Facility Layout Introduction Layout planning is determining the best physical arrangement of resources within a facility. It may be defined as a technique of locating machines, processes and plant services within the factory so as to achieve the right quantity and quality of output at the lowest possible cost of manufacturing. Objective of a good Layout Provide enough production capacity. Reduce material handling costs. Reduce congestion that impedes the movement of people or material. Reduce hazards to personnel. Increase employee morale. Reduce accidents. Utilize available space effectively & efficiently.

2. Introduction
Layout planning is determining the best
physical arrangement of resources within
a facility.
 It may be defined as a technique of
locating machines, processes and plant
services within the factory so as to
achieve the right quantity and quality of
output at the lowest possible cost of
manufacturing.
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3. Objective of a good Layout
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Provide enough production capacity.
Reduce material handling costs.
Reduce congestion that impedes the
movement of people or material.
Reduce hazards to personnel.
Increase employee morale.
Reduce accidents.
Utilize available space effectively & efficiently.

4. 
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Provide for volume & product flexibility.
Provide ease of supervision.
Facilitate co-ordination and face-to-face
communication where appropriate.
Provide for employee safety and health.
Allow ease of maintenance.
Allow high machine/equipment utilisation.
Improve productivity.

5. Factor influencing Layout
Materials
 Product
 Worker
 Machinery
 Location
 Type of industry
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6. 
Managerial Policies
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The volume of production & provision of
expansion.
The extent of automation.
Desire for rapid delivery of goods to consumers
Purchasing policy
Personnel policies.
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7. Principles of Layout
Principle of Minimum Travel
 Principle of Sequence
 Principle of Usage
 Principle of Compactness
 Principle of Safety & Satisfaction
 Principle of Flexibility
 Principle of Minimum Investment
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8. Types of Layout
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Process Layout, Functional Layout or Job shop
Layout.
Product Layout, Line processing layout or Flow
Line Layout.
Fixed Position Layout or Static Layout.
Cellular manufacturing Layout or Group
Technology Layouts.
Combination Layout or Hybrid Layout

9. Process Layout
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Group similar resources together.
For job lot manufacturer or batch production.
Involves grouping together of like machines in
one department.
E.g. machines performing drilling operations
installed in the drilling department.

11. Principles
a) The distance between departments should be
as short as possible for avoiding long distance
movement of materials
b) The departments should be in sequence of
operations
c) The arrangement should be convenient for
inspection and supervision

12. Advantages:
a) Lower initial capital investment in machines and equipments. There
is high
degree of machine utilization, as a machine is not blocked for a single
product
b) The overhead costs are relatively low
c) Change in output design and volume can be more easily adapted to
the output of variety of products
d) Supervision can be more effective and specialized
e) There is a greater flexibility of scope for expansion.

13. Disadvantages:
a. Material handling costs are high due to backtracking
b. More skilled labour is required resulting in higher cost.
c. Time gap or lag in production is higher
d. Work in progress inventory is high needing greater
storage space
e. More frequent inspection is needed which results in
costly supervision

14. Product Layout
Involves the arrangement of machines in
one line, depending upon the sequence of
operations.
 Materials are fed into the first machines
and finished products come out of the last
machine.
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16. Principles
a) All the machine tools or other items of equipments must
be placed at the point demanded by the sequence of
operations
b) There should no points where one line crossed another
line.
c) Materials may be fed where they are required for
assembly but not necessarily at one point.
d) All the operations including assembly, testing packing
must be included in the line.

17. Advantages:
a) Low cost of material handling, due to straight and short route and
absence of backtracking
b) Smooth and uninterrupted operations
c) Continuous flow of work
d) Lesser investment in inventory and work in progress
e) Optimum use of floor space
f) Shorter processing time or quicker output
g) Less congestion of work in the process
h) Simple and effective inspection of work and simplified production
control
i) Lower cost of manufacturing per unit

18. Disadvantages:
a. High initial capital investment in special purpose
machine
b. Heavy overhead charges
c. Breakdown of one machine will hamper the
whole production process
d. Lesser flexibility as specially laid out for
particular product.

19. Comparison of Product vs. Product Layouts
Process Layouts
Products:
Product Layouts
large , different
small , efficiently
Resources:
general purpose
Facilities:
more labor intensive
more capital intensive
Flexibility:
greater relative to market
lower relative to market
Processing
Rates:
slower
Handling costs:
high
Space requirements: higher
specialized
faster
low
lower

20. Fixed Position Layout
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Involves the movement of men and
machines to the product which remains
stationary.

22. Advantages:
a) It saves time and cost involved on the
movement of work from one workstation to
another.
b) The layout is flexible as change in job
design and operation sequence can be
easily incorporated.

23. Disadvantages:
a. Production period being very long, capital
investment is very heavy
b. Very large space is required for storage of
material and equipment near the product.
c. As several operations are often carried out
simultaneously, there is possibility of confusion
and conflicts among different workgroups.

24. Cellular Manufacturing Layout
In this machines are grouped into cells
and the cells function somewhat like
product layout within a larger shop or
process layout.
 A product layout is visible inside each cell.
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25. Machine
2
Machine
1
Machine
3
Materials in
Finished
goods out
Machine
5
Machine
4

26. Advantages
 Reduced material handling and transit
time
 Better use of human resources
 Easier to control
 Easier to automate

27. Disadvantages
 Expanded training and scheduling of
workers
 Increased capital investment

28. Combination Layout
Combination of three pure types:
Product , Process, and Fixed Position
Layout
Example:
Hospital: process and fixed position.

29. Importance
smooth & efficient functioning.
 Reduce manufacturing costs.
 Effective use of available area.
 Avoidance of bottlenecks.
 Better supervision.
 Improved utilisation of labour.
 Improved employee morale.
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30. Better production control.
 Minimisation of production delays.
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