Free layout examples; a wide variety of industrial layouts, within different facility types.

Principles of plant layout and design will apply widely.

Free Examples of plant layout drawing

Principles of plant layout and design will apply to most industrial situations. The layout
examples in this chapter encompass a wide variety of facility characteristics, and of
process characteristics.
No example is likely to fit your exact needs, because building, dimensions, and process
vary so much. Utilize these examples together with basic principles, found in Amazon
books by Jack Greene,
Industrial Engineering: Theory, Practice & Application
ISBN-13: 978-1482301793
https://www.createspace.com/4150791

Plant Layout and Facility Planning

Edition Two

ISBN-13: 978-1491222393
https://www.createspace.com/4381172

Jack Greene

843-422-1298

Jackson Productivity Research, Inc.

http://jacksonproductivity.com
jack@jacksonproductivity.com

Index of sample drawings

A. Single story building
1. Straight line flow
2. U shaped flow
3. In a building designed for distribution, adapt to another use
4. To place permanent equipment and avoid later interference
5. Distribution center
6. Cellular flow
7. Modular work flow
8. Clean room for sterile or aseptic liquids
9. Clean room for devices, semiconductors
10. Primary Conveyor, fed from other conveyors, from above
11. One product, with several components, not conveyorized
12.Cell and modular elements in the same layout
13. Electronics fab and test
14. Integrated plastics product
15. From dedicated cells into modular packaging lines
16. Model and prototype shops, pilot plant

B. Multi-story building
1. Multi-story building, utilize vertical flow
2. Multi-story building, two elevators
3. Multi-story building, one elevator
4. Multi-story building, services on another floor
C. Buildings set on plot plans
1. Outside storage, liquid and dry bulk materials
2. Outside storage, large components and product handling
3. Constrained by adjoining property
4. Unconstrained by adjoining property
5. Details of dock characteristics
See http://jacksonproductivity.com.draw.pdf for these same examples of plant layout and
design within particular building types. On line they are easier to read and print out, and I
am able to add to them.

Straight Line Flow

Flow is essentially straight line, although it adapts to building design.

Receiving
Dock

In Quality

Raw Materials

Main Product

Admin offices

Sub-assembly

Sub-assembly

Sub-assembly

Sub-assembly

Sub-assembly

Sub-assembly

Operating offices

Support

Building amenities

Maintenance

Package
Shipping
Dock

U Shaped Flow
In and out of the same dock

Receiving and
Shipping dock

Raw Materials Stores

Finished Goods Stores

Support

Operating offices

Admin offices

Building amenities

Maintenance

Example of a building designed for distribution, adapted to another use

Many of these facilities are empty and available. They are characterized by multiple docks and doors.
Take advantage of the docks to improve process flow for your operation. Close up the unused doors and docks.

Admin offices

Building amenities

Maintenance

Product line A
In

Out

In
Support

Operating offices

Product Line B
Out

Product Line C

Out

in

To place permanent equipment and avoid later interference

Position fixed, hard to relocate, functions and equipment along a wall that will not be used for later expansion.
Place equipment outside as well as inside exterior walls. Later, expand along other walls.

Outside,
Hoppers

Inside,
Liquid waste disposal

Bins

Rest rooms

Tanks

Fire sprinkler risers

Solid waste

In power

Water tower

In gas

Dust
collection

Water softening
Water purification

Dumpster
Blow-out walls
Pallets
Plating, degreasing
Motor control centers
Process using mezzanine

Distribution center arrangement

A DC will have many docks, and many storage racks. Straight line or U-shaped flow will depend on dock location.
Reduce travel by careful location of materials in racks; warehousing programs will help.

Shipping docks

Receiving docks

Order accumulation

Picking

Offices
Storage racks

Support

Building amenities
and
Maintenance
Possible Docks

Cellular flow
An approach in which manufacturing work centers (cells) have the total capabilities needed to
produce an item or group of similar items.

Saw one

Coat one

Saw two

CNC mill 2

Lathe one

CNC mill 1

Lathe two

EDM two

Mill one

EDM one

Cell Two for product B

Cell One for Product A

Saw three

Receiving

Lathe three

CNC mill 3

Mill three

EDM three

Shipping
Cell Three for Product C

Modular work flow

Modular work centers consist of similar equipment or capabilities, and products move among multiple work centers
before they are completed.
With or without conveyor lines.

