PLANT LAYOUT GUIDE SHEETMATERIAL

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MATERIAL FEATURES INVOLVED

Raw Materials / Incoming Materials / Material-In-Process
Finished Product / Outgoing & Packed Material
Supplies & Process Used Materials
Rejects / Repairs / Rework
Scrap / Trims / Cuttings / Waste Materials
Materials For Maintenance
CONSIDERATIONS AFFECTING PLANT LAYOUT

DESIGN & SPECIFICATIONS OF THE PRODUCT

Design Products For Ease of Manufacturing
Accurate & Up-To-Date Product Specifications
Appropriate Quality Specifications

PHYSICAL & CHEMICAL CHARACTERITICS OF MATERIALS

Size / Shape & Bulk / Weight / Condition

Special Characteristics (Heat/ Temp. / Sunlight /Fumes /Humidity/
Vibrations)
3

QUALITY & VARIETY OF PRODUCTS

Variety of Different Products
Output of Each Product
Variation in Stability of Output
Estimated Demand For New Products

COMPONENT MATERIALS & SEQUENCE OF OPERATIONS

Sequence of Assembly Operations For Each Product
Sequence of Forming Operations
Possibility of Changing Operations By
Eliminating / Combining / Dividing / Improving / Simplification

Standardized / Interchangeable Parts & Materials

PLANT LAYOUT GUIDE SHEET MACHINERY

S. No.

MACHINERY FEATURES INVOLVED

Production Machines / Process Or Treating Machines

Special Attachments / Tools / Jigs / Fixtures / Dies / Forms / Patterns

Gauges / Measuring Machinery / Test Units

Material Handling Equipment / Hand & Hand Operated Tools

Idle or Dead Machinery Items / Machinery For Maintenance

CONSIDERATIONS AFFECTING PLANT LAYOUT

1

PROCESS / METHODS
Process, methods suitable & up-to-date
New developments anticipated in process, methods
Primary Shaping / Machining / Joining / Finishing / Testing / Treating

MACHINERY, TOOLS & EQUIPMENT

Selection of Machinery, Tools & Equipment Type, Model, Make, Capacity
Number of Machines Required / Tools Attachments / Special Requirements
Considerations: Volume, Quality, Maintenance, Initial / Operating Cost, Reliability,
Space Requirements, Safety, Legislation, Standardization, Environmental, Availability,
Operator Skill Required, Associated Unpleasentories, Resale Price & Depreciation

MACHINE UTILIZATION
Balanced Operations
i.
ii.
iii.
iv.
v.

Improve The Operation

Change Machine Speeds
Bank Material & Operate Slower Machine Extra Time
Divert Extra Pieces To Machines Not In The Line
Combination Lines

Improve Man Machine Efficiency

4

MACHINERY REQUIREMENTS
Dimensions: Width, Length, Height, Extensions, Overhang, Swing
Special Requirements:
Piping
Drains
Ventilation
Supports
Foundations Protections Segregation Conditioning
Mobility
Access

Space

Clearance
Controls

Panels

Service

&

Operating

PLANT LAYOUT GUIDE SHEET MAN

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MAN FEATURES INVOLVED

Direct Labour Operators / Supervisors / Line Executives
Indirect & Supporting Activity Personnel Set-Up Men, Utility Men,
Material Handlers, Storekeepers, Shop Planners, Dispatchers, Timekeepers,
Maintenance Men, Receiving Clerks, Shipping Clerks, Helpers, Cleaners
Plant Protection PersonnelGuard, Firemen / Process Technicians / General
Office Personnel / Trainees & Instructors / First Aid Attendants
Staff / Supporting Activity Executives

