Lecture 5 Overview of Plant Layout Part 1

LECTURE 5:
O V E RV IE W O F P L A N T L AYO U T
•Prepared By: Suryani Ahmad
• Credit to
• PM Dr Siti Akhtar Mahayuddin
LEARNING OUTCOME FOR THIS TOPIC:
1 2 3
Apply and develop Apply knowledge Adapt with parties
skill and methods : and skills towards involved in plant
plant layout plant layout layout
2
CONTENTS
1. Introduction and definition

2. Factors influencing plant and
facilities location and layout
the most effective physical arrangement, either existing or in plans of industrial
facilities i.e. arrangement of machines, processing equipment and service departments
PLANT to achieve greatest co-ordination and efficiency of 4 M’s (Men, Materials, Machines and
Methods) in a plant.
LAYOUT
“Layout identically involves the allocation of space and the arrangement of equipment
in such a manner that overall operating costs are minimized”
PLANT LAYOUT
“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”
FACTORS INFLUENCING PLANT LOCATION
(1)
Ability of
Raw
Material
(7) (2)
Availabilit 7 Proximity to
y of FACTORS Markets
Labour
(3)
(6) Transport
Disposal Facilities
Facility for
(5) (4)
Waste Products
Water Availability
Supply of Power,
Fuel or Gas
(1) (2)
Ability of Proximity
Raw Material to Markets
• Raw material should be available within

the economical distance. • Cost of distribution is an important
• Reduce cost of transporting raw material item in the overhead expenses.
from the suppliers to the plant
• Easy availability of supplies required for
• Advantageous to be near to the center
maintenance and operation of the plant of demand for finished products.
• Sustain operation and supply of IBS • Nearness to the market ensures a
components consistent supply of goods to
• Get the right raw materials and right time customer and reduces the cost of
in order to eliminate interrupted in the
production, especially if the cost of
transportation.
transportation is very high
(3)
Transport
Facilities
• Transportation facilities are becoming the governing factor in economic

location of the plant.
• Suitable method of transportation like rail, road, water transportation (through
river, canals or sea) – to cater the volume of the raw materials and finished
products
• Important consideration - the cost of transportation should remain fairly small
in comparison to the total cost of production.
• Speedy transport facilities ensure timely supply of raw materials to the
company and finished goods to the customers.
• The choice of transport method and the location will depend on cost,
convenience and suitability.
(5)
(4) Water
Availabilit Supply
y of Power,
Fuel or Gas
• Continuous operation – precast

• Commonly electric power in Malaysia
concrete
• The reliability of continuous supply of • Enough water supply
electricity is an important factor for
plant operation.
(6)
Disposal
(7)
Facility for
Availability
Waste Products
of Labour
• waste products likely to • Continuous supply of labour

be produced during the governs plant location to
production process. major extent.
• Adequate number of labour
with skill specific to the
machinery.
• Productivity of labour
important factor to be
considered.
OBJECTIVE OF PLANT LAYOUT
The primary goal of the plant layout is to maximize the profit by arrangement of all
the plant facilities to the best advantage of total manufacturing of the product. The
objectives of plant layout are:
1.Streamline the flow of materials through the plant.

2.Facilitate the manufacturing process.
3.Maintain high turnover of in-process inventory.
4.Minimize materials handling and cost.
5.Effective utilization of men, equipment and space.
6.Make effective utilization of cubic space.
7.Flexibility of manufacturing operations and arrangements.
8.Provide for employee convenience, safety and comfort.
9.Minimize investment in equipment.
10.Minimize overall production time.
11.Maintain flexibility of arrangement and operation.
12.Facilitate the organizational structure.
7 P R I NC I P L E S O F P L A N T L AY O U T:
1. Integration:
A good layout is the integration of production centres facilities like workers, machinery, raw
material and supporting services in a logical and balanced manner.
2. Minimum Movements, distance and Material Handling:

The number of movements of workers and materials should be minimized. It is better to
transport materials in optimum bulk rather than in small amounts.
Minimum travel of the workers and materials, which the facilities should be arranged in
acceptable distance where straight-line movement is preferable.
3. Cubic Space Utilization:

The good layout is one that utilizes both horizontal and vertical space.
Besides using the floor space of a room, if the ceiling height is also utilized, more materials
can be accommodated in the same room. Boxes or bags containing raw material or goods can
be stacked one above the other to store more items in the same room. Overhead material
handling equipment save a lot of valuable floor space.
4. Smooth and Continuous Flow:
Bottlenecks, congestion points and back tracking should be removed by proper line balancing
techniques.
5. Safe and Improved Environments:

Working places-safe, well ventilated and free from dust, noise, fumes, odours, and other
hazardous conditions decidedly increase the operating efficiency of the workers and improve
their morale. All this leads to satisfaction amongst the workers and thus better employer-
employee relations.
6. Flexibility:
In industries where models of products change after some time, it is better to permit all
possible flexibility in the layout. The machinery is arranged in such a way that the changes of
the production process can be achieved at the least cost or disturbance.
7. Handling
Reduce material handling to the minimum
LAYOUT OF PRECAST FACTORY
(OFFSITE)
3
2
1
4
5 3
1
4
5
4
2
1
6
7
5
10
9 8
3
https://www.youtube.com/watch?v=PAz2fyZ8Ksw
https://www.youtube.com/watch?v=8yoHltK1Naw
https://www.youtube.com/watch?v=-gmWJqXEKQI
https://www.youtube.com/watch?v=M-o8WZIDldg
https://www.youtube.com/watch?v=Ip85vxEVfTE https://www.youtube.com/watch?v=NfAzn50oIvs&t=52s
https://www.youtube.com/watch?v=6AJ1ueZvrqk https://www.youtube.com/watch?v=B3APtPxlyDs
https://www.youtube.com/watch?v=nnBSuqoL-UU
THANK YOU

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LECTURE 5:

•Prepared By: Suryani Ahmad

1. Introduction and definition

“Plant layout is a floor plan for determining and

• Raw material should be available within

• Transportation facilities are becoming the governing factor in economic

• Continuous operation – precast

• waste products likely to • Continuous supply of labour

1.Streamline the flow of materials through the plant.

2. Minimum Movements, distance and Material Handling:

3. Cubic Space Utilization:

5. Safe and Improved Environments:

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