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Types of Plants Layout – 5 Common Types in Detail | Operations Management

Types of Plants Layout

➡ A plant layout is the arrangement of machines, equipment, workspace, and other resources within a manufacturing or production facility. It is crucial to efficiency and productivity.

➡ A plant’s layout directly affects its efficiency, productivity, safety, and cost-effectiveness, making it an integral part of industrial and manufacturing facilities’ design.

➡ To ensure smooth and streamlined operations, it involves arranging machinery, equipment, workstations, storage areas, and other resources within a facility strategically.

➡ Several types of plant layouts are available, each suited to different production requirements, processes, and industries.

➡ This detailed explanation will explore the most common types of plant layouts, their advantages, and disadvantages.

Some of the common types of plants layout are as follows:

Types of Plants Layout

1. Process Layout:

Process Layout as a Types of Plants Layout

➡ A process layout, also referred to as a functional layout, combines similar machines and equipment based on their functions or processes.

➡ As the name suggests, this type of layout places all machines of a particular type in one area, regardless of the product they are producing.

➡ For example, the milling machine will be located in one section, the lathe in another, etc.

Advantages:

a. Flexibility:

A flexible process layout can accommodate changes in production processes or product designs without significant reconfiguration.

b. Specialization:

Each department can specialize in a particular process, leading to a high level of expertise and efficiency.

c. Lower Investment:

Compared to other layout types, the initial investment is lower with this layout since machines are grouped according to their function.

Disadvantages:

a. Material handling:

Moving products between different process areas can lead to increased costs and requirements for material handling.

b. Complex Scheduling:

Managing the flow of materials between departments can be challenging and can cause delays.

c. Floor Space Requirement:

It is possible that a process layout will require more floor space in order to separate processes.

Applications:

The layout of a process can be used in many industries with a wide variety of products and customizations, such as job shops or companies that customize products for clients.

2. Product Layout:

Product Layout as a Types of Plants Layout

➡ The product layout arranges machines and workstations sequentially, matching the production process. It is also called the line layout or assembly-line layout.

➡ During mass production, this layout is commonly used as a means of assembling or processing products. It involves moving the products from one workstation to another.

Advantages:

a. High productivity:

The layout of products is designed to maximize continuous flow, resulting in lowered production times and higher productivity.

b. Less Material Handling:

A reduction in material handling is a result of products moving along the assembly line rather than being handled extensively.

c. Standardization:

Training and supervision are simplified with a standardized production flow.

Disadvantages:

a. Lack of Flexibility:

The layout of products is not easily adaptable to changes in product design or manufacturing processes.

b. Initial Investment:

The initial investment in setting up a product layout may be high due to the need for specialized equipment and assembly lines.

c. Dependence on Machines:

A breakdown in one machine can disrupt the entire production line.

Applications:

The layout of products is well suited to industries with high-volume production of standardized products, such as automobile manufacturing and electronics assembly.

3. Fixed Position Layout:

Fixed Position Layout as a Types of Plant Layout

➡ A fixed-position layout is used when the product is too large or impractical to move during production.

➡ All resources, equipment, and manpower are brought to the place where the product is being built or assembled.

Advantages:

a. Suitable for large products:

This layout is ideal for constructing large items such as ships, aircraft, and buildings.

b. Reduced Material Handling:

A reduced amount of material handling is possible since the product remains stationary for the majority of the time.

c. High Customization:

A high degree of customization is possible since the product can be easily customized and modified during construction.

Disadvantages:

a. Complex Coordination:

The coordination of multiple activities and resources within a limited space presents a challenge.

b. Space Constraints:

Congestion and inefficiencies at the construction site may be caused by a lack of space.

c. Higher Costs:

Costs are higher in fixed-position layouts because resources must be transported to the site.

Applications:

The use of fixed-position layouts is common in industries such as construction, shipbuilding, aircraft manufacturing, and other large-scale projects.

4. Cellular Layout:

Cellular Layout as a Types of Plant Layout

➡ In cellular layout, machines and equipment are grouped into cells, with each cell producing a specific set of products or parts. It is a combination of process and product layouts.

➡ The machines are arranged within each cell so that information and materials can flow efficiently.

Advantages:

a. Reduced Material Handling:

The movement of materials within each cell is minimized, resulting in reduced handling costs and waste.

b. Adaptability:

Cells can be easily moved and reconfigured to meet changing production needs.

c. Teamwork:

A cellular layout facilitates teamwork and a sense of ownership among employees, resulting in higher satisfaction levels.

Disadvantages:

a. Initial Planning:

An effective cellular layout requires careful planning and analysis at the outset.

b. Duplication:

The initial investment cost can increase if certain machines have to be duplicated in multiple cells.

Applications:

A cellular layout is commonly used in lean manufacturing environments and industries with medium to high production volumes.

5. Combination Layout:

Combination Layout as a Types of Plant Layout

➡ A combination layout is a combination of different types of layouts, generally incorporating both process and product layouts.

➡ It is useful for industries with multiple product lines and varying production requirements.

Advantages:

a. Optimal utilization:

Different types of layouts are combined to boost productivity and optimize resource utilization.

b. Flexibility:

A combination layout maintains a balance between the flexibility of process layouts and the efficiency of product layouts.

c. Adaptability:

Layouts of this type are adaptable to changes in production requirements and product lines.

Disadvantages:

a. Complexity:

A combination of layout types can create a complex design and implementation process.

b. Expertise Required:

In order to ensure an effective combination of layouts, proper planning and expertise are needed.

Applications:

Consumer electronics and home appliances are two industries that can benefit from combination layouts due to their diverse product lines and fluctuating production demands.

➡ A plant layout is determined by a number of factors, including type of industry, production volume, product variety, and degree of customization.

➡ In order to ensure a productive and efficient manufacturing environment, it is essential to carefully consider each layout type’s advantages and disadvantages.

➡ The layout of a manufacturing plant is crucial for the success of any operation, regardless of whether it’s for custom products, mass production, or lean manufacturing.

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References

  • J, A. (2023, July 22). What is Plant Layout? Types of Plant Layout with Example – The Investors Book. The Investors Book. https://theinvestorsbook.com/plant-layout.html
  • Admin, & Admin. (2023, December 18). Plant layout : Definition, Objectives, Types, Case Studies, Factors. Tetrahedron Manufacturing Servies. https://www.tetrahedron.in/plant-layout/
Bijisha Prasain

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