Facilities layout (plant layout)

Introduction
The term plant layout is used in broad sense to include factory layout and machine layout. A
plant layout refers to the arrangement of machinery, equipments and other industrial facilities –
such as receiving and shipping departments, tool rooms, maintenance rooms, employee amenities
etc. for the purpose of achieving the quickest and smoothest production of the lest cost.
Meaning
Plant layout may be defined as physical arrangements of industrial facilities. This arrangement
includes the space needed for material movements, storage, indirect labour and all other
supporting activities or services as well as operating equipment and personnel. Plant layout
basically:
o Placing the right equipment.
o Coupled with the right method.
o In the right place.
o To permit the processing of a product unit in the most effective manner, through the
shortest possible distance, and in the shortest possible time.
Definition
According to K.G.LOCKYER, “the disposition of the various parts of a plant along with all the
equipment used there in, is known as the plant layout, which should be designed to enable the
plant to function most effectively”.
Needs for plant layout
o When a new plant is set up to manufacture newly designed products.
o When a new product line is introduced in the factory.
o When additional space is required to meet increased demand for products.
o When frequent accident occur in the factory.
o When the existing facilities are to be rearrangement due to change in methods or
production.
o When the existing factory is shifted to a new area.
o When the cost reduction program is launched.
o When improvements are to be made by incorporating scientific and technological
innovations.
Factors affecting the plant layout decision
1. Type of production: - the plant layout for engineering unit will be quite different from
that of a flour factory.
2. Production system: - the plant layout is a continuous production system will be totally
different that under the intermitted production system.
3. scale of production: - the plant layout and material handling equipment in the large scale
organization will be different from that in the small-scale manufacturing activity.
4. Type of machine: - the use of simple-purpose and multipurpose machines substantially
affect the plant layout. Similarly noisy and vibrating machines require special attention in
the plant layout decision.
5. Type of building facility: - the plant layout in a single story building will be different
from that in a multi-story building.
 6. availability of total floor area: - the allocation of space for machines, work benches, etc is
made on the basis of the available floor area. Use of overhead space is made in case of
shortage of space.
7. possibility of future expansion:- the plant layout is made in the light of the future
requirements and installation of additional facilities.
8. arrangement of material handling equipments: - the plant layout and the material handling
services are closely related and the latter has a decisive effect on the arrangement of
production process and plant services.
Types of layout
1. Process or functional layout
2. product or line layout
3. project or fix position
1. Process layout
The layout in which all the equipments performing similar tasks are grouped together is
called the process layout.
It is also called the functional layout, as the material and machines required are grouped
depending on their functions. For example: the milling machines, machines can be grouped
together and the grinding machines can be grouped together.
Turning department
Drilling department
Welding department
Grinding department
Heat treatment department
Finished goods
Raw material
Forging department
Advantages
o A high degree of variety of products can be manufactured.
o Flexibility and adaptability to change is high.
o Machine breakdown do not cause of stoppage.
o It is easier to instill job satisfaction to workers.
o Coordination and supervision is simpler.
Disadvantages
o Higher flow time of the product due to zigzag flow through the system.
o Larger number of machine set-ups.
o Low machine utilization.
o More material handling.
2. Product or line layout: -
The layout in which the equipments are placed in the order in which they are used for
producing the product is called the product layout. The product layout is also called the line
layout, as the materials and machineries required are place in sequence. This type of layout is
useful in automobiles industries or industries where assembling of materials and part take
place. In such industries, you need to start the process by feeding in the raw materials and the
process ends with the production of the final product. In the product layout, workmen are
required in less number that automatically reduces the cost and leads to higher productivity,
as the whole process is automatic.
packing
assembly
Operation
testing
welding
Dispatching
Receiving
Testing
Advantages
o Low total flow time for the product.
o High rate of output, because there are no interruptions to the flow.
o Simple production planning.
o Less inspection.
Disadvantages
o No variety is possible.
o No flexibility is regard to design changes.
o High capital cost and capital investment.
o Less job satisfaction for labour.
Difference between production layout and process layout
BASIS PRODUCT LAYOUT PROCESS LAYOUT
1. Duplication of More duplication of plant Less duplication of plant
equipment and equipment and equipment.
2. Production control More effective because of Difficult due to number of
pre planning department.
3. Material handling less High
cost
4. Production time Less High
involved
5. Accumulation of Low High
work in progress
6. Floor area occupied less More
7. Greater utilization of Less High
machine
8. Flexibility Less High
9. application In industries which In industries which
manufacture standard manufacture goods as per
products i.e. having a requirement i.e. where non-
repetitive process. repetitive process.
Combination of product and process layout
In practice, the adoption of a pure product layout or a pure process layout in rarely seen, as it
is not possible to adopt either of these in isolation. So, we come across a combination of
product and process layout which is widely practiced, especially in factories which are
engaged in repetitive processes manufacturing standard products. This is on account of
deriving the maximum benefits accruing from both product and process layouts, there by
over coming the disadvantages of these layouts.
 3. Project or fixed position layout
The layout in which the raw materials are placed in a fixed position is called the project
layout. The project layout is also called the fixed position layouts, as the production
operation is performed at one fixed position. This type of layout is useful when number of
equipments is less. For example, aero plane and ship manufacturing industries use this type
of layouts. In this type of layouts, the machineries are heavy and therefore, they are fixed at
one position.
WORKMEN
RAW MATERIAL
TOOLS
MACHINE
Advantages
o Reduces movement of machineries and equipments.
o Minimize damage or cost of moving.
o More continuity of the assigned work force since there is no movement of raw
materials or product from one department to another. Hence, the problem or re-
planning and instructing people each time a new type of activity is to begin.
Disadvantages
o Since the same workers are involved in more operations. Skilled and versatile workers
are required. The necessary combination of skills may be difficult to find and high
pay level may be necessary.
o Movement of people and material to and from the place may be expensive.
o Equipments utilization is low because the equipment may be left at a location where it
will be needed again in a few days rather than moved to another location where it
would be productive.
Advantages of plant layout
o Better work conditions for workmen.
o Minimization in material handling.
o Minimization in damage and spoilage materials.
o Minimization in congestion of materials, machinery and workmen.
o Flexibility in changing production conditions.
The organization may decide and select the type of plant layouts based on the type of industry,
nature of the product, the size of the company and volume of production. The following are the
major types of plant layout.
1. Process layout/ functional layout/ job shop layout.
2. Product layout/ line processing layout/ flow line layout.
3. Fixed-position layout/ static layout.
4. Combination layout/ hybrid layout.
5. Cellular manufacturing layout
1. Process Layout
Process layout is a design for the floor plan of a plant to improve efficiency by arranging
machines and equipment according to its function. In process layout, similar operations or
similar machinery in each department are assembled together (for example, a drill department, a
paint department, etc.) and machines are not arranged according to a particular production
sequence. The process layout is also known as functional layout/ job shop layout.
Advantages of Process layout:

