PLANT DESIGN AND

LAYOUT
INSTRUCTOR: MADAM ZAINAB ALLY BAKARI
 COURSE DESCRIPTION
COURSE NAME: PLANT DESIGN AND LAYOUT
COURSE CODE: FVTO6105
COURSE CREDIT:
 SUB ENABLING OUTCOMES

i. Use plant layout principles in designing food processing

plant
ii. Identify plant design procedures for food processing plant.
iii.Use general guidelines that help in designing plant layout.
 Explain importance and function of
plant layout for food processing.
INTRODUCTION
• Plant layout refers to the physical arrangement of production facilities.
• The facilities include personnel, operating equipment, storage space, material
handling equipment and all other supporting services along with the design of
best structure to contain all these facilities.
• The objective of plant layout planning is a more effective work flow at the
facility, allowing workers and equipment being more productive.
• Facility layout techniques apply to the case where several physical means
have to be located in a certain area, either industrial processes/services
The plant layout process starts at an aggregate level, taking into account the
different departments
Most layouts are designed properly for the initial conditions of the business,
however, re-layout could be necessary when there are:
• Changes in production volumes
• Changes in processes and technology
• Changes in the product
• The frequency of the re-layout will depend on the requirements of the process
 Some of the important objectives of a
good plant layout are as follows:
• Overall simplification of production process in terms of equipment utilization, minimization
of delays, reducing manufacturing time, and better provisions for maintenance
• Overall integration of man, materials, machinery, supporting activities and any other
considerations in a way that result in the best compromise.
• Minimization of material handling cost by suitably placing the facilities in the best flow
sequence • Saving in floor space, effective space utilization and less congestion / confusion,
• Increased output and reduced in-process inventories
• Better supervision and control
• Worker convenience and worker satisfaction
• Better working environment, safety of employees and reduced hazards • minimization of
waste and higher productivity • avoid unnecessary capital investment • higher flexibility and
adaptability to changing conditions
 PLANT LAYOUT FACTORS
The design of any layout is governed by a number of factors and the best layout is the one that optimizes all the
factors. The factors influencing any layout are categorized into the following eight groups:
• The material factor: includes design, variety, quantity, the necessary operations, and their sequence.
• The main factor: includes direct workers, supervision and service help, safety and manpower utilization.
• The machinery factor: includes the process, producing equipment and tools and their utilization
• The movement factor: includes inter and intradepartmental transport and handling at the various operations,
storage and inspection, the materials handling equipment. Phase I: Phase II: Phase III: Phase IV: Location General
Overall Layout Detailed layout
• The waiting factor: includes permanent and temporary storage and delays and their locations.
• The service factors: include service relating to employee facilities such as parking lot, locker rooms, toilets,
waiting rooms etc.; service relating to materials in terms of quality, production control, scheduling, dispatching,
waste control; and service relating to machinery such as maintenance.
• The building factor: includes outside and inside building features and utility distribution and equipment.
• The change factor: includes versatility, flexibility and expansion Each of the above mentioned factors comprise
a number of features and the layout engineer must review these in the light of his problem. Usually the layout
design process is a compromise of these various considerations to meet the overall objectives in the best
possible manner.
 TYPES OF PLANT LAYOUT
The production process normally determines the type of plant
layout to be applied to the facility.
Generally there are five categories of plant layout:
• Process oriented plant layout (Functional Layout)
• Product oriented plant layout
• Fixed position plant layout
• Combination layout
• Cellular/group Layout
 TYPES OF PLANT LAYOUT

