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Plant Layout - Industrial Engineering

Plant layout is the physical arrangement of machines, equipment, and departments within a factory to maximize efficiency. There are several types of layouts, including product layout where machines are arranged sequentially based on production steps, process layout where similar machines are grouped, and hybrid layouts that combine features. The optimal layout depends on factors like the product, production process, machinery, manpower, and factory environment. Arranging facilities properly can improve productivity, material handling costs, maintenance access, and worker safety.

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Manas Rane
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348 views12 pages

Plant Layout - Industrial Engineering

Plant layout is the physical arrangement of machines, equipment, and departments within a factory to maximize efficiency. There are several types of layouts, including product layout where machines are arranged sequentially based on production steps, process layout where similar machines are grouped, and hybrid layouts that combine features. The optimal layout depends on factors like the product, production process, machinery, manpower, and factory environment. Arranging facilities properly can improve productivity, material handling costs, maintenance access, and worker safety.

Uploaded by

Manas Rane
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Plant Layout

Industrial Engineering

What is 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 departments to achieve greatest coordination and efficiency of 4 M's (Men,
Materials, Machines and Methods) in a plant.

Why plant layout is required?


Utilisation of
floor space
Proper and
efficient
utilization

Materials
Management
Material
movement
Material
handling costs

Ergonomics

Plant
Maintenance

Reduce
accidents
Supervision
and Control
Communication

Easy
maintenance of
machines
Easy access to
plant areas

Productivity and
Efficiency
Increased
output
Less required
time.

System Inputs Plant Layout


Factory

Machines
Policies

Product

Plant
Environment

Plant Layout

Production
Process

Types of Layout

Product
layout

Process
layout
Hybrid Layout

Fixed layout

Product Layout
In this type of layout the machines and equipments are arranged in one line depending upon the
sequence of operations required for the product. It is also called as line layout. The material moves to
another machine sequentially without any backtracking or deviation i.e the output of one machine
becomes input of the next machine. It requires a very little material handling.
It is used for mass production of standardized products
(Need to add diagram )
Examples:
Car assembly plant (Manufacturing industry)
Mc Donalds (Service industry)

Product Layout
Advantages

Disadvantages

Low cost of material handling, due to straight and short


route and absence of backtracking

Higher initial capital investment in special


purpose machine (SPM)

Smooth and continuous operations

High overhead charges

Continuous flow of work

Breakdown of one machine will disturb the


production process.

Lesser inventory and work in progress


Optimum use of floor space
Simple and effective inspection of work and simplified
production control

Lesser flexibility of physical resources

Process Layout
Advantages

Disadvantages

Lower initial capital investment is required.

backtracking

There is high degree of machine utilization, as a

machine is not blocked for a single product

specialized.

Work in progress inventory is high needing greater


storage space

production process.
Supervision can be more effective and

More skilled labour is required resulting in higher


cost.

The overhead costs are relatively low


Breakdown of one machine does not disturb the

Material handling costs are high due to

More frequent inspection is needed which results in


costly supervision

Fixed Position Layout


Advantages
The investment on layout is very small.
The layout is flexible as change in job
design and operation sequence can be
easily incorporated.
Adjustments can be made to meet
shortage of materials or absence of
workers by changing the sequence of
operations.

Disadvantages

As the production period being very long so


the capital investment is very high.

Very large space is required for storage of


material and equipment near the product.

As several operations are often carried out


simultaneously so there is possibility of
confusion and conflicts among different
workgroups.

Combined Layout
Layouts used in industries are the compromise of the above mentioned layouts. Every layout has got
certain advantages and limitations.

Flexibility is a very important factory, so layout should be such which can be molded according to the
requirements of industry, without much investment.

If the good features of all types of layouts are connected, a compromise solution can be obtained
which will be more economical and flexible.

Influencing Factors
Factors

Automobile Industry

Hospitality

Construction

Factory/ Building

High

Medium

Low

Product

High

Medium

High

Production Process

High

Medium

Low

Machinery

High

Low

Medium

Manpower

Medium

Medium

High

Policy

Medium

High

Medium

Environment

Medium

High

Low

Thank You

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