Facility Layout

Presented by

• Shashank Saxena
• Shashi Minchel
• Shikha Sinha
• Shilpi Kanstiya
• Shruti Agnihotri
• Shruti Garg
• Shuvam kaushik
• Simayan Pati
Plant layout

• A floor plan for determining and arranging the desired

machinery and equipment of a plant
• It permits
– The quickest flow of materials in processing the product
• From the receipt of the raw materials to the
shipment of the finished product
– At the lowest cost, and
– With the least amount of handling
Objectives

• Provide enough production capacity

• Reduce material handling cost
• Reduce congestion impeding movement of men and
material
• Reduce hazards to working personnel
• Utilize labour efficiently
• Increase employee morale
• Utilize available floor space efficiently and
effectively
Objectives

• Reduce accidents
• Provide for volume and product flexibility
• Provide ease of supervision and maintenance
• Facilitate co-ordination and face-to-face
communication
• Provide for employee safety and health
• Allow high machine utilisation
• Improve productivity
Principles of layout

• Principal of minimum travel

• Principle of sequence
• Principle of usage
• Principle of compactness
• Principle of safety and satisfaction
• Principle of flexibility
• Principle of minimum investment
 Basic Types of Layout

Product Layout
Process or Functional Layout
Fixed-position Layout
Cell manufacturing/GT
Mixed /Combined Layouts

04/09/10 7
 Vvolume-variety characteristics

Low VOLUME High

High

Fixed
position layout
VARIETY

Process layout

Cell layout

Product layout
Low
Product layout

• Machines arranged in a line depending upon sequence

of operations
• Material moves in a line from the first machine to the
finished product on the last machine.
• Investment higher as compared to process layout

Better suited for standardised products on a mass scale production. Ex

chemicals,paper
 Product Layout

• Plant & machinery layout is designed to cater to

continuous flow of Materials.
• The position and order in the sequence for a
machine performing particular operation is fixed.
• Once a machine is in line, it cannot perform any
operation , which is not designated in the
sequence of operations.
• There is a continuous flow of material during the
production process from start to finish.
18-12-2007 10
 PRODUCTION SUB-
RAW MATERIALS SYSTEM
RECEIVING
EDP CONTROL
OPERATION B SYSTEMS

STORAGE
OPERATION A
MATERIAL FLOW
OPERATION D

OPERATION C
SHIPPING
INFORMATION
FINISHED GOODS FLOWS

CONTINUOUS FLOW PRODUCTION SYSTEM (FLOW SHOP)

Examples of product layout

• Assembly line for air-conditioner

• Car manufacturing unit
• Car washes and
• Canteen facilities
• Laundry.
Important Considerations

All machines placed at points demanded by sequence of

operation
No crossing over of one line with the other
Materials may be fed where they are required for
assembly but not necessarily all at one point
All operations including assembly, testing and packing
included in the line
 Product layout of laundry

Classification Storage
and Washing Steam Area for Delivery
Dryer
marking of Machine press Pressed Counter
clothes clothes

• To produce one standard product in large volumes.

• Each unit produced undergoes same sequence of operations and uses same
flow of work.
• The work centers and equipments are arranged in a line for continuous
operation.
Advantages
Ensures smooth and regular flow of material and finished
goods.
Short processing time.
Reduces material handling.
Low cost labour procurement and lesser training required.
Lesser Inspection & Early detection of mistakes
Layout avoids production bottlenecks
Economy in manufacturing time
Better production control
Requires less floor area per unit of production
Work-in-progress in reduced
Disadvantages:

 Inflexible & expensive layout

Difficulty in supervision
Expansion is difficult
Any breakdown along the line can disrupt total
production
Requires heavy capital investment.
Process layout

• Grouping together of similar machines in one

department
• Material moves from one group of machines to the
other
• Movement over longer distance and along criss-
cross paths
• May also involve part finished inventory waiting

Best suited for intermittent type of production/light and heavy industries

Functional or process layout

• Here machines performing same type of

operations are installed at one place .i.e. plant is
grouped according to functions e.g. all drilling
machines are located at one place known as
drilling section.
• This type of layout is most appropriate for
intermittent (JOB and BATCH ) type of
manufacturing systems where small qty’s of a
large range of products are to be manufactured
e.g. machine tools etc.
 Process Layout
Milling

Assembly
Grinding
& Test

Drilling Plating
Process Layout - work travels
to dedicated process centers

11-12-2007 19
 PRODUCTION SUB-
SYSTEM
RAW MATERIALS
RECEIVING

OPERATION A OPERATION B
WIP WIP

STORAGE EDP
MATERIAL FLOW
FINISHE CONTR
D OL
WIP WIP
GOODS SYSTEM
S
OPERATION D OPERATION C
SHIPPING
FINISHED GOODS INFORMATION
FLOWS

INTERMITTENT FLOW PRODUCTION SYSTEM (JOB SHOP )

Process Layout Examples

• Car servicing
• Hospital-Patient requiring various tests
• Volume low & variety is more
• Garment factory producing half sleeve shirts, full
sleeve shirts, pants and suits.
• Office buildings, schools, universities, hospitals,
aerodrome, library, book store or amusement
centers are planned on this basis.
21
Important considerations

– Distance between departments as small as possible

– Departments to be located as per sequence of operation
– Convenience for inspection as well as supervision
Process layout

Air
Work Shop Office
Compressor
Fitting Table 1
Product A
Lathe 1
Fitting Table 2 Side Entry
Product B Lathe 2
Fitting Table 3
Lathe 3

Milling Welding M/C - 1

Machine
• Flow of work is not standardized
• Plant produces a variety of products Welding M/C - 2
• Some of the processes / operations Paint Shop
might be common.