CONSIDERATIONS AFFECTING PLANT LAYOUT

1

SAFETY & WORKING CONDITIONS

Floor Obstructions / Slippery Floors / Workers too Close to Hazardous Systems /
Blocked or Poorly Located Exits / Material or Machinery Protruding Into Aisle or
Work Areas / Safety Codes Enforcement
Too Cold or Drafty / Inadequate Light / Poor Ventilation / Dust & Dirt in
Environment / Disturbing Noise, Vibration, Heat / Too Cramped Workplace

MANPOWER REQUIREMENTS
Proper Type of Worker For Each Operation- Skill, Trade, Pay-Rate
Number of Shifts / Operators / Working Hours / Supporting Staff

MAN UTILIZATION
Workplace Based on Motion Economy / Balanced Man-Time Operations
Effective Use Of Supporting Personnel
METHODS FOR ATTAINING BALANCE FOR ASSEMBLY OPERATIONS

Divide Operations & Apportion The Elements / Combine Operations

Have Operators Move / Improve Operations / Improve Operator Performance
Bank Material & Do Slower Operation on Extra Time
4

OTHER CONSIDERATIONS
Method of Paying Workers / Output Count or Performance Measure /
Conditions Leading To Feeling of--- Being Afraid, Embarrassed, Discouraged
Regulations of Insurance, Compensation, Labour Contract
Top Management Attitudes

PLANT LAYOUT GUIDE SHEETWAITING

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STORAGE/ DELAY FEATURES INVOLVED

Receiving / Incoming Material Area

Raw / Purchased Material Storage
In-Process Storages
Delays Between Operations
Finished / Outgoing Material Storages
Storage of Scraps / Returns / Supplies / Packing / Rework Materials
Storage of Machinery / Equipment / Tools / Dies / Fixures
Storage of Maintenance Supplies / Spare Parts
CONSIDERATIONS AFFECTING PLANT LAYOUT

LOCATION OF STORAGE / DELAY POINTS

Storage With / Outside Production Area
For Protection / For Unbalanced Operations
Relation To Path of Flow
SPACE FOR EACH WAITING POINT
Quantity Based on Protection Period
Quantity Based on Different Production Times
Weight Limitations
Access Space
Total Space
Storing on Conveyance Possibilities
METHOD OF STORING
Use Cubic Space
Consider Outside Storages
Multiple of Item Dimensions / Unit Loads
Length Perpendicular to Main Aisles
Aisle Width Optimization
Classify Materials & Store Accordingly
Store Up-To Overhead Limits
Balance Space For Different Peak-Load Periods
SAFEGUARDS FOR WAITING MATERIALS
From Fire / Damage / Moisture / Dist / Dirt / Heat / Cold
Pilferage / Spoilage / Deterioration
EQUIPMENT FOR STORAGE / DELAY
Kind / Capacity of Material Storing Equipment
Number of Each Required
Check Against Equipment Objectives
Easy Accessibility / Strong / Safe / Sufficient Capacity / Adjustable
Protection of Material / Quick & Accurate Identification

