What are the objectives, principles and types of Plant Layout?

Plant layout is a mechanism which involves knowledge of the space requirements for the facilities and also involves their proper arrangement so that continuous and steady movement of the production cycle takes place.

Moore, a very well known name in the business world, explained plant layout as,” The plan of or the act of planning, an optimum arrangement of facilities, including personnel, operating equipment, storage space, materials handling equipment and all other supporting services along with the design of the best structure to accommodate these facilities”.

The problems related to plant layout are generally observed because of the various developments that occur. These developments generally include adoption of the new standards of safety, changes in the design of the product, decision to set up a new plant, introducing a new product, withdrawing the various obsolete facilities etc.

Objectives of a good plant layout are –
1. Providing comfort to the workers and catering to worker’s taste and liking.
2. Giving good and improved working conditions.
3. Minimizing delays in production and making efficient use of the space that is available.
4. Having better control over the production cycle by having greater flexibility for changes in the design of the product.

Principles of a good plant layout are –
1. A good plant layout is the one which is able to integrate its workmen, materials, machines in the best possible way.
2. A good plant layout is the one which sees very little or minimum possible movement of the materials during the operations.
3. A good layout is the one that is able to make effective and proper use of the space that is available for use.
4. A good layout is the one which involves unidirectional flow of the materials during operations without involving any back tracking.
5. A good plant layout is the one which ensures proper security with maximum flexibility.
6. Maximum visibility, minimum handling and maximum accessibility, all form other important features of a good plant layout.

Types of layouts –
1. Process layout – These layouts are also called the functional layouts and are very suitable in the conditions, when the products being prepared are non – standard or involve wide variations in times of processing of the individual operations.

Such layouts are able to make better utilization of the equipment that is available, with greater flexibility in allocation of work to the equipment and also to the workers. Imbalance caused in one section is not allowed to affect the working of the other sections.

2. Product layout – These layouts are also known as the line layouts or the layout by sequence. In such layouts, the manufacturing cycle is small with minimum material handling. The space required is small and quality control is easy to exercise.

3. Project layout – Such layouts are also referred to as the fixed position layouts. In these layouts, the components, heavy materials, sub assemblies – all remain fixed at one place and the job is completed by movement of machines, men and tools to the location of the operations.