Main Entry
Advantages

Each production unit of the system works independently and is not

affected by the happenings in another section of the plant.
Scope for more skilled labour leads to better quality in production.
Wide flexibility in production facilities.
Machine breakdown doesn’t disrupt production.
Lower capital investment. (Less duplication of machines).
Better utilization of resources
Full utilization of machinery
Disadvantages

More material handling.

Longer processing time:- as more time s required for material
handling, transportation n inspection.
Requires substantial production planning and control.
Requires more floor space.
Inspection s more frequent n costlier.
Requires highly skilled labour creating difficulty in labour
procurement.
Production time increased because of extra travel
Accumulation of work-in-process at different machines
Fixed position layout

• Movement of men & machinery to the product

• Product remains stationary
– Cost of moving product is high,bulky

Best suited for bulky & heavy products ex.Ships, aeroplanes etc.
Fixed Position Layout

• The material remains in a fixed position , but

the machinery, tool workmen etc are brought to
the material

18-12-2007 27
RAW MATERIALS

MACHINE & FINISHED PRODUCT

(AIRCRAFT)
EQUIPMENT AIRCRAFT ASSEMBLY

LABOUR

FIXED POSITION OR STATIC LAYOUT

Fixed position layout

• Fixed-position layout is used for products, which are

either very big in size (weight/volume) or very critical
and it is not feasible or desirable to move the product and
product remains in one position only.
• Men, materials, equipment and tools are brought to the
product for execution of the work.
• Building of space shuttle, turbines, aircrafts and ship use
fixed-position layout as it is not feasible to move these
products due to their size or weight.
Fixed Position Layout

• Employed in large project type organisation

• Example
• ISRO
• Helicopter
• Nuclear engg. Division of BHEL

18-12-2007 30
Advantages

• Men/machinery can be moved for a wide variety

of operations producing different products
• Worker identifies himself with the product &
takes pride when the work is completed
• Investment on layout is small
• High cost & difficulty in transporting a bulky job
avoided
Mixed layouts

Mixed layouts – pure basic layouts can be used in different

departments in one organisation.

Example: A hospital would be arranged on process-layout

principles. Within individual departments different
layouts are used e.g. x-ray department probably process,
surgical theatres fixed-position and the blood-processing
lab a product layout.
Combined layout

• Combination of product & process layout with an

emphasis on either
• Generally adopted in industry
• In fabrication plants including assembly,
fabrication tends to employ process layout while
assembly areas employ product layout
– Soap manufacturing industry employs product line for
manufacturing of soap, but ancillaries such as heating,
manufacturing of gleycerine, power house etc. Are arranged on
functional basis.
 PRODUCT LAYOUT

RAW MATERIAL F.P. G.C. H.T. G.G.

FINISHED
PRODUCTS
(GEARS)
RAW MATERIAL F.P. G.C. H.T. G.G.
PROCESS LAYOUT

G.C.

F.P. = FORGING PRESS G.C. = GEAR CUTTING

H.T. = HEAT TREATMENT FURNACE G.G. = GEAR GRINDING MACHINE

COMBINATION LAYOUT OR HYBRID LAYOUT FOR GEAR MANUFACTURING

Combination layout

• In an industrial plant, it is difficult to confine to one type

of layout only i.e. process or product layout.
• It becomes necessary to use process layout for some of
the activities and to use product layout for certain other
activities in the same plant.
• Cement manufacturing may need process layout for raw-
material preparation, which require crushing, grinding
and mixing of the various raw-materials such as lime-
stone, clay, bauxite and iron-ore.
Combination layout

• Once the raw materials are prepared and converted into

raw-meal by mixing different raw materials in
predetermined proportion, production processes such as
pre-heating, pre-calcining, calcinations for conversion of
raw-meal into clinker and cooling of clinker would use
product layout.
• Within the plant, workshop activities are arranged by
using process layout, whereas the packing and dispatch
operations of the cement through trucks need product
layout.
Combination layout

• If different modes of dispatches are adopted such as dispatch by

rail (both by bags and bulk containers), sea (bags and bulk
loading) or by road in trucks (bags) or in bulk containers, the
dispatch operations would need process layout.
• In cases of repairs of kiln in a cement plant, which cannot be
moved, a fixed layout is to be used.
• It is clear from the example of cement plant that a big plant needs
application of all the three types of layouts for different
applications or a combination of all the layouts for meeting the
requirements of its total operations.
Combination layout – case of a cement plant

