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Plant Layout and its Types
Layout?
       “Plant layout ideally involves allocation of space and
       arrangement of equipment in such a manner that
       overall operating costs are minimized”.




Dr. Zargari
Objectives of Layout
              1. Efficient utilization of available floor space
              2. To ensure that work proceeds from one
                 point to another point without any delay
              3. Provide enough production capacity.
              4. Reduce material handling costs
              5. Reduce hazards to personnel
              6. Utilize labor efficiently
              7. Increase employee moral.


Dr. Zargari
Objectives of Layout….Cont..

              1. Reduce accidents
              2. Provide for volume and product flexibility
              3. Provide ease of supervision and control
              4. Provide for employee safety and health
              5. Allow ease of maintenance
              6. Allow high machine or equipment
                 utilization
              7. Improve productivity


Dr. Zargari
Types of Layout

       o Manufacturing units
         a. Product;
         b. Process;
         c. Fixed Position
         d. Combined



Dr. Zargari
1.Manufacturing Layout
                 a. Product layout(line Layout):
               The materials move form one workstation to
                another sequentially without any backtracking or
                deviation.
               Materials are fed into 1st machine and semi-
                finished goods travel automatically from machine
                to machine.
               The output of one machine becoming input of the
                next.

              Eg: Food Processing Unit; Paper mill

Dr. Zargari
1.Manufacturing Layout
              a. Product layout(line Layout):
                           Eg: Paper mill




Dr. Zargari
1.Manufacturing Layout
               a. Product layout(line Layout):
              Advantage           Disadvantage

              1.Low material      1.Initial cost is very
              handling cost       high
              2.Continuous work   2.Repetitive
              3.Optimum floor     process
              space




Dr. Zargari
1.Manufacturing Layout
                     b. Process (functional)layout:

               In this type of layout machines of a similar type
                are arranged together at one place.
               The work has to be allocated to each
                department in such a way that no machines
                are chosen to do as many different job as
                possible.

              Eg: Process oriented layout for an hospital

Dr. Zargari
b. Process (functional)layout:
                 E g : P r o c e s s o r ie n t e d la y o u t f o r
                                  a n h o s p it a l

                                                          Patient A - broken leg

                                    ER
                                  triage     Emergency room admissions
                                  room               Patient B - erratic heart
                                                                 pacemaker
              Surgery


                                           Laboratories




              Radiology        ER Beds      Pharmacy            Billing/exit



Dr. Zargari
1.Manufacturing Layout
                        b. Process layout:
              Advantage             Disadvantage

              1.Low capital         1.High material
              2.Overhead cost       handling cost
              are relatively low.   2.Time lag is higher
              3.Effective
              supervision




Dr. Zargari
1.Manufacturing Layout
                      c. Fixed (position) layout:
               Here, Major products being produced is fixed
                at one location.
               All other facilities are brought and arranged
                around the work center.

              Eg: Ship building, Dam construction, flyover
                construction.


Dr. Zargari
1.Manufacturing Layout
                     c. Fixed (position) layout:
              E g : S h ip b u ild in g , D a m & f ly o v e r
                            c o n s t r u c t io n .




Dr. Zargari
1.Manufacturing Layout
                    c. Fixed (position) layout:
              Advantage            Disadvantage

              1.Save cost, as      1.Lengthy
              customization is     production period,
              necessary            heavy investment
                                   cost
                                   2.Several
                                   operations are
                                   carried out
                                   simultaniously.

Dr. Zargari
1.Manufacturing Layout
                          d. Combined layout:

               In many manufacturing units, several products
                are produced in repeated numbers with no
                likelihood of continuous production, combined
                layout is followed.

              Eg: Soap industry, all inputs are almost
                manufactured in separate units viz
                glycerin, water treatment, fragrance etc.

Dr. Zargari
1.Manufacturing Layout
                d.Combined layout:
                   Eg: S oaps




Dr. Zargari

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Plant layout and its types

  • 1. Plant Layout and its Types
  • 2. Layout? “Plant layout ideally involves allocation of space and arrangement of equipment in such a manner that overall operating costs are minimized”. Dr. Zargari
  • 3. Objectives of Layout 1. Efficient utilization of available floor space 2. To ensure that work proceeds from one point to another point without any delay 3. Provide enough production capacity. 4. Reduce material handling costs 5. Reduce hazards to personnel 6. Utilize labor efficiently 7. Increase employee moral. Dr. Zargari
  • 4. Objectives of Layout….Cont.. 1. Reduce accidents 2. Provide for volume and product flexibility 3. Provide ease of supervision and control 4. Provide for employee safety and health 5. Allow ease of maintenance 6. Allow high machine or equipment utilization 7. Improve productivity Dr. Zargari
  • 5. Types of Layout o Manufacturing units a. Product; b. Process; c. Fixed Position d. Combined Dr. Zargari
  • 6. 1.Manufacturing Layout a. Product layout(line Layout):  The materials move form one workstation to another sequentially without any backtracking or deviation.  Materials are fed into 1st machine and semi- finished goods travel automatically from machine to machine.  The output of one machine becoming input of the next. Eg: Food Processing Unit; Paper mill Dr. Zargari
  • 7. 1.Manufacturing Layout a. Product layout(line Layout): Eg: Paper mill Dr. Zargari
  • 8. 1.Manufacturing Layout a. Product layout(line Layout): Advantage Disadvantage 1.Low material 1.Initial cost is very handling cost high 2.Continuous work 2.Repetitive 3.Optimum floor process space Dr. Zargari
  • 9. 1.Manufacturing Layout b. Process (functional)layout:  In this type of layout machines of a similar type are arranged together at one place.  The work has to be allocated to each department in such a way that no machines are chosen to do as many different job as possible. Eg: Process oriented layout for an hospital Dr. Zargari
  • 10. b. Process (functional)layout: E g : P r o c e s s o r ie n t e d la y o u t f o r a n h o s p it a l Patient A - broken leg ER triage Emergency room admissions room Patient B - erratic heart pacemaker Surgery Laboratories Radiology ER Beds Pharmacy Billing/exit Dr. Zargari
  • 11. 1.Manufacturing Layout b. Process layout: Advantage Disadvantage 1.Low capital 1.High material 2.Overhead cost handling cost are relatively low. 2.Time lag is higher 3.Effective supervision Dr. Zargari
  • 12. 1.Manufacturing Layout c. Fixed (position) layout:  Here, Major products being produced is fixed at one location.  All other facilities are brought and arranged around the work center. Eg: Ship building, Dam construction, flyover construction. Dr. Zargari
  • 13. 1.Manufacturing Layout c. Fixed (position) layout: E g : S h ip b u ild in g , D a m & f ly o v e r c o n s t r u c t io n . Dr. Zargari
  • 14. 1.Manufacturing Layout c. Fixed (position) layout: Advantage Disadvantage 1.Save cost, as 1.Lengthy customization is production period, necessary heavy investment cost 2.Several operations are carried out simultaniously. Dr. Zargari
  • 15. 1.Manufacturing Layout d. Combined layout:  In many manufacturing units, several products are produced in repeated numbers with no likelihood of continuous production, combined layout is followed. Eg: Soap industry, all inputs are almost manufactured in separate units viz glycerin, water treatment, fragrance etc. Dr. Zargari
  • 16. 1.Manufacturing Layout d.Combined layout: Eg: S oaps Dr. Zargari