PLANT LAYOUT &

MATERIAL
HANDLING
Submitted by
K.N.Jakanathan

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Definition
 Layout is a Fundamental of every organization and enterprise.

 “Plant layout involves the development of physical relationships

among building equipment and production operations which will
enable the manufacturing process to be carried on efficiently”
- Morris

 Plant Layout - placement of departments,

placement of workgroups within departments,
placement of workstations,
placement of machines,
placement of stock-holding points
All within a facility

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Objectives
 Proper and efficient utilization of cubic (i.e. length, width and height)
of available floor space.
 To ensure that work proceeds from one point to another without any
delay.
 Provide enough production capacity.
 Reduce material handling costs.
 Reduce hazards to personnel.
 Utilize labor efficiently.
 Increase employee morale.
 Eliminate conjugation and bottle neck at work.
 Provide for volume and product flexibility.
 Provide ease of supervision and control.
 Provide for employee safety and health. [ Reduce accidents ]
 Allow ease of maintenance.
 Allow high machine or equipment utilization.
 Improve productivity.
 Reduce Capital Investment.

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Factors Influencing Layout
 Nature of product.
 Production process. [Including Waiting Time]
 Type of machinery.
 Repairs and maintenance.
 Human needs.
 Plant environment.
 Materials.
 Material Handling Equipments.
 Auxiliary Services.
 Future Changes.
 Factory building.

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 P&Q Analysis - Input data and Activities

Definitio Product Activity relationships

n Flow

Chart relationship (flow,

functional)
Analysi Establish space Space
s requirements Availability Maintenance
Q&C
Space relationships -
Mat. Handling
Diagram
Synthe Practical Material
sis Adjustment
Limitations Handling

Project Project Project

A B
C
Evaluation Evaluate alternative
arrangements
Selection Systematic Layout
Detail selected layout Design
mplementation Process Method 5
INSTALLATION
- Muther
Types of Layout

 Manufacturing units
► Product or line layout

► Process or functional layout

► Fixed position or location layout

► Combined layout

► Fixed Layout

►Cellular (or) Group Technology Layout

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Product oriented Plant
Layout
(Line


path.
Layout)
Machinery and Materials are placed following the product

 This type of plant layout is useful when the production process

is organized in a continuous or repetitive way.
 Continuous flow: The correct operations flow is reached

through the layout design and the equipment and

machinery specifications.
 Repetitive flow (assembly line): The correct operations

flow will be based in a line balancing exercise, in order to

avoid problems generated by bottle necks.

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Cont.,
 The plant layout will be based in allocating a
machine as close as possible to the next one
in line, in the correct sequence to
manufacture the product.
 Allocating line may be of any form, like
straight line L shape

U shaped S shaped

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Factory Product layout

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Product layout
 Product oriented plant layout
 Advantages:
 Economy material handling activities.
 Mechanization of material handling equipments.
 Work In Process almost eliminated.
 Minimum manufacturing time.
 Simplification of the production planning and control systems.
 Tasks simplification.
 Greater incentive for group.
 Disadvantages:
 No flexibility in the production process
 Low flexibility in the manufacturing times.
 High capital investment.
 Difficulty of supervising, since the person is expert in only one function.
 Every workstation is critical to the process.- The lack of personnel or shut down of a
machine stops the whole process.
 Monotonous work.
 Difficulty in expansion.

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Process oriented plant
layout (Functional
Layout)
This type of plant layout is useful when the production process is
organized in batches.
 Personnel and equipment to perform the same function are
allocated in the same area.
 The different items have to move from one area to another one,
according to the sequence of operations previously established.
 The variety of products to produce will lead to a diversity of flows
through the facility.
 The variations in the production volumes from one period to the next
one (short periods of time) may lead to modifications in the
manufactured quantities as well as the types of products to be
produced.

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Factory Process layout

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Process Layout
 Process oriented plant layout
 Advantages:

 Flexibility in the production process.

 Better control of manufacturing cost.
 No Duplication.
 Easy to handle the problems.
 Better Supervising. [Experts will be there in each department]
 Higher Individual incentive.
 Disadvantages:

 Manufacturing time increases.

 Controlling will be costly and complex.
 Material handling cost will be higher.
 More workspace required.
 Accumulation of work-in process.

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Fixed Layout
 In Fixed product layout, the products generally circulate within
the production facilities (machines, workers, etc.); in this
particular type of layout, the product does not move, the
different resources are moved to perform the operations on
the product.
 This type of layout is commonly found in industries that
manufacture large size products, such as ships or aircrafts.
 The equipment is brought to the object being processed, and
the object does not move. Example: Air craft manufacturing.
 Arranging materials and equipment concentrically around the
production point in their order of use.

