INDUSTRIAL PLANT

LAYOUT
PLANT LAYOUT

• Plant layout is the most effective physical

arrangement, either existing or in plans of
industrial facilities i. e. arrangement of
machines, processing equipment and service
deparments to achieve greatest coordination
and efficiency of 4 M's (Men, Materials, Machines
and Methods) in a plant.
INTRODUCTION

• The ability to design and operate manufacturing

facilities that can quickly and effectively adapt to
changing technological and market requirements
is becoming increasingly important to the
success of any manufacturing organization.
• In the face of shorter product life cycles, higher
product variety, increasingly unpredictable
demand, and shorter delivery times,
manufacturing facilities dedicated to a single
product line cannot be cost effective any longer.
INTRODUCTION

• Investment efficiency now requires that

manufacturing facilities be able to shift quickly
from one product line to another without major
retooling, resource reconfiguration, or
replacement of equipment.
OBJECTIVES OF PLANT LAYOUT

• Economies of materials, facilitation of

manufacturing and handling of goods properly
and efficient use of floor space.
• Ensure proper flow of goods and processes
without any delay provision for supervision and
control.
• Careful planning to avoid changes and re-layout
of a plant provision of safety to workers.
OBJECTIVES OF PLANT LAYOUT

• Meet quality and capacity requirement in the

most economical manner provision of adequate
medical facilities and refreshment facilities have
enough of material handling spaces.
PLANT LAYOUT PROBLEMS

• In industry sectors, it is important to

manufacture the products which have good
quality and meet customers's demand. This
action could be conducted under existing
resources such as employees, machines and
other facilities. However, plant layout
improvement, could be one of the tools to
response to increasing industrial productivity.
PLANT LAYOUT PROBLEMS

• Plant layout design has become a fundamental

basis of today's industrial plants which can
influence parts of work efficiency. It is needed to
appropriately plan and position employees,
materials, machines, equipment, and other
manufacturing supports and facilities to create
the most effective plant layout.
FACTORS AFFECTING LAYOUT

• Factory building. The nature size of the building

determines the floor space available for layout
while designing the special requirements i.e. air
conditioning, dust control, humidity control, noise
proffing etc must be kept in mind.
• Nature of product. Product layout is suitable for
uniform products. Process layout is suitable for
custom made products, production process in
assembly line industries product layout is better.
In job order or intermittent manufacturing
process layout is desirable.
FACTORS AFFECTING LAYOUT
• Repairs maintenance machine/equipment must be
arranged keeping in mind the movement of
operators maintenance tools.
• Human needs adequate arrangement should be
made for wash rooms, drinking water/canteen
other employee facilities.
• Plant environment heat/noise/light/ventilation
other aspects should be duly considered e.g. paint
shop/fabrication/plating section should be located
separately to protect employees from harmful
fumes etc. Adequate safety arrangement should
be made.
SUMMARY
• Decisions about layout are made only periodically.
As they have long term consequences, they must
be made with careful planning.
• The layout design affects the cost of producing
goods delivering services for many years in future.
Here we have discussed three traditional basic
layouts: a) Process b) Product c) Fixed Position
SUMMARY
• Process Layout arrange work centers according to
function. Product layouts (Assembly layout)
arrange work centers equipment in line to perform
specialized sequence of tasks.
• In fixed position layout, the product remains in
one location resources are brought to it. In
process product layouts, the design begin with a
statement of goals of facility. The layouts are
designed to meet these goals.
SUMMARY
• After initial designs have been developed,
improved designs are sought which will be
cumbersome, hence to take care of it quantitative
computer based models are used.
PLANT LAYOUT