PLANT LAYOUT AND TYPES OF LAYOUTS

PLANT LAYOUT AND TYPES OF LAYOUT

1. KIOT
Plant Layout and Facility Design
Course code: Greg 4181
Target group: 4
th
year GED
Chapter three
Plant Layout
By: Endashaw Yohannes
Kombolcha/Ethiopia
Dec, 2019
12/26/2019 1

2. 1.Meaning of plant layout
2.Objective of plant layout
3.Symptoms of bad layout
4.Advantages of good plant layout
5.Principles of plant layout
6.Types of layout
7.General flow patterns of plant layout
Outline of chapter three

3. “Plantlayoutisaplanofanoptimumarrangementof
facilitiesincluding
Personnel,
Operatingequipment,
Storagespace,
Materialhandlingequipmentand
Allothersupportingservicesalongwiththedesign
ofbeststructuretocontainallthesefacilities”.
1. Meaning of Plant Layout

4. 2. Objectives of Plant Layout
oTheprimarygoaloftheplantlayoutistomaximizetheprofitby
arrangementofalltheplantfacilitiestothebestadvantageoftotal
manufacturingoftheproductandatthesametimesatisfactoryand
safeforthepersonneldoingthework.

5. 2. Objectives of Plant Layout cont...
oHelpsforthepersonneldoingthework.
IntheSenseofUnity
oThefeelingofbeingaunitpursuingthesameobjective.
MinimumMovementofpeople,materialandresources.
Safety
oInthemovementofmaterialsandpersonnelworkflow.
Flexibility
oIndesigningtheplantlayouttakingintoaccountthe
changesovershortandmediumtermsintheproduction
processandmanufacturingvolumes.

6. 2. Objectives of Plant Layout cont...
•These main objectives are reached through the
attainment of the following facts:
Congestion reduction.
Elimination of unnecessary occupied areas.
Reduction of administrative and indirect work.
Improvement on control and supervision.
Better adjustment to changing conditions.
Better utilization of the workforce, equipment and
services.

7. 2. Objectives of Plant Layout cont...
Reductionofmaterialhandlingactivitiesandstockin
process.
Reductiononpartsandqualityrisks.
Reductiononhealthrisksandincreaseonworkers
safety.
Moralandworkerssatisfactionincrease.
Reductionondelaysandmanufacturingtime,aswell
asincreaseinproductioncapacity.
Allthesefactorswillnotbereachedsimultaneously,sothe
bestsolutionwillbeabalanceamongthem.

8. Introduction
•Tomakeadecisionaboutlayoutplanning,4differentquestionsmust
haveananswer:
1.Whichcentersdowehavetoconsider?
2.Howmuchspaceandcapacityisrequiredforeachcenter?
•Ifthereisnotenoughspace,productivitymaybereduced.
•Toomuchspaceisexpensiveandmayalsoreduceproductivity.
3.Howmustthespaceberelatedwitheachcenter?
•Spacequantity,shapeandtheelementsoftheworkcenterare
relatedtoeachother.
4.Whereshouldeachcenterbelocatedatwithinthefacility?
•Theallocationofthedifferentcentersmayaffectproductivity.

9. Design problem
Green field/current
state
Location of one
new machine
•Reasons to design production layout:
New products
Changes in demand
Changes in product design
New machines
Bottlenecks
Too large space between work station
Too long transfer times
Production Layout

10. Layout Design
Layout
Product
Logistics Process

11. oRe design of production layout
•The reasons for a re-layout are based on 3 types
of changes:
Changes in production volumes.
Changes in processes and technology.
Changes in the product.
•The frequency of the re-layout will depend on the
requirements of the process.