WAITING FACTOR
S. No.
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CHARACTERISTICS
WAITING COSTS
Handling Cost to & From The Waiting Area
Handling Cost in The Waiting Area
Cost of Record to Keep Track of Waiting Materials
Cost of Overhead & Space Charges
Interest on Money Tied up With The Idle Material & Machinery Items
Cost of Protecting The Wating Materials
Cost of Containers / Holding Equipment Tied Up
JUSTIFIED REASONS FOR WAITING MATERIAL
Take Advantage of Market Situation
Greater Savings in Overall Production Operations
Helps in Production From Delays in Tightly Scheduled Deliveries
Finished Stock Lets us Run Larger Lots
In-Process Waiting Material Allows More Economic Lot Sizes
Improves Man-Machine Utilization
Offer Protection to Subsequent Operations
STORAGE / DELAY
STORAGE: Material May Wait In A Regular Area Set Aside To Hold
Waiting Material
DELAY: Material May Wait In The Production Area When Not Immediately
Required At The Next Operation
CONDITIONS FAVOURING STORAGE WITH PRODUCTION
Low Handling Costs Desired
Requirement of Same Handling Equipment For Storage & Production
Need To Avoid Production Delays Due To Waiting Supplies
Awkward To Handle Materials Being Produced
When Rate of Production is Very Fast
Possibility of Material Spoilage In Storage Banks
CONDITIONS FAVOURING STORAGE IN SEPARATE PLACE
Need To Segregate Incompatible / Hazardous Materials
Need For Less Costly Storage Building Construction
Need To Expand Storage Space Without Disrupting Production
Energy Saving For Heating Of Storage Space Is Large
Waiting Material Requires Large Space
Handling Costs Are Low
POSSIBLE LOCATIONS OF STORAGE POINTS
Just After A Critical Operation Subject To Frequent / Long Breakdowns
Just After A Critical Inspection Station Where Rejects Occur Frequently
Ahead of Operations Dependant on Handling Device Where Jam / Blown
Fuse / Mis-Scheduled Sequence / Breakdown are Likely
Along Assembly Lines with Operations Dependant Upon Material Continuity
Between Deptts. Where Transportation Is Intermittent / Irregular
Between Operations / Deptts. Where Times Are Not Balanced

CONDITIONS FAVOURING HIGH BAY STORAGE

1.

Limited floor space available / Size of site is highly restricted

2.

Large variety of items & high turnover

3.

Possibilities of automation & lower handling / operating costs desired

4.

Need for reduced product damage

5.

Protection against pilferage is desired

6.

Need to minimize lost / misplaced items

7.

High output requires short travel distances

8.

Need a buffer structure between noisy operation & neighboring operations

9.

Items can be discharged by gravity

10. Work places at different gradients for movement by gravity

CONDITIONS FAVOURING LOW BAY STORAGE

1.

Space is freely available & is flexible

2.

Low initial cost for space & handling equipment is required

3.

Building not capable to support heavy material racks

4.

No restrictions to weight & load configurations

5.

Flexible use of handling equipment is desired

6.

Storage requires high concentration of hand-picked items

7.

No current problem with inventory control, lost / misplaced materials

8.

No current problem with product damage, pilferage, movement bottleneck

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Just after a critical operation that may be subjected to frequent breakdowns

Just after a critical inspection where rejects occur frequently / sporadically
Ahead of operations dependent on handling device where jams/ breakdowns occur frequently
Ahead of production lines / besides assembly lines where a whole series of operations
depends on continuing flow of materials
Between departments where transportation is on different equipment, is intermittent/
irregular or is likely to be interrupted
Between operations, departments where times are not balanced
Between fast operations & slower ones where relative speeds cannot be changed
Between continuing operations & intermittent ones (2 shifts operation & 1 shift assembly)

PLANT LAYOUT GUIDE SHEETMOVEMENT

MOVEMENT FEATURES INVOLVED
Chutes / Tubes / Pipes / Guide Rails /
Conveyors: Roller, Belt, Tow, Bucket, Drag, Apron, Vibrating, Troughed
Elevators: Lifts, Hoists, Winches, Cranes, Monorails,
Stacking, Tiering, Positioning Equipment, Racks, Pallets
Industrial Vehicles: Hand Operated Trucks, Powered Lift Trucks, Forklifts
Rail Cars, Engines, Tractor Trailers / Water Carriers Barges, Canals

Containers for Moving / Waiting Materials:

Plain containers Boxes, drums, trays
Collapsible, nesting & stackable containers
Bracing, strapping blocking, holding fixtures

Tanks, Vessels, barrels

Supports Pallets, skids, cradles
Shelving bins, lockers, drawers,
racks

Least Handling not always the Best Handling

OBJECTIVE
To Achieve Efficient Utilization of Resources, Eliminate Unnecessary Movements

CONSIDERATIONS AFFECTING PLANT LAYOUT

FLOW PATTERN / ROUTING
AIM: Effective material flow pattern for:

Incoming materials

Complete flow for a part of process

Outgoing materials

Flow for certain group of processes

Supply materials

Flow from one area to another

Machinery movement

Flow for atleast part of production sequence

Man movement

GUIDELINES FOR LAYOUT OF AISLES

Straight aisles

Minimum corners, avoid blind corners

Clear aisles

Avoid protruding machinery, equipment

Mark aisle limits

Avoid confused layout

Use flow charts, diagrams to find traffic intensities

Aisle for min distance

Two sided aisles

Better usefulness

Use main aisles

For thorough traffic

Minimize lost floor

Too short Waste space; Too long Backtracks
Better usefulness

Intersection at 90

Appropriate lengths

Appropriate Widths

REDUCTION OF UNNECESSARY & UNECONOMICAL MOVEMENTS

Towards Completion

Without backtracking, cross flow

On same device

Without transfers

Smoothly & Quickly

Avoid delays, rehandling, Awkward positioning

Avoid long hauls

Over shortest distance

Easily

Without rehandling, extra handling motions

Safely & Conveniently

Without damage to material, hazard to man

Use unit loads

Economically

Coordinate with Prod

Avoid handling by prod operators, bending

Coordinate with others

Integration of different handling methods

Take advantage of gravity where possible

Arrange operations one after the other

Finish operation where the next begins

COMBINED HANDLING

To serve as worktable / holding device

With forming, treating, assembly

With inspection, sorting, counting

With weighing

Effective handling can keep material

Safe from danger / In sequence
Getting mixed / lost
Easy to check, count, supervise

Poka Yoke (Electric eye counter,

limit switches, dimension gauging)
With storage

SPACE FOR MOVEMENT

AISLE SPACE: Lost Space, No Production, Greatest Traffic, Adequate Width

OVERHEAD MOVEMENT: No Floor Space Required, Avoids Aisle Congestion

UNDERNEATH FLOOR / WORKBENCHES: Food Plants, Conveyors

DOUBLE USE OF SPACE: Fold Bins, Racks

ANALYSIS OF HANDLING & EQUIPMENT

Selection of handling methods, Number of each required, ANALYZE

HANDLING EQUIPMENT

Affects Plant Layout

Selection Based Upon:
Cost Operation & Maintenance
Capacity / Safety / Reliability
Effects On Working Conditions
Compatibility With Existing Equipment

PLANT LAYOUT GUIDE SHEETSERVICE

S. No.
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SERVICE FEATURES INVOLVED

SERVICES RELATED TO MEN
Access Ways For Personnel:In & Out of Plant / Within The Plant
Employee Facilities:Parking Lots / Locker Rooms / Waiting Rooms / First Aid Rooms / Cafeteria/
Change Rooms / Library / Personnel Office / Toilets
Plant Protection:Alarms / Detectors / Extinguishers / Exits / Escapes
Lighting:Local / General
Heating & Ventilation Facilities / Offices / Conference Rooms / Training Centres

SERVICES RELATED TO MATERIAL

Quality & Inspection:Inspection Stations / Test Facilities / Laboratories / Accessibility to Work Areas
Production Control:Planning & Control Facilities / Less Handling / Less Delays Between
Operations / Space For Incoming Materials
Waste Control:Repair Areas / Efficient Handling of Waste Material / Equipment For Waste
Treatment

SERVICES RELATED TO MACHINERY

Maintenance:-Adequate Space / Access
Distribution of Auxiliary Service Lines:- Water / Electricity / Compressed Air
/ Cutting Oil / Gas / Fuel / Acids / Sewage & Waste Disposal / Steam

CONSIDERATIONS AFFECTING PLANT LAYOUT

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Procedures For Planning, Scheduling, Dispatching, Follow-Ups

Quality Control / Inspection Methods
Ordering QuantitiesLot Size / Economy Runs
Maintenance Procedures