1. Product oriented plant (Line) layout:

• This type of plant layout machines and auxiliary services are located
according to processing sequence of the product
• Only one product or one type of product, is produced in a given area
• The work centers are organized in the sequence of appearance
• The product layout is selected when the process is continuous or
repetitive and volume of production is high such that a separate
production line is justifiable
 TYPES OF PLANT LAYOUT
•Machines are not shared by different products; thus, the
production volume must be sufficient to achieve satisfactory
utilisation of the equipment
• The plant layout will be based in allocating a machine as
close as possible to the next one in line, in the correct
sequence to manufacture the product
• The raw material enters at one end of the line and goes from
one operation to another rapidly with minimum of work-in-
process storage and material handling.
Product/Line layout
 TYPES OF PLANT LAYOUT
Product oriented plant layout:
Advantages:
• Reduced material handling cost (mechanisation & straight flow)
• Work-in-process almost eliminated
• Minimum manufacturing time
• Simplification of the production planning and control systems
• Tasks simplification
• Less space is occupied by work transit and for temporary storage
• Throughput time is less
• Unskilled workers can learn and manage the production
 TYPES OF PLANT LAYOUT
Product oriented plant layout:
Disadvantages/limitations:
• No flexibility in the production process
• A change in product design may require major layout alterations
• High capital investment
• Monotonous work
• Breakdown or shut down of a machine stops the whole process
 TYPES OF PLANT LAYOUT
2.Process/functional oriented plant layout:
This type of plant layout is developed for process focused systems
• It is useful when the production process is organized in batches (small production
volumes) and products not standardised
• Personnel and equipment to perform the same function are allocated in the same
area
• The different items have to move from one area to another one, according to the
sequence of operations previously established
• The variety of products to produce will lead to a diversity of flows through the
facility
• The short term variations in the production volumes may lead to modifications in
the manufactured quantities and types of products to be produce
Process oriented plant layout
 TYPES OF PLANT LAYOUT

The advantages of a process layout are:

• Higher flexibility
• Better equipment utilization
• Greater incentive to individual worker
• More continuity of production in unforeseen conditions like
breakdown, shortages, absenteeism etc.
 TYPES OF PLANT LAYOUT
3.Group /cellular layout:
• Grouping of equipment for performing a sequence of operations on family of similar
components or products
• Useful for companies that produce variety of parts in small batches to enable them to
take advantage and economics of flow line layout
• Group technology involves two basic steps;
(1) to determine component families or groups, (2) applying group technology by arranging
the plants’ equipment used to process a particular family of components (small plants)
• Group layout is a combination of the product layout and process layout. It combines the
advantages of both layout systems
The group technology reduces production planning time for jobs. It reduces the set-up time
Group/cellular layout
 TYPES OF PLANT LAYOUT
Advantages of group layout:
• Each cell manufactures products belonging to a single family
• Cells are autonomous manufacturing units which can produce
finished parts • Single operators supervising processing machines
in a cell
• Productivity and quality maximised (work-in-progress reduced)
• Commonly applied to machined parts
• Flexible and suited to products in batches and where design
changes often occur
 TYPES OF PLANT LAYOUT
4. Combination layout:
A combination of process and product layouts combines the
advantages of both types of layouts
• Possible where an item is being made in different types and sizes
• Machinery is arranged in a process layout but the process
grouping is then arranged in a sequence to manufacture various
types and sizes of products
• It is to be noted that the sequence of operations remains same
with the variety of products and sizes.
 TYPES OF PLANT LAYOUT
Fixed position :
• This is also called the project type of layout
• The material, or major components remain in a fixed location and
tools, machinery, men and other materials are brought to this location
• It is suitable when one or a few pieces of identical heavy products
are to be manufactured and when the assembly consists of large
number of heavy parts, the cost of transportation of these parts is
very high
Common for manufacture of aeroplanes, ships etc
 TYPES OF PLANT LAYOUT
• Fixed position layout:
Advantages
• Helps in job enlargement and upgrades the skills of the
operators
• The workers identify themselves with a product in which they
take interest and pride in doing the job
• Greater flexibility with this type of layout
• Layout capital investment is lower
 Assignment

• Discuss the important aspects in the

hygienic design of a food plant that
are necessary to reduce cross
contamination and ensure product
safety