PLANT LAYOUT

Sub: Operations Management

Dr.Nitin Kubde

INTRODUCTION
The step forward, in the sequence, after location and
site decision.
The floor plan, indicating the location of the various
work centres,
plant, associated offices and supporting facilities.
Hence,
The judicious selection of the location of the plants
and machines should be in such a way, as to facilitate
uninterrupted and quick movements of input material
through pre-determined cycle of operations, till they
are transformed as outputs, in the form of products
and services, with minimum material handling and
management, with maximum efficiency and quality of
operation leading to minimum overall cost of the
entire process/ operations.

IMPORTANCE OF LAYOUT
Facilitates: Manufacturing process.
Facilitates quick movements by reduction of
transportation & waiting time
Minimises material movement & handling.
Efficient utilisation of resources:
Men, Materials, Machines.
Achieves efficiency by effective planning.
Improves quality of operations by proper selection of
plant, machinery, operations & sequencing.

the Plant Layout

Decision
1.
2.
3.
4.
5.
6.
7.
8.

Types of Production
Production System
Scale of Production
Type of machines
Type of Building Facilities
Availability of Total Floor Area
Possibility of Future Expansion
Arrangement of Material Handling
Equipment

Material Flow System

Manufacturing Process includes three

basic inputs :
1. Men
2. Machines
3. Materials

Flow of Material :
Product Layout - Short & Smooth
Process Layout - Long & Complex

Material Flow System

Material Flow System is divided in two
parts :
1. Horizontal Flow System
2. Vertical Flow System

Horizontal Flow System

The Horizontal Flow Systems are
devised in the single story building
when the flat floor area is available.
In this system, the starting point is the
receiving (R) of raw material and the
terminal point is shipment (S) of
finished goods.
In between these two points, the
materials move from one work station
to another for the processing.

Horizontal Flow System

Is denoted by the alphabetic letters :

1. I type Flow : Shortest route .

Must have roads on

both side.
Plant area has long lengths But short width.
Difficulty in returning empty containers.
Absence of rushing of outside
transportation.
Unsuitable for longer production line.

Horizontal Flow System

Is denoted by the alphabetic letters
2. L type Flow :-

Horizontal Flow System

3. U type Flow : One side road link will
be required.
Less difficulty in returning the empty
containers.
Possibility of rushing of outside
transportation.
Suitable for longer production line.
Requires square like floor area.

Horizontal Flow System

4. S or inverted S type of Flow : Requires roads on both
side.
Absence of rushing of
outside transportation.
Requires square like floor area.
Difficulty in returning empty containers.
Suitable for longer production lines.

Horizontal Flow System

5. O type Flow : One side road facility
is required.
Heavy rush of outside
transportation.
Easy in returning empty containers.
Requires square like floor area.
Suitable for longer production line.

Horizontal Flow System

6. I and U type Flow :-

Horizontal Flow System

7. I and S type Flow :-

Horizontal Flow System

8. I and O type Flow :-

Vertical Flow System

The vertical Flow System arises in case of
multi story buildings.
Multi storey building are used where
limited land area is available and the
processing is done on light materials with
the help of light machines.

Vertical Flow System

Important Vertical Flow Systems :-

TYPES OF PLANT LAYOUTS

1.

Product or Line layout

2.

Process or Functional layout

3.

Fixed Position or Project layout

4.

Combination layout (Mixed layout)

1. PRODUCT OR LINE LAYOUT

ADVANTAGES OF PRODUCT
LAYOUT
1.
2.
3.
4.
5.
6.

Low cost material handling

Smooth and uninterrupted operations
Continuous flow of work
Optimum use of floor space
Shorter processing time
Simple and effective inspection of work

DISADVANTAGES:
PRODUCT
1.
High initial capital investment
LAYOUT
2.
3.

Heavy overhead charges

Lesser flexibility

2.PROCESS LAYOUT

Product A :
Product B :

ADVANTAGES OF PROCESS
LAYOUT
1.
2.
3.
4.

Lower initial capital investment

The overhead cost are relatively low
Supervision can be more effective and
specialised
Greater flexibility

DISADVANTAGES OF
PROCESS LAYOUT
1.
2.
3.

Material handling costs are high due to

backtracking
More skilled labour is required
More frequent inspection is needed

COMPARISON BETWEEN
PRODUCT AND PROCESS
LAYOUT
PRODUCT LAYOUT
1. Investment is high
2. Space requirement is
more
3. Manufacturing time
required is more
4. Material handling is
maximum
5. Flexibility is high

PROCESS LAYOUT
1. Investment is less
2. Space requirement is
less
3. Manufacturing time
required is less
4. Material handling is
minimum
5. Flexibility is less

COMPARISON BETWEEN
PRODUCT AND PROCESS
LAYOUT
PRODUCT LAYOUT
PROCESS LAYOUT
6. Inspection is required

7. Less skilled labours

are required
8. Supervision is
required

6.Inspection is not
required at every
stage
7. More skilled labours
are required
8. Supervision is not
required

3.FIXED POSITION OR PROJECT

LAYOUT

MANUFACTURING OF
SHIP

ADVANTAGES OF FIXED
POSITION LAYOUT
1.

2.

3.

It saves time and cost involved on the

movement of work from one work
station to another
The layout is flexible as change in job
design and operation sequence can be
easily incorporated
It is more economical when several
orders in different stages of progress are
being executed simultaneously

DISADVANTAGES OF FIXED
POSITION LAYOUT
1.
2.

Production period being very long,

capital investment is very heavy
Very large space is required for storage
of material and equipment near the
product

4. COMBINATION
LAYOUT
Lathe
A
painting

Drilling

Milling

Grinding

Press
inspection

Boring

Shaping
packaging

Milling

Cellular layout