Meaning and Definition, Objective of Plant Layout & Principles of Plant Layout

Plant Layout and Material Handling

Definition of Plant Layout

Plant layout is the arrangement of machines, work areas and service areas within a factory. George R. Terry.

Plant layout involves the development of physical relationship among building, equipment and production operations, which will enable the manufacturing process to be carried on efficiently.

Meaning and Definition of Plant Layout:

Plant layout is the most effective physical arrangement, either existing or in plans of industrial facilities i.e arrangement of machines, processing equipment and service departments to achieve greatest co-ordination and efficiency of 4M’s (Men, Materials, Machines and Methods) in a plant.

Layout problems are fundamental to every type of organization / enterprise and are experienced in all kinds of concerns/undertakings.

The adequacy of layout affects the efficiency of subsequent operations. It is an important pre-requisite for efficient operations and also has a great deal in common with many problems. Once the site of the plant has been decided, the next important problem before the management of the enterprise is to plan suitable layout for the plant.

Definitions:

According to James Lundy, “Layout identically involves the allocation of space and the arrangement of equipment in such a manner that overall operating costs are minimized.”

In the words of Mallick and Gandreau, “Plant layout is a floor plan for determining and arranging the designed machinery and equipment of a plant, whether established or contemplated, in the best place, to permit the quickest flow of material, at the lowest cost and with the minimum handling in processing the product, from the receipt of raw material to the shipment of finished product.”

According to Apple, “Plant layout is planning the path each component/part of the product is to follow through the plant, coordinating the paths of the various parts so that the manufacturing processes may be carried out in the most economical manner, then preparing drawing or other representation of the arrangement and finally seeing that the plan is properly put into effect.” (Plant Layout and Material Handling by Apple).

In the words of Sansonneti and Mallick (Factory Management, Vol. 103) “It is placing the right equipment, coupled with right place, to permit the processing of a product unit in the most effective manner, through the shortest possible distance and in the shortest possible time.” The last definition seems to be most appropriate.

 

Objectives / Advantages of Plant Layout:

Following are the objectives/advantages of plant layout:

(i) Streamline flow of materials through the plant

(ii) Minimize material handling

(iii) Facilitate manufacturing progress by maintaining balance in the processes

(iv) Maintain flexibility of arrangements and of operation

(v) Maintaining high turnover of in-process inventory

(vi) Effective utilization of men, equipment and space

(vii) Increase employee morale

(viii) Minimize interference (i.e. interruption) from machines

(ix) Reduce hazards affecting employees

(x) Hold down investment (i.e. keep investment at a lower level) in equipment.

Principles of Plant Layout:

While designing the plant layout, the following principles must be kept in view:

(i) Principle of Minimum Movement:

Materials and labour should be moved over minimum distances; saving cost and time of transportation and material handling.

(ii) Principle of Space Utilization:

All available cubic space should be effectively utilized – both horizontally and vertically.

(iii) Principle of Flexibility:

Layout should be flexible enough to be adaptable to changes required by expansion or technological development.

(iv) Principle of Interdependence:

Interdependent operations and processes should be located in close proximity to each other; to minimize product travel.

(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.

(vi) Principle of Safety:

There should be in-built provision in the design of layout, to provide for comfort and safety of workers.

(vii) Principle of Smooth Flow:

The layout should be so designed as to reduce work bottlenecks and facilitate uninterrupted flow of work throughout the plant.

(viii) Principle of Economy:

The layout should aim at effecting economy in terms of investment in fixed assets.

(ix) Principle of Supervision:

A good layout should facilitate effective supervision over workers.

(x) Principle of Satisfaction:

A good layout should boost up employee morale, by providing them with maximum work satisfaction.