Types of Plant Layout

8/6/2019 Types of Plant Layout

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TYPES OF PLANTTYPES OF PLANT

LAYOUTLAYOUT


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THE PRODUCT LAYOUTTHE PRODUCT LAYOUT

Product layout is also known as line layoutProduct layout is also known as line layout

or straight line" layout. It is the kind of anor straight line" layout. It is the kind of an

arrangement of machines are gathered andarrangement of machines are gathered andarranged keeping product as a focal point.arranged keeping product as a focal point.

Materials are fed into at the starting machinesMaterials are fed into at the starting machines

and end products come out from the lastand end products come out from the last

machines or machines in the chain ofmachines or machines in the chain ofconversion.conversion.


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TYPES OF PRODUCT LAYOUTTYPES OF PRODUCT LAYOUT


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STRAIGHT LINE TYPESTRAIGHT LINE TYPE

As the title suggests the machines are arrangedAs the title suggests the machines are arranged

in a straight line sequence of operations. Thesein a straight line sequence of operations. These

machines are installed as near as possiblemachines are installed as near as possiblebecause the output of one machine is the inputbecause the output of one machine is the input

for the next machine.for the next machine.


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U SHAPED PRODUCT LAYOUTU SHAPED PRODUCT LAYOUT

U Shaped arrangement is more compact thanU Shaped arrangement is more compact than

straight line. It brings about economy in floorstraight line. It brings about economy in floor

space and allows closer supervision span thanspace and allows closer supervision span thanstraight line.straight line.


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CIRCULAR PRODUCT LAYOUTCIRCULAR PRODUCT LAYOUT

U nder this arrangement the machines are layU nder this arrangement the machines are lay

out in the shape of the circular lire a rung ringout in the shape of the circular lire a rung ring

a rose.

The operations are carried out in thea rose.

The operations are carried out in theinside or outside the circular or circle. If theinside or outside the circular or circle. If the

production is carried out outside the circle, theproduction is carried out outside the circle, the

inner side can be used for storage of rawinner side can be used for storage of raw

materials and finished goods.materials and finished goods.


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ODD ANGLE PRODUCT LAYOUTODD ANGLE PRODUCT LAYOUT

In this arrangement there is no any fixedIn this arrangement there is no any fixed

pattern for arranging the machines but ispattern for arranging the machines but is

designed to suit for suitable space.designed to suit for suitable space.


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MERITSMERITS

Uninterrupted outputUninterrupted output

Reduced amount of work in progressReduced amount of work in progress

Encourages use of automatic devicesEncourages use of automatic devices Best use of the floor spaceBest use of the floor space

Effective supervisionEffective supervision

Improved production controlImproved production control


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DEMERITSDEMERITS

Higher initial investmentHigher initial investment

Danger of break downDanger of break down

Expansion is costlierExpansion is costlierLack of flexibility in operationLack of flexibility in operation

Dangers of specialisationDangers of specialisation


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The process layout is also known as functionalThe process layout is also known as functional

layout. It is the kind of arrangement of machines andlayout. It is the kind of arrangement of machines and

equipments performing similar functions together inequipments performing similar functions together in

an associated area. It is the partioning of the plant intoan associated area. It is the partioning of the plant intoseveral work areas or departments in which area isseveral work areas or departments in which area is

occupied by similar type of machines. That is eachoccupied by similar type of machines. That is each

department as the whole is known only fordepartment as the whole is known only for

performing one operation or process of the entireperforming one operation or process of the entireprogram of the production.program of the production.

THE PROCESS LAYOUTTHE PROCESS LAYOUT


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MERITSMERITS

Lower capital lockupLower capital lockup

Greater flexibilityGreater flexibility

Quality supervisionQuality supervision Uninterrupted functioningUninterrupted functioning

Fuller utilisation of machine capacityFuller utilisation of machine capacity

Full scope for expantionFull scope for expantion


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DEMERITSDEMERITS

Difficulties to production planning and controlDifficulties to production planning and control

Excessive handling of materialsExcessive handling of materials

Larger stock piles in the processLarger stock piles in the process Possibility of more floor areaPossibility of more floor area

Elonged production cycle timeElonged production cycle time


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COMBINED LAYOUTCOMBINED LAYOUT

Combined layout is an arrangement of productionCombined layout is an arrangement of production

facilities to achieve compromised results of the bestfacilities to achieve compromised results of the best

of the best of the two basic alternative layout patternof the best of the two basic alternative layout pattern

of layout. It is possible where an item is being madeof layout. It is possible where an item is being madein different sizes and are of unique features and canin different sizes and are of unique features and can

be produced on mass scale too. The machines arebe produced on mass scale too. The machines are

arranged on the principle of process layout and thearranged on the principle of process layout and the

process grouping is then arranged in the sequence ofprocess grouping is then arranged in the sequence ofoperations to manufacture of variety of products as tooperations to manufacture of variety of products as to

type and size.type and size.


