SYSTEMATIC LAYOUT PLANNING

• Systematic Layout Planning (SLP) is a

technique developed by Richard Muther
and Associates. The 3 fundamental areas of
the technique; Relationships; Space and
Adjustment, include 10 sub-headings within
the process:
• Relationships
1. Collection of Input Data
2. Flow of Materials
3. Activity Relationships
4. Relationship Diagrams
• Space
1. Space Requirements
2. Space Available
3. Space Relationship Diagrams
• Adjustments
1. Modifying Considerations
2. Practical Limitations
3. Evaluation & Final Selection
• This technique combines quantitative
measurement of materials movement with
non-flow considerations such as noise,
fumes, temperature, supervision,
communications, personnel comfort and
movement. It’s major advantage being that
it clearly documents the logic of the layout
and easily allows input from all levels of
staff.
 PLANT LAYOUT
• A FLOOR PLAN FOR DETERMINING AND
ARRANGING THE DESIRED MACHINERY
AND EQUIPMENT OF A PLANT
• IT PERMITS
–THE QUICKEST FLOW OF MATERIALS IN
PROCESSING THE PRODUCT
•FROM THE RECEIPT OF THE RAW MATERIALS TO
THE SHIPMENT OF THE FINISHED PRODUCT
–AT THE LOWEST COST, AND
–WITH THE LEAST AMOUNT OF HANDLING
 OBJECTIVES

• PROVIDE ENOUGH PRODUCTION CAPACITY

• REDUCE MATERIAL HANDLING COST
• REDUCE CONGESTION IMPEDING
MOVEMENT OF MEN AND MATERIAL
• REDUCE HAZARDS TO WORKING
PERSONNEL
• UTILISE LABOUR EFFICIENTLY
• INCREASE EMPLOYEE MORALE
• UTILISE AVAILABLE FLOOR SPACE
EFFICIENTLY AND EFFECTIVELY
 OBJECTIVES
• REDUCE ACCIDENTS
• PROVIDE FOR VOLUME AND PRODUCT
FLEXIBILITY
• PROVIDE EASE OF SUPERVISION AND
MAINTENANCE
• FACILITATE CO-ORDINATION AND FACE-TO-
FACE COMMUNICATION
• PROVIDE FOR EMPLOYEE SAFETY AND
HEALTH
• ALLOW HIGH MACHINE UTILISATION
• IMPROVE PRODUCTIVITY
 CRITICAL FACTORS
• MATERIALS
– TYPE, AVAILABILITY, PROVISION FOR
STORAGE AND MOVEMENT
• PRODUCT
– TYPE I.E. HEAVY,LIGHT, WET OPERARTION
(CEMENT), MARKET DEMAND (DECISION ON
MACHINERY TYPE)
• WORKERS
– MALE, FEMALE (SPECIAL NEEDS), FACILITIES
• MACHINERY
– FIXED OR MOBILE POSITION OF MEN,
MACHINERY, JOB TO DECIDE MACHINERY
LAYOUT-DEPENDING ON TYPE, VOLUME OF
PRODUCTION
 CRITICAL FACTORS
• TYPE OF INDUSTRY
– SYNTHETIC
• CONSTITUENT ELEMENTS COMBINING TO MAKE THE
FINAL PRODUCT E.G. CHEMICAL INDUSTRY
– ANALYTICAL
• CONVERSION OF RAW MATERIALS INTO VARIOUS
ELEMENTS E.G. PETROLEUM INDUSTRY
– CONDITIONING
• CHANGING IN SHAPE / FORM OR PHYSICAL PROPERTIES
E.G. FOUNDARY, METAL WORKING INDUSTRY
– EXTRACTIVE
• INVOLVING SEPARATION OF ONE ELEMENT FROM THE
OTHER E.G. METAL FROM IRON ORE
– EACH OF ABOVE FURTHER CLASSIFIED INTO
• INTERMITTENT INDUSTRIES
• CONTINUOUS INDUSTRIES
 CRITICAL FACTORS
• LOCATION
– SIZE AND TERRAIN DECIDES TYPE OF BUILDING
– LOCATION DECIDES MODE OF TRANSPORTATION OF
RAW MATERIAL AND FINISHED PRODUCTS
– FUEL REQUIREMENT FOR THE PLANT
– FUTURE EXPANSION PROVISION
• MANAGERIAL POLICIES
– VOLUME OF PRODUCTION AND EXPANSION
– EXTENT OF AUTOMATION
– MAKING OR BUYING DECISION
– RAPID DELIVERY TO CUSTOMERS
– PURCHASING POLICY
– PERSONNEL POLICIES
 PRINCIPLES OF LAYOUT

