PLANT LAYOUT DESIGN

15-34
 7A-2

Facility Layout
Defined
Facility layout can be defined as the process by which the
placement of departments, workgroups within departments,
workstations, machines, and stock-holding points within a facility
are determined

This process requires the following inputs:

• Specification of objectives of the system in terms of output
and flexibility
• Estimation of product or service demand on the system
• Processing requirements in terms of number of operations
and amount of flow between departments and work centers
• Space requirements for the elements in the layout
• Space availability within the facility itself
Plant Layout and its Types
• Layout? Types of Layout
• Plant layout ideally involves Manufacturing units
allocation of space and
arrangement of equipment in a. Product;
such a manner that overall b. Process;
operating costs are minimized”. c. Fixed Position
d. Combined
Objectives of Layout
1. Efficient utilization of available floor
space
2. To ensure that work proceeds from
one point to another point without
any delay
3. Provide enough production capacity.
4. Reduce material handling costs
5. Reduce hazards to personnel
6. Utilize labor efficiently
7. Increase employee moral.
8. Reduce accidents
9. Provide for volume and product
flexibility
10.Provide ease of supervision and
control
11.Provide for employee safety and
health
12.Allow ease of maintenance
13.Allow high machine or equipment
utilization
14.Improve productivity
1.Manufacturing Layout
a. Product layout(line Layout):

• The materials move form one workstation to another sequentially without any
backtracking or deviation.
• Materials are fed into 1st machine and semi-finished goods travel automatically from
machine to machine.
• The output of one machine becoming input of the next.

Eg: Food Processing Unit; Paper mill

 Processin
Bamboo Paper
g

• .Manufacturing
Layout
a. Product
layout(line
Layout):
Eg: Paper mill
1.Manufacturing Layout
a. Product layout(line Layout):
Advantage Disadvantage

1.Low material 1.Initial cost is very

handling cost high
2.Continuous work 2.Repetitive process
3.Optimum floor
space
1.Manufacturing Layout
b. Process (functional)layout:

• In this type of layout machines of • Process oriented in Hospital

a similar type are arranged
together at one place.
• The work has to be allocated to Recep
each department in such a way tion
that no machines are chosen to do Emergency room admissions

as many different job as possible. Surgery

Laboratories
Eg: Process oriented layout for an
hospital
Radiology ER Beds Pharmacy Billing/exit
 b. Process (functional)layout:
Eg: Process oriented layout for an hospital

Patient A - broken leg

Reception

Emergency room admissions

Patient B - erratic heart
pacemaker
Surgery

Laboratories

Radiology ER Beds Pharmacy Billing/exit

 1.Manufacturing Layout
b. Process layout:
Advantage Disadvantage

1.Low capital 1.High material

2.Overhead cost are handling cost
relatively low. 2.Time lag is higher
3.Effective
supervision
1.Manufacturing Layout
c. Fixed (position) layout: Fixed (position) layout:
Eg: Ship building, Dam & flyover construction.
• Here, Major products being
produced is fixed at one
location.
• All other facilities are brought
and arranged around the work
center.

Eg: Ship building, Dam

construction, flyover
construction.
1.Manufacturing Layout
c. Fixed (position) layout:
Advantage Disadvantage
1.Save cost, as 1.Lengthy production
customization is period, heavy
necessary investment cost
2.Several operations
are carried out
simultaneously.
1.Manufacturing Layout
d. Combined layout:

• In many manufacturing units,

several products are produced in
repeated numbers with no
likelihood of continuous
production, combined layout is
followed.

Eg: Soap industry, all inputs are

almost manufactured in separate
units viz glycerin, water
treatment, fragrance etc.