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FIXED POSITION LAYOUTFIXED POSITION LAYOUT

This type of layout is called as fixed position"This type of layout is called as fixed position"or static product" layout because the neededor static product" layout because the neededmachines, tools, man power and supportingmachines, tools, man power and supporting

appliances and services are brought to aappliances and services are brought to aparticular point at which production workparticular point at which production workprogresses. This type of layout is veryprogresses. This type of layout is verycommon in case of products like ship building,common in case of products like ship building,airair crafts, launchers, heavy machines andcrafts, launchers, heavy machines andinstallations. These products are highlyinstallations. These products are highlycomplex and time consuming in final form.complex and time consuming in final form.


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MERITSMERITS

Mechanical handling of manufacturingMechanical handling of manufacturing

facilitiesfacilities

Quality productQuality product Greatest flexibilityGreatest flexibility

Must for quality and costly productMust for quality and costly product


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DEMERITSDEMERITS

It is time consumingIt is time consuming

Most space consumingMost space consuming

Strict supervision and securityStrict supervision and security


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DISTINCTIONBETWEEN PRODUCT ANDDISTINCTIONBETWEEN PRODUCT AND

PROCESS LAYOUTPROCESS LAYOUT

Arrangement of production facilitiesArrangement of production facilities In case of product layout, theIn case of product layout, themachines and equipments performing different functions are arranged onemachines and equipments performing different functions are arranged oneafter another in a single line. In process layout the machines andafter another in a single line. In process layout the machines andequipments performing similar functions are grouped in a separateequipments performing similar functions are grouped in a separatedepartment of the factory floor.department of the factory floor.

SuitabilitySuitability Product layout is most suited where there is mass andProduct layout is most suited where there is mass andstandardised production moving straight from raw material stage to end tostandardised production moving straight from raw material stage to end tofinal product. Process layout is suited for smaller lot and non standardisedfinal product. Process layout is suited for smaller lot and non standardisedproduction.production.

EconomyEconomy The product layout is costlier as there is duplication ofThe product layout is costlier as there is duplication ofmachines and equipments and the machines are not used to the full extentmachines and equipments and the machines are not used to the full extent

or capacity though there is mass production is undertaken. In case ofor capacity though there is mass production is undertaken. In case ofprocess layout the costs are comparatively much lower as there isprocess layout the costs are comparatively much lower as there isuninterrupted fuller use machines and equipments of production facilities,uninterrupted fuller use machines and equipments of production facilities,even if the production is not on mass scale.even if the production is not on mass scale.


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Expansion possibilitiesExpansion possibilities -- Layout it is possible to add to the existingLayout it is possible to add to the existingcapacity or even it may be achieved by means of intensive use of existingcapacity or even it may be achieved by means of intensive use of existing

capacity beyond the particular limit. In case of process, it is possible to addcapacity beyond the particular limit. In case of process, it is possible to addto the existing capacity or even it mat be achieve by means of intensive useto the existing capacity or even it mat be achieve by means of intensive use

of existing capacity.of existing capacity.

FlexibilityFlexibility Product layout is more rigid as it is difficult and costly toProduct layout is more rigid as it is difficult and costly tochange the existing arrangement of machines. The process layout is morechange the existing arrangement of machines. The process layout is more

flexible or adabtable.flexible or adabtable. Time span of production cycleTime span of production cycle The product layout is such anThe product layout is such an

arrangement whereby valuable time is not wasted in processing. In processarrangement whereby valuable time is not wasted in processing. In process

layout it takes comparatively much more time as material and semi finishedlayout it takes comparatively much more time as material and semi finished

product are to travel from one department to another.product are to travel from one department to another.


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TECHNIQUES AND TOOLS OF PLANTTECHNIQUES AND TOOLS OF PLANT

LAYOUTLAYOUT

A good plant layout is one w2hich is suitableA good plant layout is one w2hich is suitable

to the individual needs as no two units orto the individual needs as no two units or

individual activities are similar; they have aindividual activities are similar; they have a

unique position created by internal strengthsunique position created by internal strengths

and weakness and external threats andand weakness and external threats and

opportunities. A good layout is end product osopportunities. A good layout is end product os

wise or judicious planning which is the mentalwise or judicious planning which is the mentalprocess of creative thinking.process of creative thinking.


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TECHNIQUES OF PLANT LAYOUTTECHNIQUES OF PLANT LAYOUT

TECHNIQUES OF

PLANT LAYOUT

TEMPLATESMODEL

EQUIPMENT

LAYOUT

DRAWINGSPLOT PLAN


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Documents

Types of Plant Layout