plant...

1. Plant layout ppt by me
1. 1. PLANT LAYOUT Plant layout refers to the arrangement of physical facilities such as
machinery, equipment, furniture etc. with in the factory building 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 material to the shipment of the finished product.
2. 2. DEFINITION According to Riggs, “the overall objective of plant layout is to design a
physical arrangement that most economically meets the required output – quantity and quality.”
 According to J. L. Zundi, “Plant layout ideally involves allocation of space and arrangement
of equipment in such a manner that overall operating costs are minimized.
3. 3. DETERMINENTS OF PLANT LAYOUT 1. TYPE OF PRODUCT (size, shape and quality)
2. TYPE OF PROCESS (technology employed, sequencing etc) 3. VOLUME OF
PRODUCTIONS- (INCREASE OR DECREASE)
4. 4. IMPORTANCE OF PLANT LAYOUT • It is long-term commitment • It facilitates the
production process, minimizes material handling, time and cost, and allows flexibility of
operations • It facilitates easy production flow, makes economic use of the building, promotes
effective utilization of manpower, and provides for employee’s convenience, safety, comfort at
work, maximum exposure to natural light and ventilation. • it affects the flow of material and
processes, labour efficiency, supervision and control, use of space and expansion possibilities .
5. 5. OBJECTIVES OF PLANT LAYOUT • Proper and efficient utilization of available floor
space • To ensure that work proceeds from one point to another point without any delay •
Provide enough production capacity • Reduce material handling costs •Reduce hazards to
personnel • Utilize labour efficiently • Increase employee morale • Reduce accidents • Provide
ease of supervision and control • Provide employee safety and health • Allow ease of
maintenance • Allow high machine or equipment utilization • Improve productivity • To
minimize cost of productions • Better inter department relationship
6. 6. FACTORS INFLUENCING PLANT LAYOUT 1. Factory building :- The nature and size of
the building determines the floor space available for layout. While designing the special
requirements, e.g. air conditioning, dust control, humidity controletc. must be kept in mind. 2.
Nature of product :- Product layout is suitable for uniform products whereas process layout is
more appropriate for custom-made products.
7. 7. 3. Production process :- In assembly line industries, product layout is better. In job order or
intermittent manufacturing on the other hand, process layout is desirable. 4. Type of machinery:
General purpose machines are often arranged as per process layout while special purpose
machines are arranged according to product layout. 5. Repairs and maintenance :- Machines
should be so arranged that adequate space is available between them for movement of
equipment and people required for repairing the machines.
8. 8. 6. Human needs :- Adequate arrangement should be made for cloakroom, washroom, lockers,
drinking water, toilets and other employee facilities, proper provision should be made for
disposal of effluents, if any. 7. Plant environment :- Heat, light, noise, ventilation and other
aspects should be duly considered, e.g. paint shops and plating section should be located in
another hall so that dangerous fumes can be removed through proper ventilation etc. Adequate
safety arrangement should also be made. 8. Management policies :- management policies
regarding size, quality, employee facilities and delivery schedules should be considered while
deciding plant layout.
9. 9. DYNAMICS OF PLANT LAYOUT Increase in the output of the existing product
Introduction of a new product and diversification Technological advancements in machinery,
material, processes, product design, fueletc. Deficiencies in the layout unnoticed by the layout
engineer in the beginning.
10. 10. PRINCIPLES OF PLANT LAYOUT • PRINCIPLE OF MINIMUM MOVEMENT •
PRINCIPLE OF FLOW • PRINCIPLE OF SPACE • PRINCIPLE OF SAFETY • PRINCIPLE
OF FLEXIBILITY • PRINCIPLE OF INTERDEPENDENCE • PRINCIPLE OF OVERALL
INTEGRATION • PRINCIPLE OF MINIMUM INVESTMENT

2. 11. 11. 1. PRINCIPLE OF MINIMUM MOVEMENT As far as possible materials and labour
should be moved over minimum distances.
12. 12. 2. PRINCIPLE OF FLOW The work areas should be arranged according to the sequence
of operations so that there is continuous flow of materials without congestion. The layout
should allow for easy movement of materials without interruption or delay.
13. 13. 3. PRINCIPLE OF SPACE All available cubic space should be effectively used both
vertically and horizontally.
14. 14. 4. PRINCIPLE OF SAFETY There should be consideration for safety and convenience of
workers. There should be built in provision for the safety and comfort.
