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Facilities Layout
Introduction
For an organization to have an effective and efficient manufacturing unit, it is
important that special attention is given to facility layout
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Facility layout considers available space, final
product, safety of users and facility and convenience of operations
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Facility layout
looks at physical allocation of space for economic activity in the plant
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Meaning
Facility layout is an arrangement of different aspects of manufacturing in an
appropriate manner as to achieve desired production results
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Facility Layout Objective
A model facility layout should be able to provide an ideal relationship between raw
material, equipment, manpower and final product at minimal cost under safe and
comfortable environment
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• To promote order in production towards a single objective
• To reduce movement of workers, raw material and equipment
• To promote safety of plant as well as its workers
• To facilitate extension or change in the layout to accommodate new product
line or technology upgradation
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• To provide better customer service
Principles of Plant Layout:
While designing the plant layout, the following principles must be kept in view:

(i)

Principle of Minimum Movement: Material and labour should be moved
over minimum distances; saving cost and time of transportation and
material handling
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(iii)

Principle of Flexibility : Layout should be flexible enough to be adaptable
to changes required by expansion or technological development
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(v)

Principle of Overall Integration: All the plant facilities and services should
be fully integrated into a single operating unit; to minimize cost of
production
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(viii) Principle

of Economy: The layout should aim at effecting economy in
terms of investment in fixed assets
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Importance

Facility layout and design is an important component of a business’s overall
operations, both in terms of maximizing the effectiveness of the production
process and meeting the needs of employees
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Plant Layout decisions are important not only for a new concern but even for an
existing concern
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The change in design ,machines ,method of work and technology all demand for
a new plant layout
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• Minimization of scrap and defectives
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• Reduced costs of maintenance
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From the standpoint of the workers, a good plant layout is expected to• Reduction in the number of handling
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• Better safety and less chance of accidents
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• Increased morale and motivation
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Various managerial policies relate to future
volume of production and expansion, size of the plant, integration of
production processes; facilities to employees, sales and marketing
policies and purchasing policies etc
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(2) Plant location:
Location of a plant greatly influences the layout of the plant
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(3) Nature of the product:
Nature of the commodity or article to be produced greatly affects the
type of layout to be adopted
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For
example, soap manufacturing, sugar producing units and breweries apply
product type of layout
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Production of heavy and bulky items need different layout as compared
to small and light items
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(4) Volume of production: Plant layout is generally determined by taking
into consideration the quantum of production to be produced
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,
(a) Job production: Under this method peculiar, special or nonstandardized products are produced in accordance with the orders
received from the customers
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Ship
building is an appropriate example of this kind
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, Stationery Material Layout is suitable for job production
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Under this method,
production remains continuous in anticipation of future demand
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Standardized
products are produced under this method by using standardized
materials and equipment
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Product layout is best suited for mass
production units
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This method is generally similar to job
production except the quality of production
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If there is a scarcity of space, product layout
may be undertaken
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(6) Nature of manufacturing process:
The type of manufacturing process undertaken by a business
enterprise will greatly affect the type of layout to be undertaken
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For example, in the manufacture of cement,
lime stone and clay are mixed
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Under this method different products are extracted from one
material
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are extracted
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Jute is an important
example of this kind
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This involves the
process of separation, for example, aluminium is separated from
bauxite
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(a)Product Layout (or Line Layout):
In this type of layout, all the machines are arranged in the sequence,
as required to produce a specific product
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The raw materials are
fed at one end and taken out as finished product to the other end
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Reduced material handling cost due to mechanized handling
systems and straight flow
2
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3
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Simplified production planning and control; and simple and
effective inspection of work
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Small amount of work-in-progress inventory
6
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Disadvantages:
1
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(b) Process Layout (or Functional Layout) In this type of layout, all
machines performing similar type of operations are grouped at one
location i
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all lathes, milling machines etc
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Greater flexibility with regard to work distribution to machinery
and personnel
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2
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3
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Disadvantages:
1
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As such, material handling costs are higher
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Mechanization of material handling is not possible
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Production planning and control is difficult
4
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A Combination of Line and Process Layout
In practice, plants are rarely laid out either in product or process
layout form
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For
example, refrigerator manufacturing uses a combination
layout
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The final assembly of the product
is done in a product type layout
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Process Chart :It is a graph containing details regarding various
activities and operations taking place in the organisation from start to
the last stage of the work
(b)Process flow diagram: This is an aid to process chart
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This model diagram is prepared on the paper
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Not only machines but space covered by
furniture, equipment and other components can also form a template
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(d) Models: Three dimensional wooden models of machinery,
equipment and other devices and components can be prepared
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But this technique is very costly and only big concern can
afford to install such a measure
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(f)Machine data card: These cards are tied with different machines
operating in the plant
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, efficiency,
capacity space area covered by the machine and technique of operating
the machine etc
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It records distance and
frequency of moments between various department as it travel chart is quite
significant in process tightly out decision and has no relevance in product layout
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Relationship charts a method for portraying the example and degree of
interdepartmental development of things inside a production line
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Value

