ASSIGNMENT 1

LESSON 1 & 2: The Nature of Plant Layout & Types of Plant Layout
LIGUTAN, Willene Jane F. Facilities Planning and Design (IE17)
CEIT-06-701P Dr. Nestor Japis

I. Management of the Factors of Production

Equation from p.4:

Management × (Men + Materials + Machinery) = Production

Production depends on three basic resources:

• Men – the workers and their skills.

• Materials – raw materials or parts needed for the product.

• Machinery – equipment, tools, and technology used to process materials.

However, these three alone don’t guarantee results. They must be organized, scheduled, and

coordinated — that’s the job of management. Good management decides who will do the work, what

materials to use, when the tasks happen, and how to operate the machinery effectively.

Example: In a car assembly plant, workers install engines, dashboards, and wheels. Management

schedules shifts, ensures engine parts are delivered on time, and maintains the assembly robots.

Without management, materials could arrive late, machines might break down, or workers might be idle

— reducing production.

II. Advantages of a Good Layout

• Reduced Safety Risks – Dangerous activities are separated from main work areas.

Example: Moving flammable paint mixing to a fireproof room prevents accidents.

• Improved Worker Morale – Comfortable, organized work areas make workers more satisfied.

Example: Rearranging machines so workers avoid glare from sunlight.

Example: Welding stations arranged in a sequence reduce unnecessary walking.

• Fewer Delays – Balanced work times avoid waiting.

Example: Matching machine speeds so materials don’t pile up between stations.

• Better Floor Space Use – Optimized arrangements avoid wasted space.

Example: Shipyard reorganization increased ship production by 28% without expansion.

• Reduced Material Handling – Direct movement between processes saves time.

Example: Assembly line where products pass directly from one worker to the next.

• Higher Utilization of Machines & Labor – More efficient use of resources.

Example: Conveyor lines adjusted to handle more items without extra cost.

• Lower Inventory in Process – Faster flow reduces storage needs.

Example: Repositioning departments reduced in-process stock by 35%.

• Shorter Manufacturing Time – Less distance and waiting means faster completion.

Example: Moving packing closer to the line cut production time by 11%.

• Less Clerical Work – Smooth systems reduce paperwork.

Example: A shaft production line cut annual paper forms from 4,900 to 250.

• Easier Supervision – Supervisors can monitor workers more effectively.

• Less Congestion – Good layouts prevent traffic jams in aisles.

• Better Material Quality – Avoids contamination or damage by separating incompatible

processes.

• Easier to Adapt to Changes – Flexible layouts can expand or adjust without high costs.
 • Other Benefits – Cleaner, more organized workplaces improve maintenance and company

image.

III. Objectives of Plant Layout

• Integrate All Factors - Coordinate men, materials, machines, and support services so they

work as one system.

Example:

In a cookie factory, the mixing area is placed near the ovens, which are next to the cooling and

packaging sections. Workers, ingredients, and baking machines are arranged so production flows

smoothly without delays.

• Minimize Material Movement - Cut down on unnecessary transport between processes to

save time and costs.

Example:

In a furniture workshop, the wood-cutting section is right beside the assembly area, so cut pieces

don’t need to be carried across the entire building.

• Maintain Smooth Flow - Arrange equipment so production follows the logical sequence of

operations without backtracking.

Example:

In a bottled water plant, empty bottles move from rinsing → filling → capping → labeling →

packaging in a straight sequence, avoiding crisscross paths.

• Utilize Space Effectively - Maximize both horizontal (floor) and vertical (height) space.

Example:

A warehouse installs overhead conveyor belts and tall storage racks to use the building’s height

instead of expanding floor space.

conditions.

Example:

In a welding shop, work tables are spaced to prevent crowding, proper ventilation removes

fumes, and safety shields protect workers’ eyes from sparks.

• Keep it Flexible - Make arrangements that can easily adapt to product or process changes.

Example:

A smartphone assembly plant uses movable workbenches and modular conveyor systems so the

layout can be quickly reconfigured when a new phone model is launched.

IV. Principles of Plant Layout

1. Overall Integration - All resources — men, materials, machinery, and supporting services —

must be arranged to work as one coordinated unit. This avoids delays, confusion, and

unnecessary handling.

Example:

In a food factory, the mixing, baking, cooling, packaging, and storage areas are positioned so that

materials move logically from one step to the next without extra handling. Quality control, maintenance,

and cleaning services are also placed strategically so they can support all areas without interfering with

operations.

2. Minimum Distance Moved - Equipment and workstations should be positioned close to each

other to reduce material travel time, lower handling costs, and speed up production.