15. 15. 5. PRINCIPLE OF FLEXIBILITY Layout should be designed in the manner that
production facilities can easily be rearranged when it becomes necessary in future on account of
expansion and technological advancement.
16. 16. 6. PRINCIPLE OF INTERDEPENDENCE Interdependent operations and processes
should be located in close proximity to each other.
17. 17. 7.PRINCIPLE OF OVERALL INTEGRATION All the plant facilities and services should
be fully integrated into a single operating unit so as to maximize efficiency and minimize costs
of production.
18. 18. 8. PRINCIPLE OF MINIMUM INVESTMENT The layout should yield savings in fixed
capital investment through optimum utilization of available facilities.
19. 19. TYPES OF LAYOUTS 1. PRODUCT OR LINE LAYOUT 2. PROCESS OR
FUNCTIONAL LAYOUT 3. FIXED POSITION OR LOCATION LAYOUT 4. COMBINED
OR GROUP LAYOUT
20. 20. 1.PRODUCT OR LINE LAYOUT Under this, machines and equipments are arranged in
one line depending upon the sequence of operations required for the product. The materials
move from one workstation to another sequentially without any backtracking or deviation.
Under this, machines are grouped in one sequence. Therefore materials are fed into the first
machine and finished goods travel automatically from machine to machine, the output of one
machine becoming input of the next.
21. 21. e.g. in a paper mill, bamboos are fed into the machine at one end and paper comes out at
the other end. The raw material moves very fast from one workstation to other stations with a
minimum work in progress storage and material handling. The grouping of machines should
be done keeping in mind the following general principles. a)All the machine tools or other items
of equipments must be placed at the point demanded by the sequence of operations. b)There
should no points where one line crossed another line. c)All the operations including assembly,
testing, packing must be included in the line
22. 22. ADVANTAGES OF PRODUCT LAYOUT 1. Low cost of material handling, due to
straight and short route and absence of backtracking. 2. Smooth and uninterrupted operations 3.
Continuous flow of work 4. Lesser investment in inventory and work in progress 5. Optimum
use of floor space 6. Shorter processing time or quicker output 7. Less congestion of work in the
process 8. Simple and effective inspection of work and simplified production control9. Lower
cost of manufacturing per unit
23. 23. DISADVANTAGES OF PRODUCT LAYOUT 1. High initial capital investment in special
purpose machine 2. Heavy overhead charges 3. Breakdown of one machine will hamper the
whole production process 4. Lesser flexibility as specially laid out for particular product.
24. 24. SUITABILITY OF PRODUCT LAYOUT 1. Mass production of standardized products 2.
Simple and repetitive manufacturing process 3. Operation time for different process is more or
less equal 4. Reasonably stable demand for the product 5. Continuous supply of materials
Therefore, the manufacturing units involving continuous manufacturing process, producing few
standardized products continuously on the firm’s own specifications and in anticipation of sales
would prefer product layout e.g. chemicals, sugar, paper, rubber, refineries, cement,
automobiles, food processing and electronics etc.

3. 25. 25. 2.PROCESS OR FUNCTIONAL LAYOUT In this type of layout machines of a similar
type are arranged together at one place. E.g. Machines performing drilling operations are
arranged in the drilling department, machines performing casting operations be grouped in the
casting department. Therefore the machines are installed in the plants, which follow the process
layout. The work, which has to be done, is allocated to the machines according to loading
schedules with the object of ensuring that each machine is fully loaded. Used when the
operations system must handle a wide variety of products in relatively small volumes (i.e.,
flexibility is necessary)
26. 26. The grouping of machines according to the process has to be done keeping in mind the
following principles – 1. The distance between departments should be as short as possible for
avoiding long distance movement of materials. 2.The departments should be in sequence of
operations 3.The arrangement should be convenient for inspection and supervision
27. 27. ADVANTAGES OF PROCESS LAYOUT 1. Lower initial capital investment in machines
and equipments. There is high degree of machine utilization, as a machine is not blocked for a
single product 2. The overhead costs are relatively low 3. Change in output design and volume
can be more easily adapted to the output of variety of products 4. Breakdown of one machine
does not result in complete work stoppage 5. Supervision can be more effective and specialized
6. There is a greater flexibility of scope for expansion
28. 28. DISADVANTAGES OF PROCESS LAYOUT Material handling costs are high due to
backtracking More skilled labour is required resulting in higher cost. Time gap or lag in
production is higher Work in progress inventory is high needing greater storage space More
frequent inspection is needed which results in costly supervision
29. 29. SUITABILITY OF PROCESS LAYOUT Products are not standardized Quantity
produced is small There are frequent changes in design and style of product Job shop type of
work is done Machines are very expensive Thus, process layout or functionallayout is suitable
for job order production involving non-repetitive processes and customer specifications and
non-standardized products, e.g. tailoring, light and heavy engineering products, made to order
furniture industries, jewelry.