Closeness

A

- Absolutely Necessary

E

- Especially Important

I
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– Ordinary Importance

U

- Unimportant

X
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With the minimization of a linear function of the movement
between departments Typically CRAFT employs an improvement procedure to
obtain a layout design based on the objective of minimizing material handling costs
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The sums of each activity’s closeness relationships with all other activities
are compared and the activity with the highest total closeness relationship (TCR)
count is selected and located first in the layout matrix
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Next, an activity which must be close to the winner is selected and placed
as adjacent as possible to winner: This activity is denoted as A (closeness absolutely
necessary) and is named Victor
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These are placed, again, as close to each other
as possible
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Next, the relationship data are
searched to find an activity with a high relationship to the first activity
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If none is found, a second activity is selected at
random and placed next to the first
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The entire procedure is repeated to generate another layout
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CRAFT
It is the only one which uses flow of materials data as the sole basis for
development of closeness relationships
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A second set of input data allows
the user to enter cost of moving in terms of cost per unit moved per unit distance
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0 for all costs in the matrix
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These take the form
of an initial or an existing layout
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Plant Building
The plant building is another important factor in plant layout the building The
building that house plant should be treated as a part of productive facilities and
should there for be design in such a way that it helps in effective and efficient
operation of the plant it should be built in such a way as to meet the particular

requirement of the operations and layout of the particular industrial enterprising
in question
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Factors Governing ideal Building Designs
1
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You must be able to clearly define your aims and
objectives for wanting the site
2
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Can the site be located via Google Maps? Is it easily accessible?
Being able to find answers to questions like this will give you a head start
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Access to utility and raw materials
For any construction or building project to be successful, it must be done in a place
where there is easy access to infrastructure and utilities
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Another vital factor you should consider is the proximity to the raw materials that
will be used for the planning or construction
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You will also get to have enough
resources at your disposal to complete the job
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Being close to the raw materials required for the production process will be highly
profitable for you in the long run
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Knowing your competitors
If a commercial building is what you’re planning on the site, you need to study the
locality and know those who will likely be your competitors
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However, don’t forget to make sure that your site is located in the right place where
your target customers reside
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5
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Therefore, you must endeavor to thoroughly study the building(s)
or land that surrounds your site
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Similarly, if the site is surrounded by land, you must
determine how the land can adversely affect your planning
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6
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Knowing the size and shape will
enable you to effectively get a plan that fits perfectly
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Others factors Governing the Building Designs

• Shape of the building : most of the industrial building take the shapes of
certain English letters like “ E,F,H,I,L,T,U” , even though rectangular shapes
are found to be common and convenient
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The sawtooth roofing wear in the window face north
allow uniform distribution of light
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• Fire protection : the building must be made fire proof to the maximum
possible extent
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• Proper lighting painting and ventilation: adequate lighting and shares
higher efficiency and greater output Provision of enough day light will certain
certainly reduce accident and other hazards
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It is equally necessary to provide for sprinkler system fire and burglar
alarms and fire fighting equipment’s
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• Noise control : Care should be taken to adopt the widely used method for
controlling industrial noise
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Conclusion
Plant layout means arrangement of department and equipment’s within a factory

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