PLANT LAYOUT GUIDE SHEET BUILDING

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BUILDING FEATURES INVOLVED

Special / General Purpose Building
Single / Multi Storied Building / Shape of Building
Basement or Balcony
Windows / Floors / Roofs & Ceilings / Walls & Columns
CONSIDERATIONS AFFECTING PLANT LAYOUT
Overhead Heights & Clearances / Floor Strengths
Ceiling Loads or Structure Strengths / Floor Level Elevations
Ramp Grades & Widths / Door Locations & Type / Door Heights & Widths
Aisle Locations & Widths / Elevator Locations, Sizes & Capacities
Space & Location of Stairs / Auxiliary Service Lines
Space & Location For Fixed Equipment Installations
Window Locations & Type / Column Spacing & Type
Load Bearing Walls / Location of Receiving & Shipping Facilities
Ground Condition & Drainage / Government Regulatory Building Codes
Prevailing Winds / Slope & Contour of Ground
GENERAL PURPOSE BUILDING
Less Initial Cost / Easy To Dispose Off Profit, Closure, Better Location/
Frequent Changes-Material / Process / Design
SINGLE STORY BUILDING
Product Large & Bulky / Land Value Low / Less Price / Less Erection Time /
Heavy Production Equipment / Large Unobstructed Space Needed
SHAPE OF BUILDING
NARROW:- Natural Lighting, Dirty / Odorous / Vibration Producing
Operations / Hazardous Operations
SQUARE:- Frequent Changes-Product Design, Process, Materials /
Rearrangements / Less Building Material Required
BASEMENTS

Sloping Areas / Ample Headrooms / Sound Foundations / Waterproof Walls /

Ample Lighting / No Water Seepage / Used for wash rooms, locker rooms ,
vibration producing equipment
BALCONIES
Light Assembly Work / Offices / Supervision / Services / Maintenance Facilities
WALLS & COLUMNS
Support M.H. Equipment / brace storage racks / support balconies / services

FLOORS
Not Slippery / Adequate Strength / Same Level / Shock & Vibration Resistant

WINDOWS
Cheaper Than Wall / Artificial Lighting / Temp. Changes / Dirt & Dust / Glare

PLANT LAYOUT GUIDE SHEET CHANGE

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CHANGE FEATURES INVOLVED

Material Changes / Machinery Changes / Man Changes
Supporting Activity Changes / Changes In Product Design
Elimination of Products From Production Lines / New Product Introduction
Changes in Processing Sequence For Existing Products
Replacement of Existing Processing Equipments
Changes in Use of General Purpose & Special Purpose Equipment
Changes in Production Quantities / Production Schedules
Changes in Organizational Structure / Management Philosophies
(JIT/TQM)

CONSIDERATIONS AFFECTING PLANT LAYOUT

1
2
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4

MATERIAL CHANGES
Product Design / Material / Demand / Variety
MACHINERY CHANGES
Process / Methods / Tools / Equipment
MAN CHANGES
Working Hours / Organizational & Supervisory Changes / Skills / Trades
SUPPORTING ACTIVITY CHANGES
Handling / Storage Methods & Equipment
Service Changes (Access of Personnel / Employee Facilities / Plant
Protection, Lighting / Heating & Ventilation / Offices / Quality Control /
Maintenance / Waste Control / Production Control / Distribution)
OTHER CHANGES
External changes (Local / Industry-Wide / International)

AIDS TO FLEXIBILITY
Mobile & Movable Equipment
Self Contained Equipment / Standardized Equipment
Readily Accessible Service Lines / Building construction
Preplanned & skillful techniques of moving
Provide maximum perimeter access for receiving & shipping materials

AIDS TO ADAPTABILITY
Provide Standby Equipment / Determine Alternate Routes
Establish Banks/Buffer Stocks To Be Processed In Overtime

AIDS TO VERSATILITY
Versatile Equipment / Able Supervision To Adjust To Changing Situations