• PRINCIPAL OF MINIMUM TRAVEL

• PRINCIPLE OF SEQUENCE
• PRINCIPLE OF USAGE
• PRINCIPLE OF COMPACTNESS
• PRINCIPLE OF SAFETY AND SATISFACTION
• PRINCIPLE OF FLEXIBILITY
• PRINCIPLE OF MINIMUM INVESTMENT
 TYPES

• PROCESS LAYOUT, FUNCTIONAL LAYOUT

OR JOB SHOP LAYOUT
• PRODUCT / LINE PROCESSING OR FLOW
LINE LAYOUT
• FIXED POSITION / STATIC LAYOUT
• CELLULAR MANUFACTURING (CM) OR
GROUP TECHNOLOGY (GT) LAYOUT
• COMBINATION / HYBRID LAYOUT
 PROCESS LAYOUT
• GROUPING TOGETHER OF SIMILAR
MACHINES IN ONE DEPARTMENT
• MATERIAL MOVES FROM ONE GROUP OF
MACHINES TO THE OTHER
• MOVEMENT OVER LONGER DISTANCE
AND ALONG CRISS-CROSS PATHS
• MAY ALSO INVOLVE PART FINISHED
INVENTORY WAITING

BEST SUITED FOR INTERMITTENT TYPE OF

PRODUCTION/LIGHT AND HEAVY INDUSTRIES
 PRODUCTION SUB-SYSTEM

RAW MATERIALS
RECEIVING

OPERATION A OPERATION B
WIP WIP

STORAGE EDP
MATERIAL FLOW
CONTROL
FINISHED SYSTEMS
GOODS WIP
WIP

OPERATION D OPERATION C
SHIPPING
INFORMATION
FINISHED GOODS
FLOWS

INTERMITTENT FLOW PRODUCTION SYSTEM (JOB SHOP )

 PROCESS LAYOUT

• IMPORTANT CONSIDERATIONS
– DISTANCE BETWEEN DEPARTMENTS AS SMALL AS
POSSIBLE
– DEPARTMENTS TO BE LOCATED AS PER SEQUENCE
OF OPERATION
– CONVENIENCE FOR INSPECTION AS WELL AS
SUPERVISION
 PROCESS LAYOUT
• ADVANTAGES
– REDUCED INVESTMENT ON MACHINES, BEING
GENERAL PURPOSE MACHINES
– GREATER FLEXIBILITY IN PRODUCTION
– BETTER AND MORE EFFICIENT SUPERVISION
– GREATER SCOPE OF EXPANSION
– BETTER UTILISATION OF RESOURCES
– HADLING BREAKDOWN OF EQUIPMENT
EASIER-JOBS CAN BE TRANSFERRED TO
OTHER MACHINES
– FULL UTILISATION OF MACHINERY
 PROCESS LAYOUT

