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Plant Layout -Types and Trends

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International Journal of Scientific and Research Publications, Volume 1, Issue 1, October 2020 1
ISSN 2250-3153

Plant Layout – Types and Trends

Ridhima Tripathi

* BFTech 7th Semester NIFT Bengaluru

Abstract- The article details out the different types of plant layouts
from conventional types to the recent ones. Understanding
different types of Plant Layouts Applicable in garment Industry
from earlier times to recent times. What exactly is plant layout
then? Plant layout can be understood as arrangement of physical
facilities and processes withing the factory, in our case the
example of sewing machines arrangement can be one. The
facilities have to be arranged in such a way that the required output
is achieved with high quality at lowest cost (total) of
manufacturing.
Index Terms- Plant Layout Types, Spine layout, Product Layout,
Process Layout, Distributed Layout, Shape Based Layout, Flow
Based Layouts, Trends
when technology was not much prevalent and mass customization
concept just came into existence. The garment manufacturing was
starting to explore at that time. They were researching on the
modular line concept and even regarded it as the future trend. On
the other hand, in today’s time new layout concept has come into
being, most of which has a common idea of being flexible.
Another new technique of deciding on a plant layout which is in
practice I the use of a software which will decide the layout of the
plant. Here it will come up with the best possible scenario and will
be customized for that particular factory, hence, the shape of the
layout will be very different than the conventional designs.
In this article, various types of layouts have been put forth some
of them go back to early 2000s, and some comprise of the new
trend.

I. INTRODUCTION

C ertain research papers from 1998 and 2000 were taken to

gather the understanding of Plant Layout in earlier times
II. SPINE LAYOUT
This type of layout was regarded as the most popular layout for
complex systems in the year of 2000 [1]. The spine is basically a
central channel which signifies the flow of material of the entire
facility. The branches of the spine are where all the operations take
place, this can be termed as a department. At the node of each
branch the output/input of that department takes place. The given
example is of a shirt. One department makes the cuff, one makes
the sleeves, one makes the collar and one does the front and the
back including the yoke. All the parts flow through a common
channel i.e. the spine and serve as an input to the Assembly lines.