12. 4. Symptoms of bad layout
Symptomsthatallowustodetecttheneedforare-layout:
Somemachinesheavilyloadedandsomeidle
Excessivehandlingbyskilledworkers
Longproductioncycles&delaysondelivery
Crowdedcondition&Poorutilizationofavailablespace
Bottleneckinproduction&obstaclesinmaterialflow
Excessivefatigueonworkers&frequentaccidents
Excessivetemporarystorage&Backtracking
Difficultinsupervisionandcontrol
Idlemachinesandmanpower

13. Figure: improper production layout

14. 3. Advantages of good plant layout
Reduce internal transport to a minimum
Minimizes accidents operations
Makes supervision & production control easier
Makes maintenance and repair easier
Reduces labor turnover
Reduces production delay
Maintain floor area neat and clean
Reduces waste effort, wastages and spoiled work
Reduces back tracking and bottlenecks
Better utilization of manpower and machinery
Possible to improve production methods

15. •Any layout should satisfy the objective or principles of plant
layout for proper functioning.
•There are Nine basic principles of best plant layout
1.Principle of overall integration
2.Principle of minimum distance moved
3.Principle of flow
4.Principle of cubic space
5.Principle of satisfaction and safety
6.Principle of flexibility
7.Principle of expansion
8.Principle of versatility
9.Principle of orderliness
5. Principles of plant layout

16. Basic principles of plant layout
1.Principle of overall integration
oThe layout is best which integrates
Men,
Material,
Machinery, and
Supporting activities in a way that results best
compromise.
oIt must be convenient for people servicing or
supporting the operation as well.

17. 2) Principle of minimum distance moved
Otherthingsbeingequalthelayoutisbestwhich
permitsthematerialtomovetheminimumdistance
betweenoperations.
Byplacingsubsequentoperationsadjacenttoeach
otherreducingthewecanreducedistanceof
movement.

18. 3) Principles of flow
Other things being equal, the layout is best which
arranges the work area for each operation or process
in the same order or sequence that forms , treats, or
assembles the materials.
It means that material will move progressing from
one operation to the next towards its completion.
Congestion with other parts or other pieces of the
same part is at minimum.

19. 4) Principle of cubic space
•Other things being equal, the best layout utilizes
effectively all available space both vertical and
horizontal.
•Movement of material, men and machinery may be in
any of the three direction.
•It means taking vacant overhead space or work
surface under the floor.

20. 5) Principle of satisfaction and safety
Being other things equal, the layout is best which
makes work satisfying and safe for workers.
Safety is the major factor in most layouts.
A layout can not be good if it subjects employees to
hazardous or accidents.

21. 6) Principle of flexibility
Other things being equal, the layout is best which can
be adjusted and rearranged at minimum cost and
inconvenience.
This objective become more important ,as new
developments are taking place in scientific research
for frequent changes in product design, equipment
and production methods.
Economy can be obtained if a new layout can be made
quickly and inexpensively.

22. 7) Principle of expansion
•It should be easy to expand with out disturbing the
existing layout and production schedules
8) Principle of Versatility
•Layout should be adaptable to changes in product
design, sales requirement and process improvement
9) Principle of orderliness
•Clean work areas with suitable equipment for
removing scrap waste etc.

23. 6. Types of layout
For the purpose of production Men, Machines and
Materials are required.
Men work on materials with the aid of machinery and
tools.
For Production at least on one of them has to be moved.
Production machinery can be grouped and arranged in
different ways.
The ways and arrangement of production machinery
decides the types of layout

24. Types of layout cont..
•Common types or methods of layout are:
A.Product or line layout
B.Process or functional layout
C.Fixed position lay out
D.Combinations (group layout)
E.Cellular Manufacturing (CM) Layout

25. Thearrangementofequipmentisbasedonthe
sequenceofoperationsinthemanufactureofanindividual
product
or
agroupofsimilarproductsrequiringthesamemanufacturing
equipmentinthesamemanufacturingsequence.
Onlyoneoronetypeofproductisinoperatingarea.
Theproductmustbestandardizedandmanufacturedin
largequantities.
Verypopularinmassproductionreadymadegarment
factory
A. Product layout

26. Plant layout example Product Layout

28. Materialshandlingisautomated,hencereductionin
materialshandlingcost.
Bottlenecksinproductionlinecouldbeavoided.
Lessermanufacturingtime.
Thelayouthelpsinbetterproductioncontrol.
Itnecessitateslessfloorspaceperunitofproduction.
WIPisreducedandinvestmentthereonisminimized.
Product layout Advantages

