plant layout and its types

1. PLANT LAYOUT
AND
ITS TYPES

2.  PLANT LAYOUT :
 Plant layout is defined as “ to locate
different machines & plant services within
the factory so that the greatest possible
output of high quality at the lowest possible
total cost can be available.”
 Good plant layout is one of the vital factors
for success in factory development.

3.  THE LAYOUT DESIGN GENERALLY DEPENDS ON THE
PRODUCTS VARIETY AND PRODUCTION VOLUMES.
Four types of plant layout
are referred to,
A. Process layout(functional
layout)
B. Product layout ( Line
layout)
C. Fixed layout
D. Combined layout

4. A.PROCESS LAYOUT (FUNCTIONAL LAYOUT)
• Process layout groups machinery and equipment
according to their functions.
• Facilitates production of a variety of nonstandard
items in relatively small batches.

5.  Advantages:
1. This type of plant layout has better machine utilization.
So, here less no of machine required for the shop floor.
2. The production system is flexible to accommodate
different type of jobs.
3. Stoppage of one machine does not stop complete
production lines.
4. Change in product design does not affect the plant
layout.

6.  Disadvantages:
1. Since the material is required to move from one shop to
other shop material handling cost is higher.
2. Skilled persons are required in order to carry out the
jobs.
3. Higher inspection cost is involved.
4. The set up time for each machine is also more.

7. B. PRODUCT LAYOUT (LINE LAYOUT)
 This kind of layout is designed according the
operations required in manufacturing the product.
 The machine are arranged sequentially according
to the processes to be carried out on raw materials.
 This layout is used when the large amount of same
product is to be manufactured.

8. • PRODUCT LAYOUT SETS UP PRODUCTION
EQUIPMENT ALONG A PRODUCT-FLOW LINE, AND THE
WORK IN PROCESS MOVES ALONG THIS LINE PAST
WORKSTATIONS.

9.  Advantages:
1. The production is smooth and simple. So, the
production flow is well directed.
2. Production time per unit is short.
3. The production cost is low due to high volume.
4. Less skilled workers can operate the production
system.
5. Easy to meet according to demand of customers.

10.  Disadvantages:
1. Since the equipments are blocked for particular type of
product this require huge investment.
2. All machine cannot be fully utilized.
3. Change in the product design is making the whole
system obsolete.
4. If any machine stops, the stop the whole production
time.

11. C. FIXED LAYOUT
 A fixed-position layout places the product in one
spot, and workers, materials, and equipment come
to it.

12.  Advantages:
1. Plant layout is highly flexible and can accommodate
changes in product design , product mix and production
volume.
2. This involves minimum movements of material. So
,material handling cost is least.
3. It is possible to assign one or more skilled workers to a
project start to finish in have continuity of work.

13.  Disadvantages:
1. This kind of layout requires skilled labor.
2. Movement of equipments and men take more time , so
the time for completion of this project is more.
3. Requires close control and coordination in production
and scheduling.

14. D.COMBINED LAYOUT
 It is rare to find out pure product or process plant
layout.
 The combined layout is mostly used in order to get
the advantages of both types of plant layouts.
 In such cases machinery is arranged in a process
layout but process grouping is then arranged in a
sequence to manufacture various types and sizes
of groups.