Advantages of good plant layout are discussed along with its different types.

1. Government College of Engineering, Aurangabad
Advantages of Good Plant
Layout
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3. “A good layout results in comfort, convenience,
appearance, safety and profit. A poor layout
results in congestion, waste, frustration and
inefficiency.”
- MoNaughton Wayne
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4. 
What is plant layout?
 Basically plant layout is physical arrangement of
industrial facilities
 Orderly and proper arrangement with the use of
available resources i.e., Men, Money, Machines,
Materials and Method of production
 J. Lundy defines plant layout as follows :
 “Plant layout ideally involves the allocation of space and
arrangement of equipment in such a manner that overall
operation cost can be minimized” 4

5. 
Over crowding of men, material, machine and
equipment.
Scrap or wastage of material is more.
Difficult to supervise.
More frequent accidents.
When to think about planning
a layout?
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6. Mental or Physical stress in the
workers.
Long transportation lines.
Poor utilization of space.
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7. 
1. Product Layout ( Line Layout )
2. Process Layout ( Functional Layout )
3. Fixed Position Layout
Types of Plant Layout
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8. 
 All the equipments and machines are arranged
according the sequence of operations on product.
 Here, the layout is dictated by the ‘product’.
 Only one type of product is produced in operating area
in large number of quantities (Mass Production).
 Generally, all assembly lines in different industries
follow the ‘Product Layout’.
1. Product Layout
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9. Example :
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10. 
 Here, the layout is dictated by the ‘Process’ and not by the
‘Product’.
 In this type of layout, the machines and not arranged
according to the sequence of operations but are arranged
according to the nature or type of the operations.
 The process layout is particularly useful where low
volume of production is needed with a greater variety of
products
2. Process Layout
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11. Example 1 :
Example 2 :
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12. 
Comparison of two
layouts
Product Layout Process Layout
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13. 
 In this type, material or major component remains
stationary because it is too heavy or too big
 As product remains fixed at one location other materials,
parts, tools, machinery, man power and other supporting
equipment’s are brought to this location.
 This type of layout is used in the manufacture of boilers,
Huge aircrafts, hydraulic and steam turbines and ships
etc.
Fixed Position Layout
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15. 
Economies in material handling
 Direct channels for the flow of materials
 Cost of material handling is considerably reduced
Lesser manufacturing time
 As no involvement of backward handling of materials,
considerable saving of time in manufacturing
Advantages of Product
Layout
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16. Lesser work in progress
 Lesser accumulation of work in progress of semi
finished goods
Proper use of floor space
 Optimum use of available floor space is possible
 Due to non-accumulation of work in progress
Economy in inspection
 Need for inspection under this method is much less
and can be confined at some crucial points only
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17. Lesser manufacturing cost
 Due to less material handling, inspection cost, and
good utilization of available space there is less
manufacturing cost
Lesser labour cost
 Less skills required
 Routine task is to be carried out under this method
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18. 
Lesser flexibility
 Difficult to adopt any changes
Large investment
 Unavoidable machinery duplication
 Results in idle capacity and large capital investments
Disadvantages of Product
Layout
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19. Interruption due to breakdown
 Stoppages of work due to interdependency on
previous machines
 Reasons may be breakdown of machine, irregular
supply of material, poor production scheduling and
employee absenteeism
Lack of specialization in supervision
 Due to large variety and large quantity of machines
available in the section, one cannot be expert of all
the machines
 Hence only general supervision is possible and not
the specialized one
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20. 
Maximum utilization of machines
Greater flexibility
 Change in the sequence of operations and
machines can be made without much difficulty
Scope for expansion
 By installing additional machines without much
difficulty
Advantages of Process
Layout
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21. Specialization in supervision
 Less variety in machines hence possible
Effective utilization of workers
 Skilled operators are appointed
 Leads to effective and efficient use of their talent and
capabilities
Less work stoppages
 Production schedule is not seriously affected due to
breakdown of any machine
 Work can be transferred to the other machines
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22. 
Coverage of more floor area
Material handling is more expensive
Higher labor cost due to the requirement of
higher grades of skills
Longer total production time
Large in-process inventories
Increased inspection cost
Disadvantages of Process
Layout
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23. 
Economies of transportation
 Work is not carried from one place to another but
fixed at one position
 Saving in transportation cost
Different jobs with same layout
 Different projects
Advantages of Fixed Position
Layout
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24. Production in accordance with specifications
 Jobs can be performed in accordance with the
specification given by the customer
Scope for flexibility
 Flexibility for various changes in production
processes and designs of the products
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25. 
Large investments
Unsuitable for small products
 Not suitable for producing and assembling small
products in large quantities
Production process is time consuming
 Machines and tools etc. take more time to reach the
work place
Highly skilled workers are required
Disadvantages of Fixed Position
Layout
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