IMEE Ch3. Plant Layout

JIMMA
1
UNIVERSITY
JIMMA INISTUTE OF TECHNOLOGY

FACULTY OF MECHANICAL ENGINEERING
INDUSTRIAL MANAGEMENT AND ENGINEERING ECONOMY
Chapter Three:- Plant Layout
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CHAPTER THREE
PLANT LAYOUT
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CHAPTER FOUR-Plant Layout
3
Chapter Outlines
 Introduction,
 Criteria or principle for a good plant layout
 Objectives of Good Plant Layout,
 Types of Plant Layout,
 Techniques Used in Plant Layout.
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Introduction
4
 Plant layout refers to the physical arrangement of

production facilities.
 It is the configuration of departments, work centers
and equipment in the conversion process.
 It is a floor plan of the physical facilities, which are
used in production.
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 Plant layout refers to the arrangement of physical

facilities such as machines, equipment, tools,
furniture etc. in such a manner so as to have
quickest flow of material at the lowest cost and
with the least amount of handling in processing
the product from the receipt of raw material to the
delivery of the final product.
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Definition
6
 Facilities can be broadly defined as

buildings where people, material, and
machines come together for a stated
purpose – typically to make a tangible
product or provide a service.
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 “Plant layout is such a systematic and efficient

functional arrangement of various departments,
machines, tools, equipment and other supports
services of an industrial organization that will
facilitate the smooth processing of the proposed
or undertaken product in the most effective,
most efficient and most economical manner in
the minimum possible time”
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 According to Moore “Plant layout is a plan of an

optimum arrangement of facilities including
personnel, operating equipment, storage space,
material handling equipment and all other
supporting services along with the design of best
structure to contain all these facilities”.
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Criteria for a good plant layout

 Maximum flexibility: A good layout will be one
which can be rapidly modified to meet changing
circumstances
 Maximum co-ordination: Entry into, and
disposal from, any department or functional area
should be in such a manner that it is must
convenient to the issuing or receiving departments.
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 Maximum use of volume: Facilities should be

considered as cubic devices and maximum use
made of the volume available. This principle is
particularly useful in stores,
 Maximum visibility: All the people and materials
should be readily observable at all the time; there
should be no ‘hidden places’ into which goods or
information can get mislaid
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 Maximum accessibility: All servicing and

maintenance points should be readily accessible.
For example, equipment should not be placed
against a wall in such a manner that necessary
maintenance cannot easily be carried out.
 Minimum distance: All movements should be
both necessary and direct. Handling work adds to
cost but does not increase value; consequently any
unnecessary or indirect movements should be
avoided
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 Minimum handling: The best handling of material

and information is no handling, but where it is
unavoidable it should be reduced to a minimum by
the use of whatever devices are most appropriate.
 Minimum discomfort: poor lighting, excessive
sunlight, heat, noise, vibration and smells should be
minimized and if possible counteracted.
 Inherent safety: the major principle is to remove
the hazard altogether.
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 The best method to achieve this is to reduce the

inventory of hazardous substances such that a
major hazard is no longer presented
 Maximum security A good layout is one that
gives due consideration to workers safety and
satisfaction and safeguards the plant and machinery
against fire, theft, etc.
 Efficient process flow
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Advantages of a good layout
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 The overall process time and cost will be minimized

by reducing unnecessary handling and movement,
 Supervision and control will be simplified by the
elimination of ‘hidden corners,
 Changes in the programmers will be most readily
accommodated’
 Total output from a given facility will be as high as
possible by making the maximum effective use of
available space and resources
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 A feeling of unity among employees will be

encouraged by avoiding unnecessary segregation.,
 Quality of the products or service will be sustained by
safer and more effective methods of operation.

A well designed plant layout is one that can be
beneficial in achieving the following objectives:
 Proper and efficient utilization of available floor
spaces,
 Transportation of work from one point to another
point without any delay,

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 Proper utilization of production capacity,

 Reduce material handling costs,
 Utilize labor efficiently,
 Reduce accidents,
 Provide for volume and product flexibility,
 Provide ease of supervision and control,
 Provide for employee safety and health,
 Allow easy maintenance of machines and plant,
 Improve productivity.
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Types of Plant Layout

