Types of Plant Layout: Process, Product, and Stationary

Plant layout begins with the design of the factory building and goes up to the location
and movement of a work table. After discussion Plant Layout, this article explains
their types. The types of Plant Layout is the main three; process, product, and
stationary layout, but modern world two extra types; combination and Fixed
position Layout. All the facilities like equipment, raw materials, machinery, tools,
futures, workers, etc. are given a proper place.

Here is explain the Types of Plant Layout: process layout, product layout, stationary
layout, combination layout, and Fixed position layout.

Introduction to Contents:
 Here is explain the Types of Plant Layout: process layout, product layout,
stationary layout, combination layout, and Fixed position layout.
o
 Process Layout:
 Advantages of Process Layout:
 Disadvantages of Process Layout:
 Product Layout:
 Advantages of Product Layout:
 Disadvantages of Product Layout:
 Their clarification:
 Static Product Layout or Project Layout or stationary Layout:
 Advantages of stationary layout:
 Disadvantages of stationary layout:
 Combination Layout:
 Extra things:
 Fixed Position Layout:
 Advantages of Fixed Position Layout:
 Disadvantages of Fixed Position Layout:

There are three main types of plant layout: 1) Functional or process layout, 2) product
or line layout, and 3) stationary layout. Other types; 4) Combination and 5) Fixed
Position Layout. However, the choice of one or the other type of layout depends
upon the machines and techniques used in the production.

Process Layout:

It is also known as the functional layout and is characterized by keeping similar

machines or similar operations at one location (place). In other words, separate
departments are establishing for each specializes operation of production and
machines relating to that functions are assembled there.

For example, all lathe machines will be in one place, all milling machines at another
and so on. This type of layout generally employes for industries engage in job
order production and non-standardized products.

Advantages of Process Layout:

The following advantages of Process Layout below are;

 Wide flexibility exists as regards allotment of work to equipment and workers.

The production capacity does not arrange in rigid sequence and fixed-rate
capacity with line balancing. Alteration or change in the sequence of
operations can easily make as and when required without upsetting the
existing plant layout plan.
 Better quality product, because the supervisors and workers attend to one
type of machines and operations.
 Variety of jobs, coming as different job orders make the work more interesting
for workers.
 Workers in one section do not affect by the nature of operations carried out in
another section. e.g. a lathe operator does not affect by the rays of welding as
the two sections are quite separate.
 Like product layout, the breakdown of one machine does not interrupt the
entire production flow.
 This type of layout requires lesser financial investment in machines and
equipment because general-purpose machines, which are usually of low costs,
are used and duplication of the machine avoids. Moreover, general-purpose
machines do not depreciate or become obsolete as rapidly as specialized
machines. It results in lower investment in machines.
 Under process layout, better and efficient supervision is possible because of
specialization in operation.

Disadvantages of Process Layout:

The following disadvantages of Process Layout below are;

 Automatic material handling is extremely difficult because fixed material

handling equipment like conveyor belt cannot be possible to use.
 Completion of the same product takes more time.
 Raw material has to travel larger distances for getting processed to finished
goods. This increases material handling and associated costs.
  It is not possible to implement the group incentive schemes based on the
quantity of the manufacturing of the product.
 This type of layout requires more floor space than the product layout because
a distinct department established for each operation.
 Compared to line layout inventory investments are usually higher in case of
process layout. It increases the need for working capital in the form of
inventory.
 Under process layout, cost of supervision is high because; 1) the number of
employees per supervisor is less than result in the reduced supervisory span of
control, and 2) the work is checked after each operation.

Product Layout:

It is also known as line (type) layout. It implies that various operations on a product
are performed in a sequence and the machines are placed along the product flow line
i.e. machines are arranged in the sequence in which a given product will operate
upon. This type of layout prefers for continuous production i.e. involving a
continuous flow of in-process material towards the finished product stage.

Advantages of Product Layout:

The following advantages of Product Layout below are;

Automatic material handling, lesser material handling movements, time and cost.

 Product completes in lesser time. Since materials are fed at one end of the
layout and the finished product collects at the other end, there is no
transportation of raw materials backward and forward. It shortens the
manufacturing time because it does not require any time-consuming interval
transportation until the completion of the process of production. Line
balancing may eliminate idle capacity.
 The smooth and continuous flow of work. This plan ensures a steady flow of
production with the economy because bottlenecks or stoppage of work at
different points of production is got to eliminate or avoid due to the proper
arrangement of machines in sequence.
 Less in-process Inventory. The semi-finished product or work-in-progress is
the minimum and negligible under this type of layout because the process of
production is direct and uninterrupted.
 Effective quality control with reduced inspection points. It does not require
frequent changes in machine set-up. Since the production process integrates
and continuous, Defective practice can easily discover and segregate. This
makes inspection easy and economical.
 Maximum use of space due to straight production flow and reduced need for
interim storing.
Disadvantages of Product Layout:

The following disadvantages of Product Layout below are;

 Since the specific product determines the layout, a change in product involves
major changes in layout and thus the layout flexibility considerably reduces.
 The pace or rate of working depends upon the output rate of the slowest
machine. This involves excessive idle time for other machines if the production
line does not adequately balance.
 Machines being scattered along the line, more machines of each type have to
purchase for helping a few as stand by, because if one machine in the line fails,
it may lead to shut down of the complete production line.
 It is difficult to increase production beyond the capacities of the production
lines.
 As the entire production is the result of the joint efforts of all operations in the
line, it is difficult to implement individual incentive schemes.
 Since there are no separate departments for various types of work, supervision
is also difficult.
 Under this system, labor cost is high because; 1) absenteeism may create
certain problems because every worker is a specialist in his work or he
specializes on a particular machine. To avoid the bottleneck, surplus workers
who are generalists and can fit on several machines will have to employe; 2)
monotony is another problem with the workers. By doing the work of
repetitive nature along the assembly line, they feel bored; 3) as machines play
the dominant role in production under this system, workers have no
opportunity to demonstrate their talent; 4) noise, vibrations, temperature,
moisture, gas, etc. may cause health hazards. In this way, labor costs are high.