Clay
Yard Cyclone

BlendingSt
Bauxite orage
Yard cyclone
Raw Rotary kiln
Mill
Iron ore Inlet chamber
Yard Of kiln Clinker cooler
ESP
Lime Stone
Chimney Cement
Yard
Mill

Process layout for a portion of Product layout for a portion of

Cement plant Cement plant
Cellular manufacturing (cm) layout

• Grouping of machines into cells

• Cells function somewhat like product layout
within a larger shop or process layout
• Each cell in the cm formed to produce a single
part / a few parts
– All with common characteristics which usually requires
similar machines and settings
• Flow of parts within the cell can take many forms
Group Technology

• This is philosophy that seeks to exploit the

commonality in manufacturing and uses this as a
basis for grouping components and resources. This is
also known as cellular manufacturing.
• Pioneered by Russians
• Mid volume & mid variety scenario
• 70% of mfg. industry may fall under this category)

18-12-2007 40
CARAVAN, BATON and MIXED CELLS

BATON CELLS
CARAVAN CELLS MIXED CELLS

Operators are Operator and Products move

fixed but product from station
products move move from station to station and
from to operators move
station to station station between stations
CELLULAR MANUFACTURING
LAYOUT

CELL # 2
CELL # 1

1 2
PART D
1 2 3
3
PART X
5 4
PART Y

1 2
PART A CELL # 4
1 2
3
PART B
4 3 CELL # 3

PRODUCTION OPERATION PRODUCT OR MATERIAL FLOW

Cellular Manufacturing Layout
Heat Gear
-1111 Lathe Mill Drill -1111
treat cut

Heat
2222 Mill Drill Grind - 2222

Assembly
treat

Heat
3333 Lathe Mill Grind - 3333
treat

4444 Mill Drill Gear - 4444

cut
CM LAYOUT
ADVANTAGES

• LOWER WORK-IN-PROCESS INVENTORIES

– REDUCED MATERIAL HANDLING COSTS
– SHORTER FLOW TIMES IN PRODUCTION
– SIMPLIFIED PRODUCTION PLANNING (MEN,
MATERIAL ETC.)
– OVERALL PERFORMANCE OFTEN INCREASES BY
LOWERING PRODUCTION COSTS & IMPROVING ON-
TIME DELIVERY
– IMPROVED QUALITY
Advantages of Cellular Layout

• PPC becomes simpler

• Material handling becomes easier
• Traceability improves
• Employees are able to relate better.
• Helps in implementing SGA, Kaizen an
JIT
Cellular Layout- Examples

• Reliance industries- HDPE & LDPE

• Titan Industry
• ABB( Industrial fans & blowers)
CM layout limitations

• Reduced manufacturing flexibility & potentially

increased machine downtime
• Duplicate pieces of machinery may be needed so as
to avoid movement of parts between cells
Service facility layout

• Main difference between service and manufacturing

facility is to bring together customers & services in
many service facilities
• Facilities to provide for
– Easy entrance from the freeways and busy thoroughfares
– Large well organised and amply illuminated parking areas etc.
• Hotels, cinema halls etc have different areas to cater to
the comfort & convenience of customers
 EXIT ENTRANCE

PARKING AREA CASUALTY DEPT / INPATIENT DEPT PARKING AREA

PARKING AREA
HOSPITAL WARDS

SURGERY, RADIOLOGY,
I.C.U., TECH SERVICES

AISLES / GANGWAYS
HOSPITAL WARDS

DOCTORS
LOUNGE /
OFFICES NURSES

PARKING AREA
HOSPITAL WARDS CAFETERIA
LOUNGE
ADMIN. OFFICE

PARKING AREA CASUALTY DEPT / INPATIENT DEPT PARKING AREA

ENTRANCE EXIT

SERVICE FACILITY LAYOUT ( HOSPITAL LAYOUT )

 Service facility layout
• Layout important to achieve client-customer goal of fast service
– FAST SERVICE SUPPORTED BY POINT OF SALE SYSTEM,
SCANNERS, SELF SERVICE TO PROVIDE SPEED AS WELL AS
REDUCE COST, atms BY BANKS ETC.
• Flow line approach followed in fast food service
• Process line layout occurs in many services like medical clinics,
offices etc.
Service facility layout

• Generally, as in manufacturing
– Line layout preferred in high volume,
standardised products
• Fast food service
– Process layout preferred in service operations
also
• General offices, banks, general hospitals, municipal
offices etc.
SERVICE WAITING LINE MODULES

WAITING LINE SERVICE WAITING LINE SERVICE

FACILITY FACILITY
SINGLE CHANNEL, SINGLE CHANNEL,
SINGLE PHASE MODULE MULTIPLE PHASE MODULE

WAITING LINE SERVICE WAITING LINE SERVICE

FACILITY FACILITY

MULTIPLE CHANNEL, MULTIPLE CHANNEL,

SINGLE PHASE MODULE MULTIPLE PHASE MODULE
Layout planning methodology

• Travel chart method

• Load-distance analysis method
• Systematic layout planning method
• Analysing layouts with computers
– Aldep (automated layout designing programme)
– Corelap (computerised relationship layout planning)
– Craft (computerised relative allocation of facilities
technique)
Thank You