 Process
 Product
 Cellular
 Fixed position
 Hybrid (mixed)
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Plant layout:-Process Layout
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 Process layout is recommended for batch

production.
 All machines performing similar type of operations
are grouped at one location in the process layout
e.g., all lathes, milling machines, etc. are grouped in
the shop will be clustered in like groups.
 Thus, in process layout the arrangement of facilities
are grouped together according to their functions.
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Plant layout:- Process Layout
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 A manufacturing example of a process layout is the

machine shop, which has separate departments for
milling, grinding, drilling, and so on.
 is a format in which similar equipment or functions
are grouped together, such as all lathes in one area
and all stamping machines in another.
 Process layout is normally used when the
production volume is not sufficient to justify a
product layout.
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 Different products of customer have different

requirements therefore they may take different
routes within the process.
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Characteristics of Process Layout

 General-purpose equipment is used
 Changeover is rapid
 Operators are highly skilled
 Technical supervision is required
 Planning, scheduling and controlling functions are
challenging
 Production time is relatively long
 In-process inventory is relatively high
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An example of a process layout in a library
showing the path of just one customer
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Advantages
 In process layout machines are better utilized and
fewer machines are required.
 Flexibility of equipment and personnel is possible
in process layout.
 Lower investment on account of comparatively less
number of machines and lower cost of general
purpose machines.
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 Higher utilization of production facilities.

 A high degree of flexibility with regards to work
distribution to machineries and workers.
 The diversity of tasks and variety of job makes the
job challenging and interesting.
 Supervisors will become highly knowledgeable
about the functions under their department
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Limitations
 Backtracking and long movements may occur in
the handling of materials thus, reducing material
handling efficiency.
 Material handling cannot be mechanized which
adds to cost.
 Process time is prolonged which reduce the
inventory turnover and increases the in-process
inventory.
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 Lowered productivity due to number of set-ups.

 Throughput (time gap between in and out in the
process) time is longer.
 Space and capital are tied up by work-in-process.
Product (Assembly Line) Layout

 Product layouts are used to achieve a smooth and
rapid flow of large volumes of products or
customers through a system
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Plant layout:- Product Layout
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 In this type of layout, machines and auxiliary

services are located according to the processing
sequence of the product.
 If the volume of production of one or more
products is large, the facilities can be arranged to
achieve efficient flow of materials and lower cost
per unit.
 Special purpose machines are used which perform
the required function quickly and reliably.
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 For instance, if a portion of a manufacturing

operation required the sequence of cutting,
polishing, and painting, the appropriate pieces
of equipment would be arranged in that
sequence.
 Product layouts achieve a high degree of labor
and equipment utilization.
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 Flow is clear, predictable and easy to control.

 equipment or work processes are arranged
according to the progressive steps by which

the product is made.
 The path for each part is, in effect, a straight
line.
 Production lines for shoes, chemical plants,
and car washes are all product layouts.

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Characteristics of Product Layouts

 Special-purpose equipment are used
 Changeover is expensive and lengthy
 Material flow is continuous
 Material handling equipment is fixed
 Little direct supervision is required
 Planning, scheduling and controlling functions are
relatively straight-forward
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Therefore, the production volume must be sufficient

to achieve satisfactory utilization of the equipment.
Advantages
The flow of product will be smooth and logical in
flow lines.
In-process inventory is less.
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 Throughput time is less.

 Minimum material handling cost.
 Simplified production, planning and control
systems are possible.
 Less space is occupied by work transit and for
temporary storage
 Reduced material handling cost due to
mechanized handling systems and straight flow.
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 Perfect line balancing which eliminates

bottlenecks and idle capacity.
 Manufacturing cycle is short due to uninterrupted
flow of materials.
 Small amount of work-in-process inventory.
 Unskilled workers can learn and manage the
production
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Limitations
 A breakdown of one machine in a product line may
cause stoppages of machines in the downstream of
the line.
 A change in product design may require major
alterations in the layout.
 The line output is decided by the bottleneck machine.
 Comparatively high investment in equipments is
required.
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Plant layout:- Cellular Layout
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Cellular Layout
 Cellular manufacturing is a type of layout in
which machines are grouped into what is

referred to as a cell.
 Groupings are determined by the operations
needed to perform work for a set of similar

items, or part families that require similar
processing.
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 In-group technology layout, the objective is to

minimize the sum of the cost of transportation and
the cost of equipments. So, this is called as multi-
objective layout.
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 Cellular layout provides faster processing time, less

material handling, less work-in-process inventory,
and reduced setup time.
 Used when the operations system must handle a
moderate variety of products in moderate volumes
 Every cell contains a group of machines which are
dedicated to the production of a family of parts.
 One of the problems is to identify a family parts that
require the same group of machines.
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 Cellular layout is also called as group layouts.