Example:

In a furniture manufacturing plant, the wood-cutting section is placed right next to the assembly area

so cut pieces can be transferred immediately instead of being carried across the entire factory floor.
 3. Flow Principle - Arrange processes in the natural order of operations so work moves smoothly

from start to finish without backtracking, unnecessary detours, or congestion.

Example:

In a bakery, flour mixing comes first, then dough shaping, followed by baking, cooling, and

packaging — all arranged in that order so products don’t have to move backward at any stage.

4. Cubic Space Utilization - Use all available space — not just floor area but also vertical space

(above and below). This maximizes storage and process capacity without expanding the

building.

Example:

A warehouse installs overhead conveyor belts and tall storage racks, and even uses under-floor

ducts for utilities, making full use of the building’s cubic space.

5. Satisfaction and Safety - The layout should provide a comfortable, hazard-free work

environment, which improves employee morale and reduces accidents.

Example:

In a welding shop, workstations are spaced to prevent crowding, safety shields protect against

sparks, and ventilation systems remove harmful fumes while allowing enough natural light.

6. Flexibility - The layout should be adaptable to future changes, whether it’s new products,

increased production, or process modifications, without high costs or major disruptions.

Example:

A smartphone assembly plant uses movable work tables and modular conveyor systems so the

production line can be rearranged quickly when a new phone model is introduced.
 V. Seven Ways of Relating the Three Elements of Production

The Three Elements of Production:

• Men – Workers and their skills.

• Materials – Raw materials or parts to be processed.

• Machinery – Tools, equipment, or machines used in production.

Rule: At least one of these must move for production to happen — if all three remain stationary,

nothing gets produced.

1. Move the Material (Most common) - The material being worked on moves from one process

or machine to the next.

Example: In a bottling plant, empty bottles move along a conveyor through rinsing, filling, capping,

labeling, and packing machines.

2. Move the Man - The worker moves between different work areas or stations while materials and

machines stay in place.

Example: In a bakery, a baker moves between ovens to check, rotate, and remove bread.

3. Move the Machinery - Equipment is brought to the location of the material instead of moving

the material itself.

Example: A portable welding unit is rolled to a large steel tank that is too heavy to move.

4. Move Material and Man - The worker moves together with the material to perform operations

at various points.

Example: In a moving conveyor system for car assembly, a worker walks alongside the vehicle

installing parts.

5. Move Material and Machinery - Both the material and the required machinery/tools are moved

to the same location for work to be done.

rigs are brought to them.

6. Move Man and Machinery - The worker and their machine or equipment move together to

different work areas.

Example: In road paving, a construction crew moves with the asphalt paving machine along the

roadway.

7. Move Material, Man, and Machinery (Rare) - All three — materials, workers, and machines —

are moved together to a new location.

Example: In emergency field repairs, a mobile repair team brings both tools and spare parts to a remote

site to fix equipment.

VI. Classic Types of Layouts

1. Layout by Fixed Position - The product remains in a single location during the entire production

process, and all resources: workers, tools, and machinery — are brought to the product.

Example:

• Shipbuilding: The ship is constructed in a dock while welders, cranes, and materials are

moved to the site.

• Aircraft assembly: Large airplanes are built in one hangar; workers and specialized

equipment move to different sections of the plane to install parts.

• Large construction projects: Buildings, bridges, and dams are constructed at a fixed

location while workers and tools rotate to different work areas.

Best for:

o Very large, heavy, or fragile products that are hard to move.

o Custom-built items requiring special designs or specifications.

together in one area, regardless of the product being made. Materials move between these

process groups based on the production requirements.

Example:

• Metal fabrication plant: All drilling machines are in one department, all welding equipment in

another, and all painting tools in a separate area.

• Textile mill: Spinning machines are placed in one section, weaving looms in another, and dyeing

equipment in another.

Best for:

o Factories that produce a variety of products with different manufacturing steps.

o Intermittent demand or small-batch production where the production sequence changes

frequently.

3. Layout by Product (Line Production) - Workstations are arranged in the exact sequence of

the manufacturing process, and the product moves step-by-step from one workstation to the

next until it is completed.

Example:

• Automobile assembly line: Cars move along a conveyor belt from body assembly → painting

→ engine installation → final inspection.

• Cafeteria food preparation: Trays move from station to station — one worker adds rice, another

adds meat, another adds vegetables, and finally the tray is wrapped and served.

Best for:

o High-volume production of identical or standardized products.

o Steady, continuous demand where the same process is repeated for each product.