Chetana’s H.

S college of commerce and

economics

Group no: 3

PLANT LAYOUT
 INTRODUCTION

EFFICIENCY AND
SUITABLE LAYOUT PERFORMANCE
 WHAT IS PLANT?

Building Fixtures

MACHINES
 WHAT IS PLANT?

TOOLS

SERVICE
MACHINERY
WHAT IS PLANT?

WORK
SHOP
EQUIPMENT
 WHAT IS LAYOUT ?
ARRANGEMENT OF
FACILITIES Tools

Machines Work center

Equipment
LAYOUT
 To raise
To reduce the cost
productive
of production
efficiency

To improve speed and To avoid delays in the

quality of production production processes

OBJECTIVE

To use available To maintain

area & floor effective
economically supervision
 To make provision
To make provision
for rearrangement in
for future expansion
the plant

To provide working To provide

conditions & safety efficient materials

OBJECTIVE
 IMPORTANCE OF PLANT LAYOUT

Quick
SAVE execution
HANDLING of
Better
REMOVE Quality
OPTIMUM USE OF AVAILABLE
Control
BOTTLENECKS
AREA orders
COST
IMPORTANCE OF PLANT LAYOUT

Improved
Limited
Improved
production
investment
supervision
control

Improved
Best use
employee
of labour
morale
 Factors influencing plant layout.

1. Type of industry:
For example- the layout of chemical factory ill be different as
compared to the layout of an engineering unit. Thus, plant layout
is influenced by the type of industry.
 Factors influencing plant layout.

2.Nature of plant
location

3.Nature and size of

factory building
 Factors influencing plant layout.

4. Features of Production Process

1. The volume of work to be

handled

2. The products to be manufactured

including their components

3. The assembling process and the ancillary

services required for production activity
 Factors influencing plant layout.

5. Space available in the plant for

handling materials

6.Space required by
machines
 Factors influencing plant layout.

7. Facilities required
by workers

8.Management polices
 Factors influencing plant layout.

9.SIZE OF OUTPUT

10.Miscellaneous factors
 Various tools
and technique

Two-
METHODOLOGY dimensional
templates

Depends upon
the layout
 TYPES OF TOOLS AND
TECHNIQUE

Process charts

Process flow diagrams

Machine data
cards

Visualization of layout
 CURRENT SCENARIO

Computers help in layout engineering

Solves large and complex

problems
CURRENT SCENARIO

Saves time and effort

Finally hand-tuned and checked

for logic
PRINCIPLES OF PLANT
LAYOUT.
 PRINCIPLES OF PLANT LAYOUT.

Principle of minimum
movement Flexibility

Compactness Low investment

 PRINCIPLES OF PLANT LAYOUT.

Full utilization of
Maintain sequence available
of operation space

Safety and
Integration satisfaction
of the customers
 ADVANTAGES OF SCIENTIFIC PLANT
LAYOUT.

1.Lower production cost due to:-

Reduced material handling cost

Lower labour cost and increase in

output per man-hour

Lower cost of scrap and waste

 ADVANTAGES OF SCIENTIFIC PLANT
LAYOUT.

1.Lower production cost due to:-

Reduction in manufacturing
time

Reduction in maintenance cost of

tools & machines
 Smooth
working of the
factory
Higher
inventory turn
over Higher rate of
production per square
foot of factory floor
More effective space
utilization of machine
A faster flow
capacity & man power
of work in
process

2. ADVANTAGES OF SCIENTIFIC
PLANT LAYOUT.
ADVANTAGES OF SCIENTIFIC PLANT
LAYOUT.
3. Superior customer services due to

Quicker & more reliable deliveres

according promised dates

A better quality of product

A competitive price
ADVANTAGES OF SCIENTIFIC PLANT
LAYOUT
4.Satisfaction to workers due to

Easy and convenient physical

movement during work

Reduce floor accidents and

limited number of handlings

Better working conditions

Less physical efforts/strain

ADVANTAGES OF SCIENTIFIC PLANT
LAYOUT
5. Effective supervision due to

Reduction in the amount

of inspection

Reduction in the cost of

supervision

Limited burden of
supervision
 FEATURES OF GOOD PLANT LAYOUT

Adequate space for

free Safety to workers
movement of
workers

Effective
Maximum
Production
flexibility
Control
 FEATURES OF GOOD PLANT LAYOUT

Convenience in Adequate
storing gangway space

Minimum Minimum damage

materials & spoilage of
handling material
 Indicators of poor layout
Strain
Lowon
Long
Poor utilization Excess
workers
materials
and
of Transportation
productivity
inadequate
handling
available space and lines
profits
safety

