The document discusses the key factors affecting plant layout: - Plant layout is the physical arrangement of industrial facilities and involves allocating space and arranging equipment to minimize overall operating costs. - The objectives of plant layout are to streamline material flow, facilitate manufacturing processes, and minimize costs and production time. - Factors affecting plant layout include the characteristics of materials, machinery, labor requirements, material handling needs, waiting times, auxiliary services, building constraints, and planning for future changes.

1. Plant Layout
• Plant layout is a plan of an optimum
arrangement of facilities including
Plant Layout & Its Objectives – personnel,
– operating equipment,
– storage space,
Presented By:
Anupam Kumar
– material handling equipment and
Reader – all other supporting services along with
SMS Varanasi – the design of best structure to contain all the
Email: anupamkr@gmail.com
facilities.
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Plant Layout Objectives of Plant Layout
• Plant layout is the physical arrangement of • Streamline the flow of material through the plant
• Facilitate the manufacturing process
industrial facilities. • Maintain high turnover of in-process inventory
• It involves • Minimize materials handling and cost
– the allocation of space, and • Make effective utilization of cubic space
• Flexibility of manufacturing operations and
– arrangement of equipments arrangements
– in such a way that the overall operating costs are • Provide for employee convenience, safety and comfort
minimized. • Minimize investment in equipment
• Minimize overall production time
• Facilitate the organizational structure.
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Factors Affecting Plant Layout Factors Affecting Plant Layout
The factors affecting plant layout can be grouped into 8 • Materials • Machinery
categories: – The layout will depend on the – Information about the
characteristics of the product processes, machinery, tools
• Materials • Waiting Time to be managed at the facility, and necessary equipment, as
including: size, shape, well as their use and
• Machinery • Auxiliary Services volume, weight, and the requirements is essential to
physical-chemical design a correct layout.
• Labor • Building characteristics. – It’s essential as well to know
• Material Handling • Future Changes – The sequence and order of about space required, shape,
the operations will affect height, weight, quantity of
plant layout as well, taking machine & equipment and
into account the variety and type of workers required,
quantity to produce risks for the personnel,
requirements of auxiliary
services, etc
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2. Factors Affecting Plant Layout Factors Affecting Plant Layout
• Labor • Material Handling • Waiting time • Auxiliary Services
– Labor has to be organized in – The objective should be to – Ensuring Continuous Material – Support the main production
the production process minimize material handling as Flow through the facility, activities at the plant:
(direct labor, supervision and well as combining with other avoiding the cost of waiting
auxiliary services). operations when possible, • Related to labor:
eliminating unnecessary and time and demurrages that Accessibility paths, fire
– Environment considerations: protection installations,
costly movements. happen when the flow stops.
employees’ safety, light supervision, safety, etc.
conditions, ventilation, – Material handling does not – However, the material waiting
to flow through the facility • Related to material: quality
temperature, noise, etc. add value to the product; it’s
control.
– Process considerations: just waste. not always represents a cost
to avoid. • Related to machinery:
personnel qualifications,
maintenance and electrical
flexibility, number of workers • As stock sometimes provides and water lines.
required at a given time as safety to protect production,
well as the type of work to be improving customer service,
performed by them. allowing more economic
batches, etc.
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Factors Affecting Plant Layout Principles of Plant Layout
• The building • Future changes • To ensure the smooth functioning of a plant, …
– If it has been already – One of the main objectives of
selected, its characteristics plant layout is flexibility. • There are certain principles which must be
will be a constraint at the – It’s important to forecast the considered.
moment of designing the future changes to avoid – Principle of Integration
layout, which is different if having an inefficient plant
the building has to be built. layout in a short term. – Principle of Minimum Distance
– Possible future extensions of – Principle of Cubic Space Utilization
the facility must be taken into – Principle of Flow
account, as well as the
feasibility of production – Principle of Maximum Flexibility
during re-layout. – Principle of Safety, Security and Satisfaction
– Principle of Minimum Material Handling
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Principles of Plant Layout Principles of Plant Layout
• Principle of Integration • Principle of Cubic Space Utilization
– A good layout is one that integrates men, material, – A good layout is one that utilized both the
machines, supporting services and others in order horizontal and vertical space.
to get the optimum utilization of resources and • Principle of Flow
maximum effectiveness.
– A good layout makes the material move in the
• Principle of Minimum Distance forward direction towards the completion stage
– The facilities should be arranged such that the without back-tracking.
total distance travelled by men and materials • Principle of Maximum Flexibility
should be minimum.
– A good layout can be altered without involving
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much cost and time. 2013 Anupam Kumar
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3. Principles of Plant Layout
• Principle of Safety, Security & Satisfaction
– A good plant layout is one that gives due
considerations to For further details…
• Workers health, safety and satisfaction, and
• Safeguards the plant and machinery against fire, theft,
arson, etc. Contact
Anupam Kumar
• Principle of Minimum Handling Reader
– A good layout reduced the material handling to SMS Varanasi
the minimum. E mail: anupamkr@gmail.com
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Bibliography
• Buffa, E.S. and Sarin, R.K., “Modern Production/Operations Management,” Eighth Edition. Singapore: John Wiley & Sons
(Asia). 1994.
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• Badi, R.V. and Badi, N.V., “Production and Operations Management”, Second Edition, New Delhi: Vrinda Publication, 2008.
• Chary, S.N., “Productions and Operations Management,” Third Edition, New Delhi: Tata McGraw Hill, 2004
• Goel, B.S., “Production Operations Management”, Twenty Second Edition, Meerut, U.P.: Pragati Prakashan, 2010.
• Kachru, U. “Production and Operations Management: Text and Cases,” New Delhi: Excel Books, 2007.
• Rama Murthy, P., “Production and Operations Management,” New Delhi: New Age International, 2012.
• Chunawalla, S.A., and Patel, D.R., “Production and Operations Management,” Mumbai: Himalaya Publishing House, 2006.
• Jauhari, V. and Dutta, K., “Services: Marketing Operations and Management,” New Delhi: Oxford University Press, 2010.
• Verma, H.V., “Services Marketing: Text and Cases,” New Delhi: Dorling Kindersley, Pearson Education, 2009.
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