 Group technology (GT) is the analysis and
comparisons of items to group them into families
with similar characteristics.
 GT can be used to develop a hybrid between pure
process layout and pure flow line (product) layout.
This technique is very useful for companies that
produce variety of parts in small batches to enable
them to take advantage and economics of flow line
layout
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 The application of group technology involves two

basic steps;
 first step is to determine component families or
groups.
 The second step in applying group technology is to
arrange the plants equipment used to process a
particular family of components.
 This represents small plants within the plants.
 The group technology reduces production planning
time for jobs. It reduces the set-up time
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 The basic aim of a group technology layout is to

identify families of components that require
similar of satisfying all the requirements of the
machines are grouped into cells.
 Each cell is capable of satisfying all the
requirements of the component family assigned to
it.
 The layout design process considers mostly a
single objective while designing layouts.
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 In process layout, the objective is to minimize

the total cost of materials handling. Because of
the nature of the layout, the cost of equipments
will be the minimum in this type of layout.
 In product layout, the cost of materials handling
will be at the absolute minimum. But the cost of

equipments would not be at the minimum if the
equipments are not fully utilized.
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Advantages of Group Technology Layout

Group Technology layout can increase
 Component standardization and rationalization.
 Reliability of estimates.
 Effective machine operation and productivity.
 Customer service.
It can decrease the

 Paper work and overall production time.
 Work-in-progress and work movement.
 Overall cost.
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Limitations of Group Technology Layout

 This type of layout may not be feasible for all
situations.
 If the product mix is completely dissimilar, then
we may not have meaningful cell formation.
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Plant layout:- Fixed Position Layout
48
Fixed Position Layout

 This is also called the project type of layout. In this
type of layout, the material, or major components
remain in a fixed location and tools, machinery, men
and other materials are brought to this location.
 This type of layout is suitable when one or a few
pieces of identical heavy products are to be
manufactured and when the assembly consists of
large number of heavy parts, the cost of
transportation of these parts is very high
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Plant layout:- Fixed Position Layout
49
 Fixed-position layout is used when product is very

bulky, heavy or fragile
 Fixed-position layouts are used in large
construction projects (buildings, power plants, and
dams), shipbuilding, and production of large
aircraft and space mission rockets.
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Plant layout:- Hybrid (mixed) Layout
50
Hybrid (mixed) Layout

 Actually, most manufacturing facilities use a
combination of layout types.
 An example of a hybrid layout is where
departments are arranged according to the types
of processes but the products flow through on a
product layout.
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 For instance, supermarket layouts are

fundamentally of a process nature, and however
we find most use fixed-path material-handling
devices such as roller-type conveyors both in the
stockroom and at checkouts, and belt-type
conveyors at the cash registers
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 Hospitals also use the basic process arrangement,

although frequently patient care involves more of a
fixed-position approach, in which nurses, doctors,
medicines, and special equipment are brought to
the patient.
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Facilities Planning Process:
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1. Define (or redefine) the objective of the facility,

2. Specify the primary and support activities to be
performed in accomplishing the objective.
Requirements in terms of:
• Operations, • Equipment,
• Personnel, • Material flows should be
satisfied.
3. Determine the interrelationships among all
activities
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4. Determine the space requirements for all activities,

5. Generate alternative facilities plans,
6. Evaluate alternative facilities plans (alternative
locations and alternative designs),
7. Select a facilities plan,
8. Implement the facilities plan,
9. Maintain and adapt the facilities plan,
10. Redefine the objective of the facility.
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Plant Design Situations may arise
56
 design and erection of a completely new plant

 design and erection of an addition to the existing
plant
 the facility or plant operations and subsequent
expansion restricted by a poor site, thereby
necessitating the setting up of the plant at a new
site
 addition of some new product to the existing
range
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 adoption of some new process /replacement of

some existing equipment
 modernization / automation of the existing
facility
 expansion of the plant capacity
 relocating the existing plant at a new site because
of new economic, social, legal or political factors
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Factors that influence layout:
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 Volume, weight of items to be produced.

