Plant Layout

Prepared by, Mohammad Faizul Haque 1

Introduction
• Production results from the working of – men, materials and
machinery.

• One or more pieces of materials are taken and their – form,

nature or chemical characteristics are changed by using
machinery including tools and equipments to give a product.

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Plant Layout:
• The layout of a factory, workshop or working area
means the position of the departments or shops in
the factory and of the machines, work places and
storage points in the working areas, including officers
and staff facilities relative to one another.
• A bad layout can add a good deal of time to the total
work. Contents of a process which causes
unnecessary movement of material & consumes time
& energy of the worker without any value addition in
completion of a job.

Prepared by, Mohammad Faizul Haque 3

Objectives of Plant Layout:
• Facilitate the manufacturing process
• Minimize the materials handling
• Maintain flexibility of arrangement of operations
• Maintain high turn over of works in process
• Hold down investment in equipment
• Make economical use of floor area
• Promote effective utilization of labour
• Provide employee convenience and comfort in doing the work

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• Promote effective utilization of labour:
i) Reduce manual handling
ii) Minimize walking
iii) Balance machine cycles so that man & machine are not idle
iv) Laying the machine in such a way that supervision is
simplified

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Plant Layout Problems:
• Change of Design
• Enlargement of a Department
• Reduction of a Department
• Addition of a department
• Addition a new product
• Moving a department
• Planning a new plant

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Types of Layout:
• 1. Layout by fixed position/fixed material location (e.g. ship building)
• 2. Layout by process/function (e.g. all welding in one area, all drilling in
one area)
• 3. Layout by product/line production
- In fixed position layout, the major product being produced is fixed at one
location. Equipment labour and components are moved to that location.
All facilities are brought and arranged around one work center. This type of
layout is not relevant for small scale entrepreneur. A fixed position layout
regarding shipbuilding.
- A process layout is one which all machines or processes of the same type
are grouped together.
- A product layout is one which all machines or process concerned in the
manufacture of the same product or range of product are grouped
together.

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Fixed Position Layout:

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Process Layout:

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Product Layout:

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• Fixed Position Layout: Advantages & Disadvantages
• Process Layout: Advantages & Disadvantages
• Product Layout: Advantages & Disadvantages
• Which of the layout types to be used:
– 1. Layout by fixed position/fixed material location
– 2. Layout by process/function
– 3. Layout by product/line production

Prepared by, Mohammad Faizul Haque 11

Factors affecting layout:
• 1. Material
• 2. Machinery
• 3. Men
• 4. Movement
• 5. Waiting
• 6. Service
• 7. Building
• 8. Flexibility

Prepared by, Mohammad Faizul Haque 12