Plant Layout

PLANT LAYOUT

Layout is a Fundamental of every organization and enterprise. Kitchen, Retailers, offices, service organization and all the enterprises have a specific layout. Plant layout depends on decisions already taken on location, capacity, facility, manufacturing method and material handling techniques.

OBJECTIVES OF PLANT LAYOUT

The objectives of plant layout are:

Minimize investment in equipment. Minimize overall production time. Utilize existing space most effectively. Provide for employee convenience, safety and comfort. Minimize materials handling cost.

CLASSIFICATION OF LAYOUT
Layouts can be classified into the following four categories. Process layout Product layout Group layout Fixed position layout

PROCESS LAYOUT
In a process layout, similar machines and services are located together. Therefore, all drills will be located in one area of the plant. Process layout is normally used when the production volume is not sufficient to justify a product layout. Typically, job shops employ process layout due to the variety of products manufactured and their low production volumes.

PRODUCT LAYOUT
Product layout is used when machines and auxiliary services are located according to the processing sequence of the product.

The product layout is selected when the volume of production of a product is high.
In a strict product layout, machines are not shared by different products.

Group Layout

Combination of both product layout and process layout. Group layout is possible where an item is made in different size and types.

FIXED POSITION LAYOUT A fourth type of layout is the static product layout, or layout by fixed position, in which the physical characteristics of the product dictate as to which type of machine and men are to be brought to the product.

ADVANTAGES AND LIMITATIONS OF PROCESS LAYOUT ADVANTAGES Machines are better utilized; fewer machines are required. A high degree of flexibility in terms of task allocation to machines exists. Comparatively low investment in machines is required. LIMITATIONS Material handling cost will be high. Production planning and control systems are more involved. Time is longer. Higher grades of skills are required.

ADVANTAGES AND LIMITATIONS OF PRODUCT LAYOUT ADVANTAGES The flow of product will be smooth and logical in flow lines. Throughput time is less. Material handling cost is minimum. Operators need no be skilled. LIMITATIONS A breakdown of one machine in a product line may cause stoppages of machines in the downstream of the line. A change in product design may require major alterations in the layout. Comparatively high investment in equipment is required.