 Nature of the Product/service to be provided.
 Cost of the building to house the operation.
 The product mix that must have a facility.
 The fragility of the product or component
 The type of machinery
 Repairs and Maintenance.
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Design of Process Layout
Example 5.1
59
Load Summary Chart
FROM/TO DEPARTMENT
Department 1 2 3 4 5
1 — 100 50
2 — 200 50
3 60 — 40 50
4 100 — 60
5 50 —
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Process Layout
Example 5.1
60
Load Summary Chart
FROM/TO DEPARTMENT
1 — 100 50
2 — 200 50
3 60 — 40 50
4 100 — 60
Composite 5Movements Composite
50 Movements
—
23 200 loads 35 50 loads
24 150 loads 25 50 loads
13 110 loads 34 40 loads
12 100 loads 14 0 loads
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Process Layout
Example 5.1
61
Load Summary Chart
FROM/TO DEPARTMENT
1 2 3
1 — 100 50
2 — 4200 50 5
3 60 — 40 50
4 100 — 60
50 Movements
—
23 200 loads 35 50 loads
24 150 loads 25 50 loads
13 110 loads 34 40 loads
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Process Layout
Example 5.1
62
110
Load Summary Chart
FROM/TO 100
DEPARTMENT 200
1 2 3
50
50
1 — 100 50 60
2 — 4200 50 5
3 60 — 40 50
40
4 100
Grid 1 — 60
Composite Movements
5 Composite
50 Movements
—
23 200 loads 35 50 loads
24 150 loads 25 50 loads
13 110 loads 34 40 loads
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Process Layout
Example 5.1
63
Load Summary Chart
FROM/TO 100
DEPARTMENT 150
1 2 4
Department 1 2 3 4
200 505 40 60
110
1 — 100 50 50
2 — 200 50 3 5
3 60 — 40 50
4 100
Grid 2 — 60
50 Movements
—
23 200 loads 35 50 loads
24 150 loads 25 50 loads
13 110 loads 34 40 loads
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Relationship Diagramming Or
64
Qualitative Ranking Example
A Absolutely
necessary
E Especially
important
IImportant
Production O Okay
O U Unimportant
Offices A X Undesirable
U I
Stockroom O E
Shipping and
A X A
receiving U U
U O
Locker room O
O
Toolroom
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Machine component Incident
65
Matrix
Machines
Parts 1 2 3 4 5 6 7 8 9 10 11 12
A x x x x x
B x x x x
C x x x
D x x x x x
E x x x
F x x x
G x x x x
H x x x
Figure 5.8 04/14/24

66
Machines
Parts 1 2 4 8 10 3 6 9 5 7 11 12
A x x x x x
D x x x x x
F x x x
C x x x
G x x x x
B x x x x
H x x x
E x x x
Figure 5.9 04/14/24

67
Revised Cellular Layout
Assembly
8 10 9 12
11
4 Cell 1 Cell 2 6 Cell 3
7
2 1 3 5
A B C
Raw materials
Figure 5.9 04/14/24

68
1 2 3
Cells 1,2,4,8 & 10 3,6 & 9 5,7,11 & 12

Part A, D & F C&G B,H & E
Families
04/14/24

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JIMMA

JIMMA INISTUTE OF TECHNOLOGY

 Plant layout refers to the physical arrangement of

 Plant layout refers to the arrangement of physical

 Facilities can be broadly defined as

 “Plant layout is such a systematic and efficient

 According to Moore “Plant layout is a plan of an

Criteria for a good plant layout

 Maximum use of volume: Facilities should be

 Maximum accessibility: All servicing and

 Minimum handling: The best handling of material

 The best method to achieve this is to reduce the

 The overall process time and cost will be minimized

 A feeling of unity among employees will be

safer and more effective methods of operation.

point without any delay,

 Proper utilization of production capacity,

Types of Plant Layout

 Process layout is recommended for batch

 A manufacturing example of a process layout is the

 Different products of customer have different

Characteristics of Process Layout

 Operators are highly skilled

 Technical supervision is required

 Planning, scheduling and controlling functions are

 In-process inventory is relatively high

 Higher utilization of production facilities.

 Lowered productivity due to number of set-ups.

Product (Assembly Line) Layout

 In this type of layout, machines and auxiliary

 For instance, if a portion of a manufacturing

and equipment utilization.

 Flow is clear, predictable and easy to control.

according to the progressive steps by which

and car washes are all product layouts.

Characteristics of Product Layouts

 Changeover is expensive and lengthy

 Material flow is continuous

 Material handling equipment is fixed

 Little direct supervision is required

 Planning, scheduling and controlling functions are

Therefore, the production volume must be sufficient

 Throughput time is less.

 Perfect line balancing which eliminates

which machines are grouped into what is

needed to perform work for a set of similar

 In-group technology layout, the objective is to

 Cellular layout provides faster processing time, less

 Cellular layout is also called as group layouts.

 The application of group technology involves two

 The basic aim of a group technology layout is to

 In process layout, the objective is to minimize

will be at the absolute minimum. But the cost of

Advantages of Group Technology Layout

 Effective machine operation and productivity.

It can decrease the

 Work-in-progress and work movement.

Limitations of Group Technology Layout

we may not have meaningful cell formation.

Fixed Position Layout

 Fixed-position layout is used when product is very

Hybrid (mixed) Layout

 For instance, supermarket layouts are