 Lower initial capital investment 

 The optimum level of degree of machine use.
 Breakdown of one machine does not affect the entire production process.

Disadvantages of Process Layout

 More floor space is required

 Better coordination and planning is required

2. Product Layout
In the product layout, processing equipment and machines are organized according to the
sequence of operations of the product where an only a single type of products is produced in an
operating area. Product layout is suitable for standardized products which are produced in large
quantities. In the product layout, raw material moves from one machine to another machine
deviation (i.e. the output of one machine becomes the input of the next machine) in a sequence
without any backtracking or It is used for mass production of standardized products. The product
layout is also known as line processing layout/ flow line layout.
Advantages of Product layout:

 Low cost of material handling

 Lesser inventory and work in progress
 The continuous flow of work
 Smooth and continuous operations

Difference between process and product layout

Process layout Product layout
Customized goods Standardized goods
Varied path Direct path
Low/fluctuating demand High/stable demand
Fixed costs= low, variable cost= Fixed costs = high
high Variable costs = low
General-purpose equipment Special purpose equipment
Functional grouping of activities Sequential grouping of activities
3. Fixed-position Layout
In a fixed position layout, the major component stays in a fixed location, instead, the machinery,
manpower, materials, parts, tools, and other supporting equipment are taken to this location. The
main component of the product is in a static position because it is too heavy to move from a
place to another, so bringing the necessary tools and equipment’s to workplace along with the
manpower is more economical and convenient. The example of fixed-layout manufacturing is
the manufacture of hydraulic and steam turbines, boilers, and ships, etc. Fixed-position layout is
also known as the static layout. 
Advantages:
Independent Production centers of fixed-layout ensure effective planning and loading.
Greater flexibility for change in product design, product mix and production volume.
Disadvantages of Fixed Position Layout:
Fixed Position Layout requires highly skilled manpower
Time-consuming due to movement of machines equipment’s to production center
It require complicate work schedule
4. Combined layout
 The combined layout is a flexible manufacturing layout where the merits of both process &
product layout are combined. Flexibility is a very important requirement of factory layout, so If
the good features of all types of layouts are connected, a most economical and flexible solution
can be obtained. The combined layout is also known as the hybrid layout. 
5. Cellular manufacturing layout
Cellular manufacturing layout is the layout where machines are grouped into cells and the cells
function somewhat like a product layout within a larger shop where each cell performs an entire
production function from starting to end.