PLANT LAYOUT

PREPARED BY –
• RUSHIKA JAIN
• DEEPAK BHANUSHALI
• DANIEL MATTA
• ANKIT NANDHA
• PAWAN RASKAR
• NIHAR SHAH
 INTRODUCTION
Plant Layout refers to the arrangement of physical facilities such as machines, equipments,
furniture, etc in such a manner so as to have quickest flow of material at the lowest cost and with
the least amount of handling in processing the product from the receipt of raw material.
 OBJECTIVES
 Proper & Efficient utilization of floor space.
 Proper utilization of production capacity.
 Reduce material handling costs.
 Reduce accidents.
 Transportation of work from one point to another without any delay.
 Provide ease of supervision and control.
 Improve productivity.
 Allow easy maintenance of machines and plant.
 Provide for employee health and safety.
 Provide for volume and product flexibility.
 PRINCIPLES OF PLANT LAYOUT:
1 . Principle of Integration
2 . Principle of Minimum Distance
3. Principal of Cubic Space Utilization
4. Principal of Flow
5. Principal of Maximum Flexibility
6. Principle of Safety, Security and Satisfaction
7. Principle of Minimum Handling
 NEED FOR PLANT LAYOUT
• Design changes
• Expansion of the enterprise
• New product
• New department reallocation or of the existing department
• A new plant is to be set up

BENEFITS OF PLANT LAYOUT

• Reduction in number of accidents, loss of man-hours and wastage of equipment
• Better provision for maintenance and inspection of the production capacity, work in process and the work
completed
• Reduction in cost of supervision
• Better utilization of available floor space
 FACTORS INFLUENCING PLANT LAYOUT
FACTORY BUILDING : NATURE AND SIZE OF BUILDING DETERMINES THE FLOOR SPACE
NATURE OF PRODUCT : PRODUCT LAYOUT IS FOR UNIFORM PRODUCTS WHEREAS
PROCESS IS FOR CUSTOM MADE PRODUCTS

TYPE OF MACHINERY : GENERAL PURPOSE MACHINES ARE ARRANGED AS PER PROCESS

LAYOUT AND SPECIAL PURPOSE MACHINES ARE ARRANGED ACCORDING TO PRODUCT LAYOUT.

REPAIRS AND MAINTENANCE : MACHINES SHOULD BE ARRANGED SO THAT ADEQUATE

SPACE IS AVAILABLE.

HUMAN NEEDS : ADEQUATE ARRANGEMENT FOR WASHROOM, LOCKERS, DRINKING WATER

ETC.

PLANT AND ENVIRONMENT : HEAT, LIGHT, NOISE, VENTILATION SHOULD BE DULY

CONSIDERED.
 TYPES OF PLANT LAYOUT
● Product layout
Equipment and machines are arranged according to sequence of operation
● Process layout
Machines are arranged according to the nature or type of operations
● Fixed position layout
Major component remain in fixed location and other are brought to the location
● Combination type of layout
Compromise of the above mentioned layouts
PRODUCT LAYOUT PROCESS LAYOUT
• Continuous flow • Intermittent Flow
• Layout According to Resources
• Dedicated Resources • Criss crossing of components
• Ex-Machine Shops, Auto
• Work Movement
Repair Shops
• Ex-Car Assembly line ,Coke
factory.
 CASE STUDY- TUSHAR ENGINEERING AND
WORKS.
• Problem Statement-Only 90% of workshop space is effectively utilized.
• Aim - Make Changes in location of departments that will reduce the number of moves and
calculations of total material handling time.
 NEW PLANT LAYOUT

 After PQRST Analysis and Material flow analysis

following design layout is proposed.
 Product layout is selected.

RESULTS
 The total time required to complete the operation per unit has reduced by 35 Sec.
 Overall distance travelled (i.e. Material flow) during manufacturing has minimum.
 The formation of logistic center eliminates delays and minimizes transport because of its central
location.
 ADVANTAGES AND DISADVANTAGES OF PRODUCT AND
PROCESS LAYOUT

Process Layout Product Layout

Advantages: • Sharing of specialized and • Standardized product/process

costly equipments. routing.

• More flexibility • Operational control is simpler

• Less vulnerable to breakdown • High output rate is possible

Disadvantages: • Large inventory build up • Low tolerance to breakdowns

• Operation control is difficulty • Duplication of equipment

leading to high cost

• Excess material handling • Lower Flexibility due to

dedication of resources
 FIXED POSITION LAYOUT

• When the product to be manufactured is bulky or difficult to move, fixed position layout is
used
• By proper workplace organization it is possible to exercise greater control on the process
and remove unwanted processes and delays from the system.
• The emphasis in fixed-positioning layouts is not so much on optimum positioning of
resources but to enable managers gain better control of material flow
• For example: Workplace organization at Thermax
GROUP TECHNOLOGY/ CELLULAR TECHNOLOGY

 GT finds out the commonality in manufacturing and uses it as a basis for grouping
components and resources

 Plant Layout is made in such a way that for a products with similar characteristics the available
components are grouped into product families

 Appropriate measure of manufacturing similarity is used to identify product families

 Corresponding to the part families the machine groups are identified dissimilar machines are
grouped into cells
 OBJECTIVES OF GROUP
TECHNOLOGY
 Reduce average lot size
 Increase part variety
 Increase variety of materials
 Achieve close tolerance
 Improve scheduling
 Reduce tooling
 Increase equipment utilization
BENEFITS
 Components will not travel outside the
cell
 Production planning becomes easier.
 efficiency and production is increased
 Material handling is improved, more
traceability
 E.g. TITAN
 REFERENCE
S:
1. http://www.yourarticlelibrary.com
2. https://www.slideshare.net
3. https://www.learnpick.in
4. http://elearning.nokomis.in
5. https://www.researchgate.net