30. 30. 3.FIXED POSITION OR LOCATION LAYOUT In this type of layout, the major product
being produced is fixed at one location. Equipment labour and components are moved to that
location. All facilities are brought and arranged around one work center. This type of layout is
not relevant for small scale entrepreneur. E.g. - shipbuilding
31. 31. ADAVANTAGES OF FIXED POSITION LAYOUT 1. It saves time and cost involved on
the movement of work from one workstation to another. 2. The layout is flexible as change in
job design and operation sequence can be easily incorporated. 3. It is more economical when
several orders in different stages of progress are being executed simultaneously. 4. Adjustments
can be made to meet shortage of materials or absence of workers by changing the sequence of
operations.
32. 32. DISADVANTAGES OF FIXED POSITION LAYOUT Production period being very long,
capital investment is very heavy Very large space is required for storage of material and
equipment near the product. As several operations are often carried out simultaneously, there
is possibility of confusion and conflicts among different workgroups.
33. 33. SUITABILITY OF FIXED POSITION LAYOUT Manufacture of bulky and heavy
products such as locomotives, ships, boilers, generators, wagon building, aircraft
manufacturing, etc. Construction of building, flyovers, dams.
34. 34. 4.COMBINED OR GROUP LAYOUT Certain manufacturing units may require all three
processes namely intermittent process (job shops), the continuous process (mass production
shops) and the representative process combined process In most of industries, only a product
layout or process layout or fixed location layout does not exist. Thus, in manufacturing concerns
where several products are produced in repeated numbers, Generally, a combination of the
product and process layout or other combination are found in practice.

4. 35. 35. e.g. for industries involving the fabrication of parts and assembly, fabrication tends to
employ the process layout, while the assembly areas often employ the product layout. In soap,
manufacturing plant, the machinery manufacturing soap is arranged on the product line
principle, but ancillary services such as heating, the manufacturing of glycerin, the power house,
the water treatment plant etc. are arranged on a functional basis.
36. 36. RECENT TRENDS IN PLANT LAYOUT Plant layout is the art and science of bringing to
gather men, materials, methods and supporting facilities in the form of a given arrangements
that suits individuals industrial activity to have the benefits of profits maximizations through
economy, efficiency, effectiveness and productivity. The designing and instilling a layout is the
responsibility of Engineering and planning department. The process of preparing layout is an art
and well as science.
37. 37. The recent trends in layout are as follows – 1. The use of computerized facilities design:
The various techniques have been developed and used in layout engineering such as ALDEP
(Automated layout design program), CORELAP (Computerized relationship layout planning),
CRAFT (computerized related allocation of facilities technique), CALP (computer Aided layout
planning) etc. These and other programme can save time and effort in large and complex layout
problems.
38. 38. 2. The use of various tools and techniques for planning the layout – Templates: It is a
pattern which consists of thin plate of wood or metal which serves as gauge or guide in
mechanical work. A plant layout template is a scaled representation of physical object in a
layout. Model equipment: Model or three dimensional models represents machinery installed
in a factory. It is a replica or a miniature prototype of machine and equipment. These show
minor details and can be mounted on a thick plastic sheet.  Layout drawing: Layout drawings
are the replica of a factory floor plan showing the space management. It is blue print which
indicates the total square feet where all the equipment has to be arranged.
39. 39.  Plot plan: Is a miniature of the entire factory building including the facilities of workers.
 Line balance: is phase of assembly line study that equally divides then works to be done
among workers so that the total number of employees required is minimum. OR concepts like
linear programming, dynamic programming and optimal methods are used to study line balance
problem.
40. 40. FACTORY BUILDING A ideal plant building is the one which is built to house the most
efficient layout that can be provided for the process involved, and artificially attractive and of
such standard shape and design which is flexible its use and expansive units construction. The
building ensures functional smoothness of the operation. It should be strong enough to
withstand damages, vibrations and heavy machines.
41. 41. FACTORS IN DESIGNING IN FACTORY BUILDING Adaptability. Expandability.
Product and equipment. Employees facilities and services areas. Materials handling.
