The document discusses different types of plant layouts: product layout, process layout, and fixed position layout. A product layout arranges machines by the sequence of operations on a product. A process layout groups similar machines together regardless of the product sequence. A fixed position layout keeps large components stationary while bringing equipment to them. The advantages and disadvantages of each layout type are also outlined.

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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