29. Expensiveandinflexiblelayout.
Supervisionisdifficult.
Expansionisdifficult.
Breakdownofanymachineryinalinecoulddisturbthe
wholesystem.
Asingleoperatorabsenteeisminalinecoulddisturbthe
wholesystem.
Product layout disadvantages

30. Similar equipment and similar operations are grouped
together
Useful where product is not standardized and low
volume is required
It has greater flexibility
Advantageous when products of dissimilar types being
manufactured.
B. Process layout

32. Plant layout example Process Layout

33. Bettersupervisionisachievablethroughspecialization.
Investmentsonmachinesarereducedastheyaregeneral
purposemachines.
Thereisgreaterflexibilityintheproduction.
Thislayoutprovidesbetteruseofmenandmachines.
Itiseasiertohandleanybreakdownofmachinesthrough
takingthemachinetoanothermachinestation.
Theinvestmentcostsonmachinesarecomparativelylower.
Process layout Advantages

34. Process layout disadvantages
Movementofmaterialsisdifficult.
Requiresmorefloorspace.
Sincethework-in-progresshastomovefromoneplace
toanothertolookforamachine,theproductiontimeis
generallyhigh.
TheWIPaccumulatesatdifferentplaces.

35. The material and or major component ,remains in a
fixed locationand tools, machinery and men and other
pieces of material brought to this location.
Useful if the product is Extremely large or heavy (
like air craft and ship building ) and extremely low
volume of output (like housing industries)
High skill is demanded
Very common before industrial revolution
C. Fixed position layout

37. Permitstheplanttoelevateskillofoperators
Lessmaterialmovement
Greaterflexibilityallowsfrequentchangesinproduct
design,productmixandproductionvolumeofdemand.
Layoutcapitalinvestmentislow.
Menandmachinescanbeutilizedfornumerouskinds
ofoperationsmanufacturingdifferentproducts.
Thecostsoftransportationforabulkyproductare
avoided.
Fixed position layout Advantages

38. Highlyskilledmanpowerisrequired
Movementsofmachinesandequipmentstoproduction
centremaybetimeconsuming
Complicatedfixturesmayberequiredforpositioning
ofjobsandtools.Thismayincreasecostof
production.
Fixed position layout disadvantages

39. • Combinedlayoutsmakesthestrongpointsof
 product,
 process,and
 fixedpositionlayouts.
o Nowadayspurestateofanyoneformoflayoutis
rare.
o Ifthegoodfeaturesofalltypesoflayoutare
connectedacompromisesolutioncanbeobtained
whichwillbemoreeconomicalandflexible
D. Combined ( Group) lay outs

41. PRODUCTION VOLUME AND PRODUCT VARIETY
DETERMINES TYPE OF LAYOUT
Group layout
process layout
Product variety
Production volume
product layout
Fixed
Position
Layouts

42. E. CELLULAR MANUFACTURING (CM) LAYOUT
Inthiskindoflayout,themachinesaregenerally
assembledintocellswhichfunctionfairlylikeaproduct
layoutwithinaprocesslayout.
Everycellinthisdesignisshapedtoproducesingle
parts,allwithcommonattributes,whichtypicallymeans
theynecessitatethesamemachinesandhavesimilar
machinesettings(RameshBabu2006).

43. Plant layout example Cellular Layout

44. E. CELLULAR MANUFACTURING (CM) LAYOUT
A.Advantages:
LowerWIPinventories.
Reducedmaterialhandlingcosts.
Flowtimeofmaterialsislessinproductionplanning.
Improvedvisualcontrolofprocesswhichenables
quickersetups.
Manufacturingflexibility.
Reducedmachinestoppagetime.

45. 7. GENERAL FLOW PATTERNS OF PLANT LAYOUT
"FlowPattern"meansthesystemtobeadoptedfor
themovementofrawmaterials,fromthebeginningand
uptotheendofmanufacturing.
Theoverall-objectiveoftheFlowpatternistoplanfor
theeconomicalmovementoftherawmaterials
throughouttheplant.

