PLANT LAYOUT

Introduction
It includes decisions regarding the physical
allocation of the economic activity centers
in a facility.


Plant layout
Objectives of Facility Layout
Minimizing material handling costs
Efficient utilization of
Space
Labor
Eliminate
Bottlenecks
Waste or redundant movement
Objectives of Facility Layout
Facilitate
Organization structure
Communication and interaction between workers
Manufacturing process
Visual control
Minimize
Manufacturing cycle time or customer flow time
investment
Provide
Convenience, safety and comfort of the employees
Flexibility to adapt to changing conditions
Factors affecting Plant Layout

1. Materials
2. Machinery
3. Labor
4. Material Handling
5. Waiting Time
6. Auxiliary Services
7. The building
8. Future Changes
Basic Types of Layouts
Product Layout
Used in a flow shop for a high volume, standard products
Process Layout
Used in a job shop for a low volume, customized products
Fixed Position Layout
Used in projects for large products e.g., airplanes, ships and
rockets
Cellular layouts
A cell contains a group of machines dedicated for a group of
similar parts
Suitable for producing a wide variety parts in moderate
volume

Product Layout
The pieces of equipment required to make a
Particular product are grouped together
Continuous flow
Repetitive flow (assembly line)
Product Layout for Wine Manufacturer


Advantages
Reduced material
handling activities.
Work in Process almost
eliminated.
Minimum manufacturing
time.
Simplification of the
production planning and
control systems.
Tasks simplification.
Disadvantages:
No flexibility in the
production process.
Low flexibility in the
manufacturing times.
High capital investment.
Every workstation is critical
to the process
The lack of personnel or shut
down of a machine stops the
whole process.
Monotonous work.
Product Layout Advantages and
Disadvantages
Process Layout
Personnel and equipment to perform the same function
are allocated in the same area.
Sequence of operations previously established.
Process Layout for a Machine Shop

Advantages of Process layout

1. Best use of specialization of machines &
employees
2. Flexible variety of products
3. General purpose machines less costly
4. Ability to follow diverse paths
5. Less vulnerable to shutdowns
6. Machine breakdown less of problem
7. Small batch product economy
8. Suitable for incentive pay



Disadvantages of Process layout



1. General purpose machines slower
2. Work routing, scheduling difficult
3. Material handling costs high
4. Material moves slowly
5. Partially finished inventory high large
storage space
6. Communication difficult
7. Some limit to size of parts
Fixed Position Layout

The equipment is brought to the object being
processed, and the object does not move.
Example; House construction.
Cellular Layouts
Every cell contains a group of machines which are
dedicated to the production of a family of parts
Source: J. T. Black, Cellular Manufacturing Systems Reduce Set Up
time, Make Small-Lot Production Economical, Industrial Engineering
Magazine, Nov. 1983. Used with permission from the author.
Cellular Manufacturing Layout
Advantages of Cellular Layouts
Reduced material handling and transit time

Reduced setup time

Reduced work-in-process inventory

Better use of human resources

Better scheduling, easier to control and automate
Disadvantages of Cellular Layouts

Sometimes cells may not be formed

Some cells may be poorly balanced cells.
workers must be multi-skilled and cross-trained.

High capital investment.