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Factory Fixed Layout

Raw
Material AIR CRAFT ASSEMBLY

Finished
Machine &
product
Equipment
AIRCRAFT

Labour

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Fixed Layout
Advantages of stationery Layout:
 Layout is fully flexible and is capable of absorbing any sort of
change in product and process.
 Lower labor cost [People are drawn from functional departments]
 Saving in time
 Less floor space because machines and equipment are in
moving position.
 Most suitable way of assembling large and heavy products.

Disadvantages Of Stationery Layout:

 Higher capital investment
 Unsuitability for manufacturing or assembling small products in
large quantities. It is suitable only in case where the product is
big or the assembling process is complex.

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Combined Layout or Mixed
Layout
 Manufacturing concerns where several products
are produced in repeated numbers with no
likelihood of continuous production , combined
layout is followed.
 Generally, a combination of the product and
process layout or other combination are found,
in practice, e.g. for industries involving the
fabrication of parts and assembly, fabrication
tends to employ the process layout, while the
assembly areas often employ the product layout.
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Factory Combined
Layout
Milling Grinding Painting Packing

3
1 2 4
C
o
m
1 2 b 4
i
n
e
1 d
2 4

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 P-Q Analysis

Q
u
a
n
t
i
t Product
y Layouts

Fixed
Position
Layouts Mixed Layouts Process Layouts

Number of different products

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CELLULAR OR GROUP
TECHNOLOGY LAYOUT
 Work cells
 Definition:
 Group of equipment and workers that perform a sequence of
operations over multiple units of an item or family of items.
 Looks for the advantages of product and process
layouts:
 Product oriented layout: Efficiency
 Process oriented layout: Flexibility
 Group Technology
 Grouping outputs with the same characteristics to families, and
assigning groups of machines and workers for the production
of each family.

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CELLULAR OR GROUP
TECHNOLOGY LAYOUT
 In a cellular layout the design is not according to
the functional characteristics of equipment, but
rather by self-contained groups of equipment
(called cells), needed for producing a particular
set of goods or services.
 Group technology, or cellular manufacturing,
classifies parts into families so that efficient
mass-production-type layouts can be designed
for the families of goods or services.

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 Cellular Layout
Process (Functional)
Group (Cellular) Layout
Layout
A cluster
or cell
T T T CG CG T T T
M
T T T SG SG M M T

D D M D
M M D D D
SG CG CG D

M M D D D SG

Similar resources placed Resources to produce similar

together products placed together

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CL or GT: BENEFITS

Advantages
 Lower work-in-process Inventories
 Reduced material handling costs.
 Shorter flow times in production.
 Simplified production planning. (MEN, MATERIAL ETC.)
 Overall performance increased by lowering production costs &
improving on time delivery.
 Improved Quality.
Disadvantages
 Reduced manufacturing flexibility & potentially increased machine
downtime.
 Duplicate pieces of machinery may be needed so as to avoid
movement of parts between cells.

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 Break Even Analysis
o ut
y ut
la o
c ed Lay
Fi
x ess l ay ou t
o Pr
oc
e ll o r GT
C
s
t Product layout
s

Use fixed Use Use cell Use product Volume 24

position process or GT
 EXAMPLE OF SYSTEMATIC LAYOUT
PLANNING: REASONS FOR CLOSENESS
Justification Code

Code Reason

1 Type of customer

2 Ease of supervision

3 Common personnel

4 Contact necessary

5 Share same price

6 Psychology

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 EXAMPLE OF SYSTEMATIC LAYOUT
PLANNING: IMPORTANCE OF CLOSENESS

Priority code
Line Numerical
Value Closeness
code weights
A Absolutely necessary 16
E Especially important 8
I Important 4
O Ordinary closeness OK 2
U Unimportant 0
X Undesirable 80

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 EXAMPLE OF SYSTEMATIC LAYOUT PLANNING:
RELATING REASONS AND IMPORTANCE

Area
From To
2 3 4 5 (sq. ft.)
A U I A
1. Credit department 100
6 -- 4 6
U I A
2. Saree department 400
-- 1 1,6
Note U X
3. Wine department Notehere
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 EXAMPLE OF SYSTEMATIC LAYOUT
PLANNING:
INITIAL RELATIONSHIP DIAGRAM

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required to to be
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 EXAMPLE OF SYSTEMATIC LAYOUT
PLANNING:
INITIAL AND FINAL LAYOUTS

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Re-layout
 A good plant layout involves not only the
designing and installing of the layout for the
first time but also revision of existing layout.
 The best layout becomes obsolete over a
period of time.

