Plant Layout and its Types
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“Plant layout ideally involves allocation of space and arrangement of equipment in such a manner that overall operating costs are minimized”.
Layout?
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Objectives of Layout
1. Efficient utilization of available floor space2. To ensure that work proceeds from one
point to another point without any delay3. Provide enough production capacity.4. Reduce material handling costs5. Reduce hazards to personnel6. Utilize labor efficiently7. Increase employee moral.
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Objectives of Layout….Cont..
8. Reduce accidents9. Provide for volume and product flexibility10.Provide ease of supervision and control11.Provide for employee safety and health12.Allow ease of maintenance13.Allow high machine or equipment
utilization14.Improve productivity
Dr. Zargari
1. Manufacturing unitsa. Product; b. Process; c. Fixed Position d. Combined
Types of Layout
Dr. Zargari
1.Manufacturing Layouta. Product layout(line Layout):
The materials move form one workstation to another sequentially without any backtracking or deviation.
Materials are fed into 1st machine and semi-finished goods travel automatically from machine to machine.
The output of one machine becoming input of the next.
Eg: Food Processing Unit; Paper mill
Dr. Zargari
1.Manufacturing Layouta. Product layout(line Layout):
Eg: Paper mill
Dr. Zargari
1.Manufacturing Layouta. Product layout(line Layout):
Advantage Disadvantage
1.Low material handling cost2.Continuous work3.Optimum floor space
1.Initial cost is very high2.Repetitive process
Dr. Zargari
1.Manufacturing Layoutb. Process (functional)layout:
In this type of layout machines of a similar type are arranged together at one place.
The work has to be allocated to each department in such a way that no machines are chosen to do as many different job as possible.
Eg: Process oriented layout for an hospital
Dr. Zargari
b. Process (functional)layout:Eg: Process oriented layout for an
hospital
Surgery
Radiology
ER triage room
ER Beds Pharmacy
Emergency room admissions
Billing/exit
Laboratories
Patient A - broken leg
Patient B - erratic heart pacemaker
Dr. Zargari
1.Manufacturing Layoutb. Process layout:
Advantage Disadvantage
1.Low capital2.Overhead cost are relatively low.3.Effective supervision
1.High material handling cost2.Time lag is higher
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1.Manufacturing Layoutc. Fixed (position) layout:
Here, Major products being produced is fixed at one location.
All other facilities are brought and arranged around the work center.
Eg: Ship building, Dam construction, flyover construction.
Dr. Zargari
1.Manufacturing Layoutc. Fixed (position) layout:
Eg: Ship building, Dam & flyover construction.
Dr. Zargari
1.Manufacturing Layoutc. Fixed (position) layout:
Advantage Disadvantage
1.Save cost, as customization is necessary
1.Lengthy production period, heavy investment cost2.Several operations are carried out simultaniously.
Dr. Zargari
1.Manufacturing Layoutd. Combined layout:
In many manufacturing units, several products are produced in repeated numbers with no likelihood of continuous production, combined layout is followed.
Eg: Soap industry, all inputs are almost manufactured in separate units viz glycerin, water treatment, fragrance etc.
Dr. Zargari
1.Manufacturing Layoutd.Combined layout:
Eg: Soaps