• LIMITATIONS
– DIFFICULTY IN MOVEMENT OF
MATERIALS
– LAYOUT REQUIRES MORE SPACE
– DIFFICULTY IN PRODCUTION CONTROL
– PRODUCTION TIME INCREASED
BECAUSE OF EXTRA TRAVEL
– ACCUMULATION OF WORK-IN-PROCESS
AT DIFFERENT MACHINES
 PRODUCT LAYOUT
• MACHINES ARRANGED IN A LINE DEPENDING
UPON SEQUENCE OF OPERATIONS
• MATERIAL MOVES IN A LINE FROM THE FIRST
MACHINE TO THE FINISHED PRODUCT ON THE
LAST MACHINE.
• INVESTMENT HIGHER AS COMPARED TO
PROCESS LAYOUT

BETTER SUITED FOR STANDARDISED PRODUCTS ON

A MASS SCALE PRODUCTION. EX CHEMICALS,PAPER
 PRODUCTION SUB-SYSTEM

RAW MATERIALS
RECEIVING

OPERATION B

STORAGE
OPERATION A EDP
CONTROL
MATERIAL FLOW
OPERATION D SYSTEMS

OPERATION C
SHIPPING
FINISHED GOODS INFORMATION
FLOWS

CONTINUOUS FLOW PRODUCTION SYSTEM (FLOW SHOP)

 PRODUCT LAYOUT

• IMPORTANT CONSIDERATIONS
– ALL MACHINES PLACED AT POINTS DEMANDED BY
SEQUENCE OF OPERATION
– NO CROSSING OVER OF ONE LINE WITH THE OTHER
– MATERIALS MAY BE FED WHERE THEY ARE
REQUIRED FOR ASSEMBLY BUT NOT NECESSARILY
ALL AT ONE POINT
– ALL OPERATIONS INCLUDING ASSEMBLY, TESTING
AND PACKING INCLUDED IN THE LINE
 PRODUCT LAYOUT

• ADVANTAGES
– REDUCTION IN MATERIAL HANDLING COST
DUE TO MECHANISATION
– LAYOUT AVOIDS PRODUCTION BOTTLENECKS
– ECONOMY IN MANUFACTURING TIME
– BETTER PRODUCTION CONTROL
– REQUIRES LESS FLOOR AREA PER UNIT OF
PRODUCTION
– WORK-IN-PROGRESS IN REDUCED
– EARLY DETECTION OF MISTAKES
 PRODUCT LAYOUT

• LIMITATIONS
– LAYOUT INFLEXIBLE
– LAYOUT EXPENSIVE
– DIFFICULTY IN SUPERVISION
– EXPANSION IS DIFFICULT
– ANY BREAKDOWN ALONG THE LINE
CAN DISRUPT TOTAL PRODUCTION
 FIXED POSITION LAYOUT

• MOVEMENT OF MEN & MACHINERY TO

THE PRODUCT
• PRODUCT REMAINS STATIONARY
– COST OF MOVING PRODUCT IS HIGH,BEING
BULKY

BEST SUITED FOR BULKY & HEAVY

PRODUCTS EX.SHIPS, AEROPLANES ETC.
RAW MATERIALS

MACHINE & FINISHED PRODUCT

EQUIPMENT
AIRCRAFT ASSEMBLY (AIRCRAFT)

LABOUR

FIXED POSITION OR STATIC LAYOUT

 FIXED POSITION LAYOUT
ADVANTAGES
• MEN/MACHINERY CAN BE MOVED FOR A
WIDE VARIETY OF OPERATIONS
PRODUCING DEFFERENT PRODUCTS
• WORKER IDENTIFIES HIMSELF WITH THE
PRODUCT & TAKES PRIDE WHEN THE
WORK IS COMPLETED
• INVESTMENT ON LAYOUT IS SMALL
• HIGH COST & DIFFICULTY IN
TRANSPORTING A BULKY JOB AVOIDED
CELLULAR MANUFACTURING (CM)
LAYOUT
• GROUPING OF MACHINES INTO CELLS
• CELLS FUNCTION SOMEWHAT LIKE
PRODUCT LAYOUT WITHIN A LARGER
SHOP OR PROCESS LAYOUT
• EACH CELL IN THE CM FORMED TO
PRODUCE A SINGLE PART / A FEW PARTS
– ALL WITH COMMON CHARACTERISTICS
WHICH USUALLY REQUIRES SIMILAR
MACHINES AND SETTINGS
• FLOW OF PARTS WITHIN THE CELL CAN
TAKE MANY FORMS
 CELLULAR MANUFACTURING LAYOUT

