This document discusses plant layout and location. It begins by outlining the learning outcomes, which include understanding different types of layouts and factors affecting plant layout and location. It then defines facility layout and discusses the scope and objectives of layout planning. The document describes four main types of layouts - process, product, grouping technology, and fixed position layouts - and notes their advantages and disadvantages. It also discusses re-layout and explains the reasons and symptoms for needing one. Finally, it covers issues to consider for facility location, such as proximity to customers, costs, infrastructure, and business climate.

1. 103211 - PRODUCTION MANAGEMENT
C H A P T E R – I I I
PLANT
LAYOUT & LOCATION
Dr.KarthikMohandoss
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2. LEARNING OUTCOMES
By the end of this chapter you will be able to understand
 Layout
 Factors affecting plant layout
 Scope & objectives of layout
 Different types of layout
 Advantages of disadvantages of each layout types
 Re-layout
 Location & issues related to location
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3. WHAT IS FACILITY LAYOUT?
The layout facility is the physical location of the various
departments/units of the facility within the premises of the facility.
The departments may be located based on the considerations such as:
 Less walking distance
 Logical sequence of the processing requirements of the product
 Emergency services, etc
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4. DEFINITION
A facility layout is an arrangement of everything needed for
production of goods or delivery of services. A facility is an
entity that facilitates the performance of any job. It may be a
machine tool, a work centre, a manufacturing cell, a machine
shop, a department, a warehouse, etc. (Heragu, 1997).
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5. TO MAKE A DECISION ABOUT LAYOUT PLANNING,
4 DIFFERENT QUESTIONS MUST HAVE AN ANSWER:
 Which centers do we have to consider?
 How much space and capacity is required for each center?
If there is not enough space, productivity may be reduced.
Too much space is expensive and may also reduce productivity.
 How must the space be configured at each center?
Space quantity, shape and the elements of the work center are related to
each other.
 Where should each center be located at within the facility?
The allocation of the different centers may affect productivity.
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6. FACTORS AFFECTING PLANT LAYOUT
 The factors affecting plant layout can be grouped into 8 categories:
 Materials
 Machinery
 Labor
 Material Handling
 Waiting Time
 Auxiliary Services
 The building
 Future Changes
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7. SCOPE OF FACILITY LAYOUT
Related to material
 Less material handling and minimum transportation cost
 Less waiting time for in-process inventory .
Related to work place
 Safe working conditions from the point of ventilation, lighting, etc.
 Minimum movement of workers
 Least chances of accidents, fire, etc.
 Proper space for machines, worker, tools, etc.
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8. OBJECTIVES
 Simpler plant maintenance.
 Increased productivity, better product quality, and
reduced cost.
 Least set-up cost and minimal change-over.
 Objective related to flexibility.
 Scope for future expansion.
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9. DIFFERENT TYPES OF LAYOUT
1.Process Layout
2.Product Layout
3.Grouping Technology Layout
4.Fixed Position Layout
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10. 1.PROCESS LAYOUT
• suitable when product having standard features is to be produced in
large volumes.
• the specialized machines and equipments are arranged one after
another in the order of sequence required in the production process.
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11. Advantages of Process Layout:
• Greater Flexibility
• Better and more efficient supervision possible through
specialization
• Capacity of different product line can be expanded easily.
• Better utilization of men and machine.
Disadvantages of Process Layout :
•More floor space
•More work in progress
•More distance travelled by the product. 11
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12. 2.PRODUCT LAYOUT
It is appropriate for producing one standardized product,
usually in large volume. It is also called as flow-shop
layout or straight line layouts. The machines are arranged
according to the progressive steps by which the product is
made.
Example: chemical, paper, rubber, refineries, cement
industry, quarry.
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15. Advantages:
Mechanization of materials is possible and material handling cost
can be reduced.
It requires less floor area.
It facilitates better production control.
Production bottlenecks are avoided.
Disadvantages:
Expansion of product line is difficult.
There is difficulty is supervising.
Breakdown of equipment disrupts the production. 15
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16. 3.GROUPING TECHNOLOGY LAYOUT
Grouping technology layout of cellular manufacturing
layout is made for a single part family i.e parts with
common characteristics. In this layout dissimilar
machines are grouped into cells and each cell functions
like product layout.
Advantage and Disadvantages:
It reduces material handling cost and simplifies machine
changeovers. It reduces in-process inventory and
automate the production but reduces the flexibility. 16
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18. 4.FIXED POSITION LAYOUT
When due to size, shape and other characteristics
constraints, the products cannot be moved, the machine and
operators move around the product.
Example: construction of a building, assemble of an
aircraft or ship.
Advantage:
Less investment is required in this layout and less transport
cost as bulky machines are not moved.
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20. RE - LAYOUT
 The reasons for a Re-layout are based on 3 types of changes:
 Changes in production volumes.
 Changes in processes and technology.
 Changes in the product.
 The frequency of the Re-layout will depend on the
requirements of the process.
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21. SYMPTOMS THAT ALLOW US TO DETECT THE
NEED FOR A RE-LAYOUT:
 Congestion and bad utilization of space.
 Excessive stock in process.
 Long distances in the work flow process.
 Simultaneous bottleneck and workstations with idle time.
 Qualified workers carrying out too many simple operations.
 Labor anxiety and discomfort. Accidents at the facility.
 Difficulty in controlling operations and personnel.
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22. LOCATION
Where should a plant or service facility be located? This is a
top question on the strategic agendas of contemporary
manufacturing and service firms, particularly in this age of
global markets and global production. Dramatic changes in
international trade agreements have made the world truly a
“global factory,” allowing companies greater flexibility in
their location choices.
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23. ISSUES IN FACILITY LOCATION
 Proximity to Customers
 Business Climate
 Total Costs
 Infrastructure
 Quality of Labour
 Suppliers
 Other Facilities
 Free Trade Zones 23
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24. Thank You
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