Ineffective Congestion of
Long production
Excessive amount
Production
supervision and material,
cycles and delays
of work
control in
on components &
bottlenecks
inprocess
delivery
employees assemblies
 DRAWBACKS OF POOR
LAYOUT
Low production density and under
utilization of plant capacity

Absence of flexibility in the plant

production facilities

Inadequate safety provisions

for workers

Long processing time due to too

many delays, temporal storage and
bottlenecks
 DRAWBACKS OF POOR
LAYOUT
Improper utilization of plant site
and inadequate transportation
facilities for the movement of
materials

Uneconomical materials
handling

Inadequate storage facilities

Equipment and machinery not easily

accessible for maintenance and
repair due to poor layout
 DRAWBACKS OF POOR
LAYOUT
Costly inspection quality
standards are difficult to maintain

Poor lighting , ventilation and

space for the movement of
workers

Over specialization of
production facilities
 PROCESS LAYOUT

• grouping together like machines

E.g..
1. Machines performing drilling operations are installed
in the drilling dept.
2. machines performing casting operations are grouped
in casting dept.

• ‘General purpose machines’.

• No machines should be ideal.

 GROUPING PRINCIPLES OF MACHINE

Distance between
departments must
be short

Location of
departments

Convenience
for inspection

Convenience
for
supervision
 ADVANTAGES

Reduced Greater Greater

investments flexibility incentives

Better
Better & more
Greater scope utilization of
e ff i c i e n t
supervision for expansion men &
machines
 ADVANTAGES

Easier to handle
breakdown

Va r i e t y m a k e s
the job
interesting
DISADVANTAGES:
• Difficulty in movement of materials and machine

• More floor space.

• Difficulty in production control.

• more production time

• Accumulation of work in progress.

PROCESS LAYOUT FOR

MEDICAL CLINIC
Neurology Gynecology Laboratory test

Rest room
Patient waiting
Reception
hall X-ray
room
Plastic &
Reconstructive
surgery
pediatrics

pediatrics

Patient entrance
pharmacy clinic

Patient exit clinic

 PRODUCT LAYOUT
• arrangements of machines in one line,
• depending upon sequence of operations.
• special purpose machines
• The product layout is followed in plants manufacturing standardized products on a
mass scale such as chemical, paper, sugar, rubber, refineries & cement industries.

EXAMPLE:

‘back office’ of services such as banks and insurance companies.

 GROUPING PRINCIPLES OF MACHINE

• Placement should be according to sequence.

• There should be no points where one line crosses
another line.
• Materials may be fed where they are required for
assembly, but not necessarily all at one point.
• All the operations should be included in the line.
 ADVANTAGES
• High output rate

• Low unit cost

• Labour specialization

• avoids production bottlenecks.

• Short processing time

• less floor area

• greater incentives
 DISADVANTAGES
• Dull and repetitive jobs.

• inflexibility.

• expensive.

• difficulty of supervision.

• Expansion is difficult.

• breakdown of equipment leads to shutdown.

 PRODUCT LAYOUT IN MANUFACTURING
PRODUCT

STARTS DRILL PRESS

PRODUCTION LATHE #2

PACKAGING
MACHINE
DRILL
PRESS PAINTING
#1 MACINE

FINISH
PRODUCTION
 F I XED LAY OUT
Involves the movement The materials or major
of men & components remains in a fixed
machines location

EXAMPLE:
Manufacturing of bulky & heavy products, such as, construction of
buildings and dams, locomotives, ships, boilers, aircraft & generators.
 ADVANTAGES

High cost &

difficulty in Greater enthusiasm
transporting of workers

Investment is very
small
Wide variety of
operations and
products
 DISADVANTAGES
Production period is Capital investment is
very long very heavy

Large space is
required for storage

Possibility of
confusion and
conflicts
 FIXED POSITION LAYOUT

Raw materials

m/c’s & AIR CRAFT

Finished produc
equipments ASSEMBLY (air craft)
Labour
CONCLUSION
 1.EFFICIENT PLANT LAYOUT

Floor space

Minimum cost

Improves productivity

Improves productivity
 2.DECIDING THE LAYOUT

Nature of product

Production process

Size of building

Human needs
 3.PLANT LAYOUT SHOULD

Health and safety

Free and efficient

flow

Future expansion and

diversification