Lighting, ventilation and air-conditioning. Fire protection. Security and services and
maintenance.
42. 42. TYPES OF BUILDINGS The decision on choosing a suitable type for a particular firm
depends among other things on the manufacturing process, the area of land, and the cost of
construction. The industrial building can be grouped under four types – 1. Single storey building
2.High bay and monitor types 3.Multi-storey building 4.Special building
43. 43. Single storey building: The reduced cost of land and extensive transport facilities have
encouraged single storey buildings in sub-urban areas. High bay and monitor types: It is a
single storey structures with roof surrounded by a monitor, giving maximum overhead space.
The overhead space may be used to operate crane and other overhead facilities. The monitor
provides natural ventilation and side walls with glass provide natural lighting. Multi-storey
building: In big cities costs of land is high and has no much scope of horizontal expansion
which has given ways to multi-storey. Special building: these are needed for certain
manufacturing processes. Eg the aircraft industry needs a building with spans 300 to 500 feet in
length.

5. 44. 44. PLANT UTILITIES Plant utilities refer to such services as lighting, ventilation, air-
conditioning etc. All these deserve due consideration from operations management as they
contribute to increased efficiency and greater output. The types of plant facilities and services
are as follow: 1. Plant Lighting 2. Ventilation 3. Air-conditioning 4. Industrial Sanitation 5.
Noise control 6. Industrial safety
45. 45. A. Plant lighting: Adequate lighting is necessary for a worker to perform his job with ease
and accuracy. According to all India General Standards a minimum of 14 to 18 lumens of
illuminations is considered adequate. Importance of Good illumination:  Ease of
seeing./reduced eye strain,  Improved quality of work.  Better utilization of floor space. 
Good housekeeping.  Fewer accidents.  Improved employee morale/ better supervision. 
Flexible layout.
46. 46. There are two major source of lighting – 1. Day light 2.Artificial light 1. Day light - It is
natural lighting which is received from the sun. 2. Artificial light – It refers to illumination
through artificial means as bulbs and tubes. Types of artificial lights are – a. General lighting -
General lighting is provided by fixtures, luminaries or grid system placed 10 ft above the work
area. The light is provided uniformly over the whole department in a sufficient intensity to
satisfy the requirement of the general manufacturing conditions within it.
47. 47. b. Supplementary lighting – It involves the provision of intense light at the point of work or
in adjacent areas to suit the worker particular requirement. TYPES OF LIGHT SOURCES – 1.
Filament or incandescent lamps. 2. Discharge lamps or fluorescent lamps. 3. Electro-
luminescent lamps, mercury vapor lamps.
48. 48. B. VENTILATION – Ventilation is concerned largely with engineering techniques for
controlling air currents within the plant and for introducing outdoor air in a pattern and on a
scale that is just adequate to maintain satisfactory air purity. Importance of ventilation are –
Protection of the health of workers. Preservation of quality of the product Meets legal
requirement.
49. 49. TYPES OF VENTILATION 1. General ventilation – To keep the working conditions at
acceptable comforts level. To keep contaminants in the air within safe limits. 2.General
exhaust ventilation – It is a system for preventing the contamination of factory air by
withdrawing the contaminant at its source into a duct system for discharge to the building
exterior.
50. 50. SOURCES OF VENTILATION 1. NATURAL VENTILATION 2. MECHANICAL
VENTILATION C. AIR CONDITIONING - Industrial air-conditioning requires controlover
temperatures, humidity, dust, purity and odors. Objectives of air-conditioning 1. To protect
worker’s health. 2. To improve workers comfort level. 3. To secure specified temperature
conditions. 4. To improve the quality of products. 5. Product preservations. 6. To reduce
maintenance charges. 7. To improve employer-employee relations.
51. 51. D. INDUSTRIAL SANITATION - Sanitation refers to controlof the spread of infection and
other insults to the health of the employees. Occupational disease caused by the industrial
process leads to employee’s dissatisfaction and turnover. OBJECTIVES – Supply of portable
water. Disposal of waste and effluents. Provision of food which is free from contamination.
Elimination of insects and rodents. Provision of personal services. Good housekeeping.
52. 52. E. NOISE CONTROL -Noise is unwanted and unpleasant sound. Elements – Impairs the
hearing of employees. Results in fatigue and nervousness. Vibration causes damage to
machinery and equipments. Bad working environment Noise controlmethods – Control by
absorption Control at source Control by ear protection
53. 53. BREAK EVEN ANALYSIS