Figure 2. Structure of the Spine Layout

This type of layout was designed for modular plants. They

Figure 1. Spine layout of a Shirt Manufacturing
described the spine as the artery through which the product will be
flowing throughout the factory. An advantage of this layout would
be that each individual department can be removed or added
without disturbing the main layout. The disadvantage would be
that now each department layout has to be considered instead of
the earlier one.
International Journal of Scientific and Research Publications, Volume 1, Issue 1, October 2020
ISSN 2250-3153
III. PRODUCT LAYOUT
This layout helps in producing high volume goods efficiently by
arranging the machines/equipment in the form of an assembly line.
Out here the process starts on one side and the output assembled
product is produced and delivered at the other side of the line. The
output of one machine is the input of another machine. In this
layout if one or two machines are missing or are not working due
to breakdown then the process will not happen. The line will have
to wait in this case till the machine starts working again.
This example given below is of a green plain weave classic shirt
and trouser of the same material, produced in two different
departments. The idea is that in this scenario the machines will be
clubbed together based on the product which is being produced.
This is taken in a macro level. If we consider a micro level then
the example would be there is a cuff department, in this
department all the activities pertaining to the formation of cuff will
happen here. The top stitch, edge cutting, button attachment,
button holing etc., all the operations which are required for the
formation of a cuff will happen in one department where all the
required machines will be clubbed together. This layout is a
typical product layout which solely depends on the product
produced.
Figure 3 Macro view of Product Layout
Figure 4 Micro view of one department in product layout
[2]
Advantages of this layout are as follows: -
1) The idea of this layout is that we are avoiding all the
bottleneck operations.
2
2) The manufacturing time reduces
3) We are able to control the production flow
4) It requires lesser floor area for production.
5) WIP is reduced.
6) Material handling time is reduced because it happens in
one continuous flow.
Disadvantages of this layout are:
1) It is a very expensive layout and moreover inflexible
layout
2) Because of its inflexibility expanding the layout will be
very difficult.
3) Any Breakdown occurring will cause the entire line to
stop.
IV. PROCESS LAYOUT
This type of layout unlike product layout is based on the
process. Similar machines are grouped together based on
their uniqueness to produce an output. Products will be
passing in such a way that whichever part is requiring
riveting will go to that machine group, whichever part
requires bartacking will go to that particular group.
Example taken below is of a denim shirt and denim trouser.
Both require bartacking and riveting and thus whichever
part of the denim shirt and trouser requires these to
operations will go to the respective group of machines.
Figure 5 Process Layout example
This type of layout is not recommended for a continuous
flow, rather it is best for an intermittent type of flow. While
grouping the machines one must consider the distance
between the departments, since, the grouping of machines
will already create a lot of material handling. So, it would
be advisable to keep them closer to reduce the material
movement.
International Journal of Scientific and Research Publications, Volume 1, Issue 1, October 2020
ISSN 2250-3153
[2]
Advantages of this type of layout are:
1) This type of layout has greater flexibility because all
the similar machines are grouped together.
2) There is better supervision.
3) Investments on machines is reduced. Earlier for two
different products all the machines are setup. In this case
since the machines are combine lesser machines are
required.
4) Breakdown of one machine does not affect the entire
line.
Disadvantages are as follows: -
1) Movement of material to different groups of machines
is difficult.
2) This type of layout utilizes more space
3) Production time is high due to high WIP [ this is caused
because the parts have to go the right machine each time
in the entire production process].
V. HYBRID LAYOUT
This type of layout is a most common layout in the garment
industry. The garment factory does not use completely
product or process, it mostly uses a combination of both.
Such a combination is termed as the Hybrid Layout. Most
of the manufacturing lines are arranged in such a way that
the production lines follow the process layout and the
assembly line follow the product layout. This type of layout
is best suited for scenarios where the product is being
produced in various types and sizes. [1]
Out here irrespective of the type and size the sequence of
operations is kept similar.
Figure 6 Hybrid layout example
3
VI. CELLULAR LAYOUT [2]
In this kind of layout, the machines are generally assembled
into cells which function fairly like a product layout within
a process layout. Every cell in this design is shaped to
produce single parts, all with common attributes, which
typically means they necessitate the same machines and
have similar machine settings.
Advantages are:
1) Lower WIP inventories.
2) Reduced material handling costs.
3) Flow time of materials is less.
4) Improved visual control of process which enables
quicker set ups.
Disadvantages are:
1) It is not very flexible.
2) Spare equipment could be necessary so that parts need
not be transported between cells.
VII. DISTRIBUTED LAYOUT
This type of layout is an alternative to the conventional
layouts when the demand and product mix variation is high.
Here similar departments (machines) are distributed
throughout the factory floor to increase access to these
resources from different regions of the layout. This is done
to minimize the material handling costs. This is because out
here the material flow requirement is dictating the
placement of the machine. [1]
The machines in this layout are relocated frequently in a
year. The machines are believed to be light weight and to
be on wheels for easy movement. Out here as well we are
trying to make the lines more flexible and making
relocation of each department feasible. In a report stating a
Delphi survey, it was seen that the committee on Visionary
manufacturing Challenges for 2020 identified adaptable
processes and equipment and reconfiguration of
manufacturing operations. These two will help companies
in achieving two of the six grand challenges to remain
productive and profitable. The challenges which will be
achieved are: “Achieve concurrency in all operations” and
“reconfigure manufacturing enterprise rapidly in response
to changing needs and opportunities”. [3]
This type of layout is preferred when the product demand
and the product mix is highly variable. An example can be
of a factory which produces seasonal apparels.
International Journal of Scientific and Research Publications, Volume 1, Issue 1, October 2020 4
ISSN 2250-3153

XI. U-SHAPED LAYOUT

VIII. BASE ON SHAPES [4],[1] This type of layout is best suited when the start and the end
process operations lie on the same end. In such cases the
machines are arranged in the form of a U shape. The
Researchers are trying to understand different shapes advantage with this layout is that the same workers can be
which would enable the best flow of materials in a utilized for both supplying the materials and handling the
production factory finished goods. The production rate becomes consistent
because the supply of materials and handling of finished
goods happens at the same rate.
IX.
LOOP LAYOUT [5]
In this layout the material flows in a loop. It starts at one
end follows the loop and ends at that same end. In the
example given the process starts with quality check [
probably a check for mitering] and the process ends with a
quality check. This layout forms a closed loop. It is useful
in cases where the start and the end operation are the same.

Figure 9 U-shaped Layout

XII. COMB SHAPED LAYOUT

This type of layout is formed by combining linear lines,

such that each part preparation line is also a linear line and
are connected to the main line, from where the material
flows to the point where those parts are required.
Figure 7 Closed loop formation of T-shirt production

X. STAR LAYOUT

This type of layout is used when multiple operations start

from or end in one operation. In the example below all the
outputs from different department which require label
attachment are arranged around the label attachment
department. After the attachment all of them go to the
finishing section.