CELL # 2
CELL # 1

1 2
PART D
1 2 3
3
PART X
5 4
PART Y

1 2
PART A CELL # 4
1 2 3
PART B
4 3 CELL # 3

PRODUCTION OPERATION PRODUCT OR MATERIAL FLOW

 CM LAYOUT
ADVANTAGES
• LOWER WORK-IN-PROCESS INVENTORIES
– REDUCED MATERIAL HANDLING COSTS
– SHORTER FLOW TIMES IN PRODUCTION
– SIMPLIFIED PRODUCTION PLANNING (MEN,
MATERIAL ETC.)
– OVERALL PERFORMANCE OFTEN INCREASES
BY LOWERING PRODUCTION COSTS &
IMPROVING ON-TIME DELIVERY
– IMPROVED QUALITY
 CM LAYOUT
LIMITATIONS
• REDUCED MANUFACTURING FLEXIBILITY &
POTENTIALLY INCREASED MACHINE
DOWNTIME
• DUPLICATE PIECES OF MACHINERY MAY BE
NEEDED SO AS TO AVOID MOVEMENT OF
PARTS BETWEEN CELLS
 COMBINED LAYOUT
• COMBINATION OF PRODUCT & PROCESS
LAYOUT WITH AN EMPHASIS ON EITHER
• GENERALLY ADOPTED IN INDUSTRY
• IN FABRICATION PLANTS INCLUDING
ASSEMBLY, FABRICATION TENDS TO
EMPLOY PROCESS LAYOUT WHILE
ASSEMBLY AREAS EMPLOY PRODUCT
LAYOUT
– SOAP MANUFACTURING INDUSTRY EMPLOYS PRODUCT
LINE FOR MANUFACTURING OF SOAP, BUT ANCILLARIES
SUCH AS HEATING, MANUFACTURING OF GLEYCERINE,
POWER HOUSE ETC. ARE ARRANGED ON FUNCTIONAL
BASIS.
 PRODUCT LAYOUT

RAW MATERIAL F.P. G.C. H.T. G.G.

FINISHED
PRODUCTS
(GEARS)

G.C. H.T.
RAW MATERIAL F.P. G.G.
PROCESS LAYOUT

G.C.

F.P. = FORGING PRESS G.C. = GEAR CUTTING

H.T. = HEAT TREATMENT FURNACE G.G. = GEAR GRINDING MACHINE

COMBINATION LAYOUT OR HYBRID LAYOUT FOR GEAR MANUFACTURING

 SERVICE FACILITY LAYOUT

• MAIN DIFFERENCE BETWEEN SERVICE AND

MANUFACTURING FACILITY IS TO BRING
TOGETHER CUSTOMERS & SERVICES IN MANY
SERVICE FACILITIES
• FACILITIES TO PROVIDE FOR
– EASY ENTRANCE FROM THE FREEWAYS AND BUSY
THOROUGHFARES
– LARGE WELL ORGANISED AND AMPLY ILLUMINATED
PARKING AREAS ETC.
• HOTELS, CINEMA HALLS ETC HAVE
DIFFERENT AREAS TO CATER TO THE
COMFORT & CONVENIENCE OF CUSTOMERS
 EXIT ENTRANCE

