process
03
Where time and
motion studies can
be done to determine
the rate of work.
04
Where a possibility
of a good balance of
labor and equipment
exists.
05
Where minimum of
inspection is
required.
Where materials and 06

products permit bulk
or continuous
handling by
mechanical parts.
07
Where minimum of
set-ups are required.
Process Layout (or Functional Layout)
In this type of layout, all

machines performing similar type
of operations are grouped at one
location i.e. all lathes, milling
machines etc. are grouped in the
shop and they will be clustered in
like groups.
Process Layout (or Functional Layout)
For example:
Again using the garment

manufacturing example, a process
layout would group multiple
sewing stations together for
different clothing items in one
area, then locate inspection,
wrapping and packaging stations
for different items together in
different areas.
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Advantages
01 02 03
Greater Lower
flexibility with Higher
investment
regard to work utilization of
distribution to due to general production
machinery and purpose
facilities.
personnel. machines
Advantages
04 05
Breakdown of
one machine
Variety of jobs does not
makes the work
challenging ad result in
interesting. complete
stoppage of
work.
disadvantages
Backtracking
and long Mechanization Production
movements of material planning
occur in handling is not and control
handling of possible. in difficult.
materials.
01 02 03
disadvantages
As the work
More space has to pass
requirement through
different
departments.
04 05
Suitability of process Layout
Product layout is suitable in the following cases, where:
01 Non-standardized
products are
manufactured
It is difficult to
02
achieve good labor
and equipment
balance.
03 Production is not
carried on a large
scale.
It is difficult to
04
undertake adequate
time and motion
studies.
It is frequently
05 necessary to use the
same machine or work
station for two or more
difficult operations.
During the sequence of

06
operations, many
inspections are
required.
07 Process may have to be

brought to work,
instead of “vice-versa”.
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COMBINATION LAYOUT
In practice, plants are

rarely paid out either in
product or process layout
form.
COMBINATION LAYOUT
Generally, a combination
of the two basic layouts is
employed; to derive the
advantages of both
systems of layout.
COMBINATION LAYOUT
 Process layout is used to

produce various operations like
stamping, welding, heat
treatment being carried out in
different work centers as per
requirement.
COMBINATION LAYOUT
 The final assembly of the

product in done in a product
type layout.
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Fixed position layout
It is called
stationary
In this type of
layout.
layout,
materials and
Typical
machines are
examples are:
brought to a
ship-building,
product that
air-craft
remains in one
manufacturing,
place owing to
wagon
its size.
building, etc.
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Production Plan

Plant Layout: Principles

IGCALINOS, Jay Mark D.

Principle of Overall Integration

Principle of Smooth Flow

All the machines are arranged

It is called line layout because

The raw materials are fed at

For a garment manufacturer, stations for sewing

Same machines Delicate

Where materials and 06

In this type of layout, all

Again using the garment

During the sequence of

07 Process may have to be

In practice, plants are

 Process layout is used to

 The final assembly of the

02 You can simply impress your audience and add a

04 You can simply impress your audience and add a

Your Text Here

Your Text Here

Your Text Here

Principle of Overall Your Text Here Your Text Here

2015 2017 2019

Principl 2016 2018

Your name Your name Your name Your name

Get a modern PowerPoint Presentation that

You can simply impress your audience and add a

Get a modern PowerPoint Presentation that is

Your Text Here

Your Text Here

Your Text Here

Your Text Here Your Text Here

Your Text Here Your Text Here

Add Text Add Text

Get a modern PowerPoint Get a modern PowerPoint

Get a modern PowerPoint Presentation that is beautifully

Get a modern PowerPoint Presentation that is beautifully

01 You can simply impress your audience and add a

Your Picture Here and Send to Back

Your Picture Here

Your Text Here

03 You can simply impress your audience and add a

Content Here Content Here

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Your Text Here

Your Text Here Your Text Here

Simple Portfolio and appeal to your Presentations. Easy to change colors,

Designed add a unique zing and appeal to your Presentations. Easy to

Get a modern PowerPoint Get a modern PowerPoint

Get a modern PowerPoint Get a modern PowerPoint

$1,500 $1,800 $1,600 $1,100

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You can simply impress your audience and add a

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