Their clarification:

It is now quite clear from the above discussion that both the systems have their own
merits and demerits. Advantages of one type of layout are generally the
disadvantages of other types. Thus to secure the advantage of both the systems a
combined layout may design.

Static Product Layout or Project Layout or stationary Layout:

The manufacturing operations require the movements of men, machines, and

materials, in the product layout and process layout generally the machines are fixed
installations and the operators are static in terms of their specified work stations.

It is only the materials which move from operation to operation for processing. But
where the product is large in size and heavy in weight, it tends to be static e.g.
shipbuilding. In such a production system, the product remains static and men and
machines move to perform the operations on the product.

Advantages of stationary layout:

The advantages of this stationary layout are as under:

 Flexible: This layout is fully flexible and is capable of absorbing any sort of

change in product and process. The project can complete according to the
needs of the customers and as per their specification.
 Lower labor cost: People are drawn from functional departments. They move
back to their respective departments as soon as the work is over. This is
economical if several orders are at hand and each one is in a different stage of
progress. Besides, one or two workers can assign to a project from start to
finish. Thus it reduces labor cost.
 Saving in time: The sequence of operations can change if some materials do
not arrive or if some people are absent. Since the job assignment is so long,
different sets of people operate simultaneously on the same assignment doing
different operations.
 Other benefits: They are; 1) It requires less floor space because machines and
equipment are in moving position and there is no need for fixing them. 2) This
arrangement is the most suitable way of assembling large and heavy products.

Disadvantages of stationary layout:

The disadvantages of this stationary layout are as under:

 Higher capital investment: Compared to the product or process layout, capital

investment is higher in this type of layout. Since several assignments are
taking, investment in materials, men, and machines makes at a higher cost.
 Unsuitability: This type of layout is not suitable for manufacturing or
assembling small products in large quantities. It is suitable only in the case
where the product is big or the assembling process is complex.TYPES OF
PLANT LAYOUT: PROCESS, PRODUCT, AND STATIONARY.

Combination Layout:

A combination of process and product layouts combine the advantages of both types
of layouts. Moreover, these days pure product or process layouts are rare. Most of
the manufacturing sections are arranging in process layout with manufacturing lines
occurring here and there (scattered) wherever the conditions permit. A combination
layout is possible where an item makes in different types and sizes.
In such cases machinery arranges in a process layout but the process grouping (a
group of the number of similar machines) then arranges in a sequence to manufacture
various types and sizes of products. The point to note is that no matter the product
varies in size and type, the sequence of operations remain the same or similar.

Extra things:

A combination layout is also useful when several items are producing in the same
sequence but none of the items are to produce in bulk and thus no item justifies for
an individual and independent production line. For example, files, hacksaws, circular
metal saws, wood saws, etc. can manufacture on a combination type of layout.

Nowadays in the pure state, any one form of layouts discussing above rarely finds.
Therefore, generally, the layouts used in industries are the compromise of the above-
mentioned layouts. Every layout has got certain advantages and limitations.
Therefore, industries would to like use any type of layout as such.

Flexibility is a very important factory, so the layout should be such which can mold
according to the requirements of the industry, without much investment. If the good
features of all types of layouts are connecting, a compromise solution can obtain
which will be more economical and flexible.

Fixed Position Layout:

This type of layout is the least important for today’s manufacturing industries. In this
type of layout, the major component remains in a fixed location, other materials,
parts, tools, machinery, manpower and other supporting equipment’s are brought to
this location.

In other types of layouts discussed earlier, the product moves past stationary
production equipment, whereas in this case the reverse applies; men and equipment
are moving to the material, which remains at one place and the product completes at
that place where the material lies.

The major component or body of the product remains in a fixed position because it is
too heavy or too big and as such it is economical and convenient to bring the
necessary tools and equipment’s to work along with the manpower. This type of
layout uses in the manufacture of boilers, hydraulic and steam turbines and ships, etc.

Advantages of Fixed Position Layout:

The advantages of Fixed Position Layout are as under;

 Material movement reduces.

 Capital investment minimizes.
 The task usually finishes by a gang of operators, hence continuity of
operations ensures.
 It is possible to assign one or more skilled workers to a project from start to
finish to ensure continuity of work.
 It involves the least movement of materials.
 There is maximum flexibility for all sorts of changes in product and process.
 Several quite different projects can take with the same layout.
 Production centers are independent of each other. Hence, effective planning
and loading can make. Thus the total production cost will reduce.
 It offers greater flexibility and allows the change in product design, product
mix, and production volume.

Disadvantages of Fixed Position Layout:

The disadvantages of Fixed Position Layout are as under;

 Highly skilled manpower requires.

 It usually involves a low content of work-in-progress.
 There appears to be low utilization of labor and equipment.
 It involves high equipment handling costs.
 Movement of machines equipment’s to production center may be time-
consuming.
 Complicated fixtures may require for positioning of jobs and tools. This may
increase the cost of production.