PARKING AREA CASUALTY DEPT / INPATIENT DEPT PARKING AREA

PARKING AREA
HOSPITAL WARDS

SURGERY, RADIOLOGY,
I.C.U., TECH SERVICES

AISLES / GANGWAYS
HOSPITAL WARDS

DOCTORS
LOUNGE /
OFFICES NURSES

PARKING AREA
HOSPITAL WARDS CAFETERIA
LOUNGE
ADMIN. OFFICE

PARKING AREA CASUALTY DEPT / INPATIENT DEPT PARKING AREA

ENTRANCE EXIT

SERVICE FACILITY LAYOUT ( HOSPITAL LAYOUT )

 SERVICE FACILITY LAYOUT

• LAYOUT IMPORTANT TO ACHIEVE CLIENT-

CUSTOMER GOAL OF FAST SERVICE
– FAST SERVICE SUPPORTED BY POINT OF SALE SYSTEM,
SCANNERS, SELF SERVICE TO PROVIDE SPEED AS WELL
AS REDUCE COST, ATMs BY BANKS ETC.
• FLOW LINE APPROACH FOLLOWED IN FAST FOOD
SERVICE
• PROCESS LINE LAYOUT OCCURS IN MANY
SERVICES LIKE MEDICAL CLINICS, OFFICES ETC.
 SERVICE FACILITY LAYOUT

• GENERALLY, AS IN MANUFACTURING
– LINE LAYOUT PREFERRED IN HIGH
VOLUME, STANDARDISED PRODUCTS
• FAST FOOD SERVICE
– PROCESS LAYOUT PREFERRED IN
SERVICE OPERATIONS ALSO
• GENERAL OFFICES, BANKS, GENERAL
HOSPITALS, MUNICIPAL OFFICES ETC.
 SERVICE WAITING LINE MODULES

WAITING LINE SERVICE WAITING LINE SERVICE

FACILITY FACILITY
SINGLE CHANNEL, SINGLE CHANNEL,
SINGLE PHASE MODULE MULTIPLE PHASE MODULE

WAITING LINE SERVICE WAITING LINE SERVICE

FACILITY FACILITY

MULTIPLE CHANNEL, MULTIPLE CHANNEL,

SINGLE PHASE MODULE MULTIPLE PHASE MODULE
 LAYOUT PLANNING
• NEED FOR FUTURE REVISIONS CAUSED DUE
TO EXPANSIONS, TECHNOLOGICAL
ADVANCES, IMPROVED LAYOUTS ETC
• MAJOR CRITERIA FOR SELECTING AND
DESIGNING LAYOUTS
– MATERIAL HANDLING COST
• MATERIAL HANDLING COSTS MINIMISED BY USING
MECHANISED MATERIAL HANDLING EQUIPMENTS
– WORKER EFFECTIVENESS
• GOOD LAYOUT PROVIDES WORKERS WITH A
SATISFYING JOB AND PERMITS THEM TO WORK MORE
EFFECTIVELY AT THE HIGHEST SKILL LEVEL
• GOOD COMMUNICATION SYSTEM AND WELL PLACED
SUPPORTING ACTIVITY LOCATIONS IMPORTANT
 LAYOUT PLANNING
METHODOLOGY
• TRAVEL CHART METHOD
• LOAD-DISTANCE ANALYSIS METHOD
• SYSTEMATIC LAYOUT PLANNING
METHOD
• ANALYSING LAYOUTS WITH COMPUTERS
– ALDEP (AUTOMATED LAYOUT DESIGNING
PROGRAMME)
– CORELAP (COMPUTERISED RELATIONSHIP
LAYOUT PLANNING)
– CRAFT (COMPUTERISED RELATIVE
ALLOCATION OF FACILITIES TECHNIQUE)
THANK YOU
 REFERENCES

• PRODUCTION & OPERATIONS MANAGEMENT:

ASWATHAPPA / BHAT
• MODERN PRODUCTION / OPERATIONS
MANAGEMENT: BUFFA / SARIN
• PRODUCTION OPERATIONS MANAGEMENT:
LEVIN / MCLAUGHLIN et al