Birla Institute of Technology & Science, Pilani

Work Integrated Learning Programmes Division

Plant Layout & Design

Digital Learning Handout

Course Title Plant Layout & Design

Course No(s) ET ZC424/POWAB ZC482
Credit Units 4
Credit Model
Instructor-In-Charge PAVAN POTDAR
Version Number
Date

Course Description:
 This is an introductory course on Plant Layout & Design with emphasis on the analysis, design and
evaluation of manufacturing facilities and material handling systems.
 The topics covered include definition of facilities planning, role of product process and schedule design,
flow analysis and activity relationship, capacity and space requirements planning, material handling
systems and equipment, storage and warehousing and performance evaluation and selection among
alternatives.

Scope & Objective of Course:

Plant location and its layouts are major cost areas for any plant. The primary objective of this course is to
introduce basic concepts of plant location and its layout and design. Students completing this course will be
able to understand:
• The concepts of planning, locating and designing efficient facilities
• Material handling systems and their applicability
• Evaluation of layouts and locations.

Text Book(s):

T1 Agarwal, G.K., Plant Layout and Material Handling, Jain Brothers, New Delhi, 2007.

Reference Book(s) & other resources:

R1 James A. Tompkins, John A. White, Yavuz A. Bozer and J.M.A. Tanchoco., Facilities
Planning, 4th ed., John Wiley & Sons (2013).
R2 Francis R. L., McGinnis Jr. L. F., and White J. A., Facility Layout and Location: An
Analytical Approach, PHI, New Delhi, 2002.
Experiential Learning Components:

1. Lab work: None.

2. Project work: None.
3. Case study: None.
4. Work integrated Learning Exercise: None.
5. Design work/Field work: None.

Content Structure:

Contact Hour List of Topic Title Sub-Topics Reference

 Definitions, objectives, T1-Ch.1
principles of plant layout
Introduction to Plant
1-2
Layout
 Advantages of good plant layout
 Need for re-layout and types of
layout problems
 Types of industry, product T1-Ch.2
design
 Methods of production,
machinery and equipment,
material
Factors influencing
3-4  Movement of material/men
Plant Layout
 Employee facilities, services
 Factory building, expansion,
flexibility
 Adaptability and Versatility,
Location/Site
 Types of Layouts T1-Ch.3
5-6 Types of Layout
 P-Q chart & BEA
 Procuring basic data T1-Ch.4
 Product analysis and design of
Procedure for Plant
7-8 production process
Layout
 Calculation for equipment
requirements
9-10 Procedure for Plant  Selection of specific material T1 – Ch4
Layout handling equipment
 Determine the space required
 Develop and evaluate
alternative layouts
 Installation, follow up and
 implementation of layout
 Techniques and tools for T1-Ch.5
planning layout
 Assembly chart
 Operation process chart
 Multi product process chart
 Flow process chart
Techniques and Tools  Flow diagram
11-12
for Planning Layout  Man machine chart
 Two handed process chart
 String diagram
 Travel diagram
 Visualising layout
 Drafting and sketching
 Template and block
 Computerised layout planning, T1-Ch.6
Quantitative Layout
13-14
Analysis
 Allocation method
 Activity relationship chart
 Quantitative layout analysis T1-Ch.7
 Computerised layout planning
 Allocation method
 Activity relationship chart
15-16 Line Balancing
 Line balancing
 Balancing losses
 Parameters of line balancing
problems
Lecture
17-18 Tutorial Class  Topics to be covered: 1-16 (T1)
slides
 Plant services and auxiliary T1-Ch.8
Plant services and departments
19-20
Auxiliary Departments  Receiving, storage, warehousing
 Tool room, plant services
 Factory building T1-Ch.9
 Factors influencing factory
building
21-22 Factory Building
 Features of industrial buildings
 Layout in an existing building
 Layout for a new building
 Introduction to material handling T1-Ch.10
 Definitions, scope, benefits,
Introduction to Material
23-24 limitations of material handling
Handling
 Analysis of material handling
systems
  Unit load concept
 Material handling equipment T1-Ch.11
 Conveyors
Material Handling
25-26
Equipment  Hoists, cranes and monorails
 Mobile material handling
equipment
 Improving and revising existing T1-Ch.12
layout
Improving and Revising
27-28
Existing Layout
 Need for changing layout
 Procedure for layout revision
and improvement
 Evaluation for an effective T1-Ch.13
Evaluation of Effective layout
29-30
Layout  Measurement of effectiveness
 Methods of evaluation
 Plant location T1-Ch.14
 Location problems
31-32 Plant Location  Factors influencing location
 General procedure for selection
of site
 Quantitative Methods T1-Ch.15
33-34 Evaluation of Location
 Qualitative Methods
35-36 Tutorial Class  Topics to be covered: 17-34 T1

Evaluation Scheme:

Legend: EC = Evaluation Component; AN = After Noon Session; FN = Fore Noon Session

Evaluation Name Type (Open Weight Duration Day, Date,
Component (Quiz, Lab, Project, Mid- book, Closed Session, Time
term exam, End semester book,
exam, etc.) Online, etc.)
EC - 1 Quiz I / Assignment – I Online 5% 7 days August 16-30,
2021
Quiz II / Assignment – II Online 5% 7 days September 16-
30, 2021
Quiz III / Assignment III Online 5% 7 days October 16-30,
2021
EC - 2 Mid-sem Open book 35% 2 hours Sunday,
26/09/2021 (FN)
10 AM - 12 Noon
EC - 3 Comprehensive Open book 50% 2 hours Sunday,
14/11/2021 (FN)
10 AM - 12 Noon
Syllabus for Mid-Semester Test (Closed Book): Topics in Contact Hours: 1 to 16
Syllabus for Comprehensive Exam (Open Book): All topics
Important links and information:
Elearn portal: https://elearn.bits-pilani.ac.in
Students are expected to visit the Elearn portal on a regular basis and stay up to date with the
latest announcements and deadlines.
Contact sessions: Students should attend the online lectures as per the schedule provided on the
Elearn portal.
Evaluation Guidelines:
1. EC-1 consists of either two Assignments or three Quizzes. Students will attempt them
through the course pages on the Elearn portal. Announcements will be made on the
portal, in a timely manner.
2. For Closed Book tests: No books or reference material of any kind will be permitted.
3. For Open Book exams: Use of books and any printed / written reference material (filed or
bound) is permitted. However, loose sheets of paper will not be allowed. Use of
calculators is permitted in all exams. Laptops/Mobiles of any kind are not allowed.
Exchange of any material is not allowed.
4. If a student is unable to appear for the Regular Test/Exam due to genuine exigencies, the
student should follow the procedure to apply for the Make-Up Test/Exam which will be
made available on the Elearn portal. The Make-Up Test/Exam will be conducted only at
selected exam centres on the dates to be announced later.
It shall be the responsibility of the individual student to be regular in maintaining the self-study
schedule as given in the course handout, attend the online lectures, and take all the prescribed
evaluation components such as Assignment/Quiz, Mid-Semester Test and Comprehensive Exam
according to the evaluation scheme provided in the handout.

Instructor-in-charge

(ETZC 424)