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Reasons for Re-Layout
 Product Design Change.
 New Product Production.
 Changes in volume of demand.
 Facilities become obsolete.
 Rearranging the department within the factory.
 Consideration of safety.
 Change in location of market.
 Poor worker environment.
 Cost reduction.
 Technology Advancement.
 Improvement in layout technology.

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Plant location’s influence
Plant layout
 Location may affect make/buy decisions.
 Location near the source.
 Location near the transport facilities.
 Easy Power supply.
 Cheap labour.
 Climate.
 Waste disposal facility.

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Material handling systems

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Role of material handling in
logistics
 As the science is getting developed new
modern equipments are getting introduced
in material handling area.
 It is accelerating the activity of loading and
unloading. These equipments are used for
the movement of material over a short
distance.
 The bulk handling of the material takes
place in shipyards, ports, airports etc.
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 Material handling Operation
steps
 Unloading the incoming material from transport
vehicle.
 Moving the unloaded material to assigned
storage places in warehouses.
 Lifting the material from the storage place
during order picking.
 Moving the material for inspection & packing.
 Loading the boxes on transport vehicle.

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Material Handling
Efficiency
 Designing the system for continuous flow
of material.
 No idle time.
 Going in for the standard equipments – it
reduces the cost.
 If possible use gravitational force.
 continuous material movement is most
economical

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Selecting Material handling
Equipment
 Volume of operations.
 Speed of handling.
 Productivity.
 Nature of product.
 Size, shape, weight of the product.
 Nature of equipment.

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Commonly used equipments in industry –

Lift
 Fixed Path
Conveyors

Wheeled trolley
 Variable Path Forklift truck.
Overhead cranes

 Auxiliary Rigging, Clamps

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Variable path
 Wheeled trolley – two wheeled and four wheeled trolleys
are used for transferring boxes from one place to another
place within the organization. Trolleys have wide range of
sizes and shapes. Organizations decide as per their
requirement.
 Overhead cranes - these are used for movement of
heavy items but for a shorter distances. The movement is
controlled by a person having controls in his hand. Many
times it is a computerized activity. These cranes are
installed on the fixed girders near the ceiling.

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Wheeled Trolley Overhead Crane inside the factory

Overhead cranes outside the factory 40

 Forklift truck – this is highly useful in material
handling activity. It got invented after II world war.
The main advantages are,
 Movement of larger loads over a longer distance.
 Moving the load vertically also.
 Movement of loads vertically and horizontally,
exactly positioning for loading and unloading
operations.
 It can transfer the load in any direction.

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Fixed Path

 Conveyors – these are used where

continuous flow of material is essential. It is
used in mass production activity on
production shop floor also. conveyors are
widely used in automated warehouses in big
retail shops.

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 Wheel conveyors – the small wheels made
out of steel or plastic bearing. The load is
kept on the bearings and either pushed or
gravitational force is utilized for the forward
movement of the material.
 Roller conveyor – these are mainly used in
docks for faster unloading of the goods.
They are like wheel conveyors but powered
rollers are used.

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 Belt conveyor – these are commonly
used for material movement. It is used in
mass production activity.
 Chain conveyor – this is mainly used for
movement of heavy material. It is used in
mass production activity also. Pallets are
kept on the chain and stoppers are
provided for carrying out the production
related work.

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Wheel Conveyor Belt Conveyor

Chain Conveyor Roller Conveyor 45

• LIFT
These are used to lift the heavy materials
vertically. It is useful to lift to upper floor.

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Auxiliary
 Clamps
These are used for mainly clamping and picking
the material in large volumes. It can have more
number of trailers.
eg. Clip, metal mesh, Hooks, rings, oblong
links.
 Riggings
These are used for picking and placing the
materials. It is lengthy depends on use.
eg. Chains, ropes, wires.

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Riggings,Clamps,Chains,oblong links

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Factors influencing
material handling
equipments
 Required path of travel (fixed or variable)
 Nature of the material.
 Physical characteristics of the building.
 Space requirement of handling equipment.
 Required handling capacity.
 Cost consideration.

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Relation between plant layout and
Material Handling
 Close relation between plant layout and Material Handling.
 Material Handling methods influence the layout and factory building.
 Material Handling is to be considered as an integral part of plant
layout to design low cost handling system.
 Good Material Handling is resulted based on the arrangement of
production equipment, location of departments, logical sequence of
operations, location of stores, tools.
 Material Handling system/equipment can be selected only after the
appropriate floor plan.
 Plant layout considers the points for material receiving and shipping
of products
 Careful arrangement of work centers and storage areas
 Consider horizontal or vertical material transportation

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Thank you…

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