PLANT LAYOUT

MEANING AND DEFINITION

Plant layout means the arrangement of departments and equipments within factory. It concern with the orderly arrangement of machines, work areas and service areas so as to obtain the maximum output at the lowest possible cost. It involves maximum and effective utilisation of resources available in a factory.

DEFINITION

“Plant layout is the arrangement of machines, work areas and service areas within a factory’’

--R.TEERY

OBJECTIVES OF PLANT LAYOUT1. To ensure the most effective and optimum

utilisation of the available area.2. To promote efficient production planning and

control.3. To minimize accident.4. To ensure better quality product.5. To provide better customer service.6. To ensure less scrap.7. To minimize production delays.8. To provide safety to the men working in the plant.9. To reduce manufacturing costs.10. To improve morale of employees.

ADVANTAGES OF GOOD LAYOUT

FROM THE STANDPOINT OF THE WORKER, a good plant is expected to---

1. Reduce their effort2. Reduce the number of accidents3. Improve the working conditions 4. Expand the process of specialization

FROM THE STANDPOINT OF THEMANUFACTURING COSTS

1. Reduce the maintenance costs;2. Reduce the tool replacement costs3. Ensure the better control 4. Minimize the waste of raw material

consumption

FROM THE STANDPOINT OF CAPITAL INVESTMENT

1. Maintain proper inter-departmental balance

2. Hold permanent investment at a minimum

3. Reduce the work-in-process and the stock of finished products

4. Reduce the amount of material, handling equipment required

5. Ensure better utilization of available floor space

TYPES OF PLANT LAYOUT

There are three main types of plant layout

1. Product or line layout2. Process or function layout3. A combination of product and

process layout

PRODUCT AND LINE LAYOUT

Product or line layout refers to the arrangement of machines or equipment in a line. The purpose is to arrange the production equipment in a sequence that it is in the same sequence as required for the manufacture of a product without any deviation of materials. This system of arrangement is also know as ‘straight-line layout.

RECEIPT OF RAW MATERIAL

DESPATCH OF FINISHED GOODS

Product A

Product B

ASSEMBLY

LINE OF OPERATION/ EQUIPMENT ARRANGMENT

ADVANTAGES OF PRODUCT OR LINE LAYOUT

1. Reduce in cost of production 2. Reduce in the labour costs3. Effective control of production4. saving in manufacturing time5. Optimal use of floor space

PRCESS OR FUNCTIONAL LAYOUT Process or functional layout refers to an

arrangement whereby similar machines are placed in one department for one separate operation. This type of layout is also know as ‘one type’ or ‘process grouping method’.

For example an industry is manufacture of three different product, all of which involve common operation, welding, painting, grinding. Under this type of arrangement, we may have one welding department, one painting department and the grinding department, all the product will have to go through these department for the performance of these specialised operations

A COMBINATION OF LINE AND PROCESS LAYOUT It is a layout which involves use of

both line and process layout.