This document provides a comparative analysis of product and process type plant layouts. It defines plant layout as the arrangement of physical facilities needed for production. Product layouts are used for high-volume, standardized products and arrange resources sequentially along straight lines based on product routing. Process layouts group similar operations together and are used for customized, low-volume products. The document compares the two layouts on factors like material handling costs, flexibility, and suitability for different production types. It provides examples of each layout in different industries.

1. A COMPARATIVE ANALYSIS
OF PRODUCT & PROCESS
TYPE OF PLANT LAYOUTS
Presented By :
Soumya Ranjan Nandi
Ananya Itishree Mishra
Madhusmita Mohanty
Suraj Prakash Nayak

2. INTRODUCTION TO PLANT LAYOUT
DESIGN
 Plant layout refers to the arrangement of the
physical facilities that are needed for the process
of production.
Physical facilities such as machineries , equipment,
tools etc. are arranged in such a manner so as to
have a quickest flow of materials at the lowest
possible costs and with the least amount of
handling in processing the product from receipt of
raw material to the delivery of final product.
Plant layout is the most effective physical
arrangement, either existing or in plans of
industrial facilities i.e. arrangement of machines,
processing equipment and service departments to
achieve greatest co-ordination and efficiency of
4 M’s (Men, Materials, Machines and Methods) in

3. Technically , In the words of Sansonneti
and Malilick (Factory management
Vol.103)
“It is planning the right equipment,
coupled with right place, to permit the
processing of a product unit in the most
effective manner, through the shortest
possible distance and in the shortest
possible time.”

4. There are many types of Plant layout to
be selected for a specific plant as per
its productivity and requirements, some
of which are:
1. Product Type Or Line Type
2. Process Type Or Function Type
3. Project Type Or Fixed Position Type
4. Combined Type Or Hybrid Type Or
Group Type
5. Cellular Type

5. PRODUCT/LINE LAYOUT
Found in industries which produce high-volume,
highly standardized products that require
highly standardized, repetitive processes.
Here, resources are arranged sequentially
and laid out in a straight line, based on the
routing of the products.
Some Examples of this type of layout are:
Manufacturing Industry of Sugar, Automobile,
Steel, Cement, Fertilizer etc. A pictorial
representation of a product type of layout is given
in Next Slide.

6. Fig: Product
Layout

7. Advantages & Disadvantages
Advantages Disadvantages
Low material handling cost per unit Machine stoppage stops the
complete line
Less Congestion work-in-progress Product design change or process
change causes the layout to become
obsolete
Mass Amount of Production. Less flexible
Smooth, simple, logical, and direct
flow
Higher equipment investment usually
results Less machine utilization
Less skill is required for personnel Initial capital investment and
overhead charges are high.
Effective supervision and control
Optimum use of floor space.

9. PROCESS/FUNCTION LAYOUT
 Process layouts are found primarily in job shops, or
firms that produce customized, low-volume
products that may require different processing
requirements and sequences of operations.
 Process layouts are facility configurations in which
operations of a similar nature or function are
grouped together. Their purpose is to process goods
or provide services that involve a variety of processing
requirements. Examples include Machine Shops,
Hospitals, banks, auto repair shops, and public
libraries.

10. Fig: Function
layout

11. Advantages & Disadvantages
Advantages Disadvantages
Better machine utilization Increased material handling Cost.
Diversity of tasks for personnel Increased work in progress
Initial capital investment and
Overhead Cost are Relatively Low.
Longer production lines as Time Gap is
High.
Change in Product design and process
design can be incorporated easily
Routing and scheduling pose continual
challenges
More continuity of production in
unforeseen conditions like breakdown,
shortages, absenteeism

12. Process layout In A Garment
Factory

13. COMPARISON TABLE
BASIS PRODUCT LAYOUT PROCESS LAYOUT
Definition Similar Machines are arranged
according to their sequence of
needed operations.
Similar Machines are located in one
space as per their featured
operations.
Suitability Mass production and least
variety of products.
Moderate production and more
variety products.
Flow of Work Smooth and continuous. Not continuous ; Time lag is present.
Job Movement Very less. More.
Floor Space Less is Needed. More is Needed.
Automation Full Automation in material
handling is possible.
Automation in material handling is
not effective.
Production Type Continuous Type/Mass
production mainly Assembly.
Intermittent Type/Job Shop & batch
production.
Processing Time Faster Slower

14. BASIS PRODUCT LAYOUT PROCESS LAYOUT
Facilities are Capital Intensive. Labor Intensive.
Flexibility in
Production
Lesser as per the Market Trends. More as per the Market Trends.
Handling Costs Low High
Man power Semi-skilled and unskilled Specific Skill set labor.
Material Handling Fixed path (eg: Conveyer belt) Variable path (eg: Forklift)
Focus On Product Output Efficiency Product Output Flexibility
Layout Decision Line Balancing Machine Location
Main Goal Equalize work at each station. Minimize Material handling
Cost.

15. THANK YOU