46. 7. GENERAL FLOW PATTERNS CONT..
Quiteoftenlayoutdesignstartswiththeflowsystemand
buildingdesignaremodifiedaccordinglybutsometimesthe
flowmustbeadoptedtoexistingbuildings.
Mostcommonerrorinmaterialflowis
o Back-haulingortheback-trackingofmaterials,
which means that
oncethematerialhaspassedthroughanoperationitmust
maintainitsdirectionanddoesnotretraceitspath.

47. 7.1. FLOW SYSTEMS OF PLANT LAYOUT
Basedontheflowsystemsplantlayoutcanbe
classifiedintotwo:
1.Horizontallayoutand
2.Verticallayout.
Thehorizontalflowsystemisadoptedonashopfloor
Verticalflowisadoptedwherematerialhastomovein
amulti-storebuilding.

48. 1. HORIZONTAL FLOW LINES
Therearefivebasictypesofhorizontalflow
line:
A.I-FloworLineFlowhorizontalflowlines
B.L-Flowhorizontalflowlines
C.U-Flowhorizontalflowlines
D.S-Flowhorizontalflowlines
E.O-Flowhorizontalflowlines

49. A. I-FLOW or LINE FLOW HORIZONTAL FLOW LINES
Itisthesimplestformofflow.
Inthis,materialsarefedatoneendandcomponents
leavethelineattheotherend.
ThistypeiseconomicalinspaceandconvenientinI-
shapedbuildings.

50. B. L-FLOW HORIZONTAL FLOW LINES
ItissimilartotheI-FlowandisusedwhereI-line
cannotbeaccommodatedintheavailablespace
Figure: L-flow horizontal flow line

51. C. U-FLOW HORIZONTAL FLOW LINES
Inthis,bothfeedingandoutputtakeplaceatthesameend,
i.e.,itallowsbothreceivinganddispatchingofgoodstobe
doneat'oneside.
IncomparisontoIorL-Flow,thismethodiseasierfor
supervision.
Figure: U-Flow horizontal flow lines

52. D. S-FLOW HORIZONTAL FLOW LINES
Iftheproductionlineissolongthatzigzaggingonthe
plantflooris"necessarythisS-flowisadopted.
Thistypeprovidesefficientutilizationofspaceandis
compactenoughtoalloweffectivesupervision.
Figure: S-Flow horizontal flow lines

53. E. O-FLOW HORIZONTAL FLOW LINES
Thistypeisusedwhereprocessoroperationsareperformed
on-arotarytableorarotaryhandlingsystem.
Thecomponentsaremovedfromoneworkingstationtothe
otherandwhentheyleavetheO-line,acompletesetof
processesoroperationshavebeenperformed.
Thecomponentsinspectedbeforetheyaremovedontoa
secondlineforanadditionalseriesofprocess-oroperations
ortoanassemblyline.
Figure: O-Flow horizontal flow lines

54. COMBINATIONS OF BASIC HORIZONTAL FLOW
Theseabovementionedbasicflowlinesaremostlyused
byindustriesinvariouscombinations.
Figure: Combinations of basic horizontal flow

55. I. UNIDIRECTIONAL FLOW
Whenthematerialispassedfromonetoanother
withouthavingtopassalongthesamepath
Figure: Combinations of basic horizontal flow

56. II. RETRACTION FLOW. (REPEATED FLOW )
Inthistype,theflowisrepeatedi.e.twoormorenon-
consecutiveoperationsareperformedonthesamemachine.
Inthisflow,theavailablemachinetimeisfullyutilizedbut
scheduleshavetoallowforrepeatedmachinesetting-
e.g.,eachtimeamachineisswitchedoverfromoneoperation
toanother.
Figure: Retraction Flow. (Repeated flow )

57. 2. VERTICAL FLOW LINES
Thistypeofflowisformulti-storeybuildings.Sothat
thematerialshandlingsystemsandcontrolmechanisms
operateeffectively,
Figure: Vertical Flow lines

58. 2. VERTICAL FLOW LINES CONT...
Figure: Vertical Flow lines

59. Reading
Plant lay out and material handling
(R.B Choudary)
1)Chapter Two –Introduction to plant
layout

60. 12/26/2019 60