Figure 10 Combed shape Layout

XIII. FLOW BASED LAYOUTS

Apart from shaped layouts there are some flow-based

layouts which are preferred based on the cycle time and
flow of production in a factory.

Figure 8 Star Layout example

International Journal of Scientific and Research Publications, Volume 1, Issue 1, October 2020 5
ISSN 2250-3153

Zig-Zag Layout XV.HANGER CONVEYOR LAYOUT

This type of Layout removes the earlier Work-in-progress as it

does not involve use of progressive bundle system. allows all
the material needed for a specific garment to be transported as
a unit directly to the sewing machine of any workstation. When
an operation is completed at one workstation, the system either
mechanically or automatically sends the unit on to the next
Figure 11 Zig-Zag Layout of a T-shirt Production work station. It was designed to reduce material handling time.
The layout of such a system has to be continuous and cannot
break in between. The layout follows a loop shape along which
Circular layout
the materials flow.

Figure 14 Hanger conveyor layout

XVI.SOFTWARE USED TODAY TO CREATE A CUSTOMIZED

Figure 12 Circular Layout LAYOUT — LATEST TREND

ALDEP (Automated layout design program), CORELAP

XIV. QUICK RESPONSE LAYOUT
Out here several operations are combined together in such
a way that the entire line is balance. An operator performs
two or more operations together to ensure that the
production efficiency is high.
(Computerized relationship layout planning), CRAFT
(computerized related allocation of facilities technique),
CALP (computer Aided layout planning). These are some of
the few software which are being used to produce a customized
layout as per the production requirement and to produce
maximum efficiency.

XVII. Layout simulation with ARENA software

This is one of the examples taken for the simulation software

being used nowadays to produce an efficient layout. This
software considers the processing time at the sewing
department as the input data which is converted into a logic
model using an analyzer. The model also asks for the distance
of material movement of the current facility. Based on all this
data a proposed layout is shown in comparison with the initial
layout.

Figure 13 QR Layout
International Journal of Scientific and Research Publications, Volume 1, Issue 1, October 2020 6
ISSN 2250-3153

ACKNOWLEDGMENT
I would like to thank Associate Professor Mr. Arivoli N for his
guidance in all the respective classes. His teachings have played a
major role in writing this report.

REFERENCES
[1] Saifallah Benjafaar, Sunderesh S. Heragu, and Shahrukh A. Irani. NEXT
GENERATION FACTORY LAYOUTS: RESEARCH CHALLENGES AND
RECENT PROGRESS. Dec. 2000. URL:
http://dept.me.umn.edu/labs/ngfl/ngfl.pdf.
[2] Textilecourse. Plant Layout in Textile and Garment Industry. Feb. 2019.
URL : https://textilecourse.blogspot.com/2019/02/plant-layout-textile-
Figure 15 Arena Simulation proposed Assembly line layout garment-industry.html.
[source: http://ieomsociety.org/ieom_2016/pdfs/669.pdf] [3] Md. Mominul Islam et al. “An Optimal Layout Design in an Apparel
Industry by Appropriate Line Balancing: A Case Study”. Double Blind Peer
The above figure shows the new proposed Assembly line layout Reviewed International Research Journal 14(5) (2014), pp. 1–12.
by balancing the lines. [4] Farhad Shafigh, Fantahun M. Defersha, and Soha Eid Moussa. A
mathematical model for the design of distributed layout by considering
production planning and system reconfiguration over multiple time periods.
Jan. 2015. DOI: 10.1007/s40092-015-0102-1. URL:
XVIII. CONCLUSION https://link.springer.com/article/10.1007/s40092-015-0102-

In the Garment Industry if we see as an overview is mostly a 1#:~:text=Distributed%

hybrid layout. However, when we see lean manufacturing, we can 20layout%20has%20emerged%20as,the%20layout%20(Baykasoglu
see different shapes and types of layouts being used. This is mostly %202003)..
because in Lean setup we balance the lines based on cycle time [5] Dr.S.Kathirvelu Subramanian. Garment production systems. June 2017.
and we try to combine various operations to increase efficiency. URL: https:
In doing so a unique flow of materials is seen. Probably, this is one
//www.slideshare.net/DrSKathirveluSubrama/garment-production-
of the reasons for layout simulation software to exist. systems-76962841.

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