Saw module
for all
products

Products
A, B, C

Lathes module
for all
products

are routed
to the module
if work is to
Mill module
for all
products

be performed

EDM module
for all
products

there; on a
dedicated or a
multi-product
CNC mill module
for all
products

machine.
Different

Coating module
for all
products

product,
different flow.

Clean room for sterile or aseptic liquids

Characterized by material pass thrus, employee change rooms, sterilization.
With or without conveyor lines.

Container

In line sterilize

Wash

Fill line one, HEPA filters

Out conveyor

Spatial or physical separation

Area, bulk

In line sterilize

or

Fill line two, HEPA filters

Inspection
Out conveyor

Spatial or physical separation

In Line

In line sterilize

Fill line three, HEPA filters

Out conveyor

Fill line four

and / or
Sterilizing

Spatial or physical separation

In line sterilize

To

and / or
Packaging

Out conveyor

Spatial or physical separation

People,
Material,
Equipment

Lower
Room Class

Pass
thru

Pass
thru
Most rigorous room class
Employee
Gowning
Area

Rigorous room class

People

Equipment
Sterilization
Area

Bulk
Material
Sterilize

Equipment

Material

10

Clean room for devices, semiconductors

Characterized by material pass thrus, employee change rooms, superior HVAC
Usually involves conveyors

Parts

Assembly line one

Out conveyor

To

Sub
Wash

Spatial or physical separation

Inspection

Assembly
Area, bulk

Assembly line two

Out conveyor

and / or

and
or

Spatial or physical separation

Sterilizing

Parts Prep
In Line

Assembly line three

Out conveyor

Spatial or physical separation

Assembly line four

and / or
Packaging

Out conveyor

Spatial or physical separation

People,
Material
Equipment

Lower
Room Class

Pass
thru

Pass
thru
Most rigorous room class
Employee
Gowning
Area

Rigorous room class

People

Equipment
Clean up
Area

Bulk
Material
Entry

Equipment

Material

11

A 10

Primary Conveyor, fed from other conveyors, from above

Detail is driven by the product components and sequence of steps and assembly.

Maintenance

Finished goods
Shipping dock

Support
Cartoning

Cartons to FG

Building

Receiving dock
Feed from
semi direct
to conveyor

amenities
Sub-assembly B

First process
Steps

Operating offices
Sub-assembly A

Admin offices

On- line operations

12

A 11

One product, with several components, not conveyorized

This example shows kitting, sub assemblies, final assembly, test, pack, ship in a U shape..

Shipping and receiving docks

Pack

Final test

Raw materials
Kitting
Final assembly

Sub-assembly

Operating offices
Support
Maintenance

Design and
Engineering

Building amenities

13

Admin offices

A 12

Cell and modular elements in the same layout

Not an uncommon arrangement, especially when equipment has accumulated over time.
With or without conveyor lines.

Product One

R&D

Support
Modular metal working

Engineering,

Assembly
Cell

Assembly
Cell

Raw Materials
Plating

Design

Assembly
Cell

Assembly
Cell

Product Two
Modular plastics working
Operations

Admin

Assembly
Cell

Assembly
Cell

Assembly
Cell

Assembly
Cell

Finished Goods

Docks
Building Amenities

14

Model
Shop

A 13

Electronics fab and test

Integrated manufacture; subassembly, fab, assembly, and test in clean rooms.
Because parts are small, materials handling moves many parts at one time.

Maintenance

Building Amenities

Raw materials stores

Admin

Test

Subassembly

Assembly

Operations
Packing

Support

Design and

Clean Rooms, special purpose equipment

Engineering

Assembly

15

Receiving,
Shipping
Docks

A 14

Integrated plastics product

Molding, sub-assembly, tumbling barrels for smoothing, assembly, through distribution

DC
In
Docks

Distribution Center
Racks

DC
Out
Docks

Pick and Pack

Ramps, this DC was built without fill for cost purposes.

DC administration
To DC
Assembly

Raw material stores

Next sequence

Sub-assembly

Plant admin and operation offices

Building amenities

Plant
Receiving dock

Plastics Injection Molding

16

A 15

From dedicated cells into modular packaging lines

A typical layout; in this example specialized product filling flows into general purpose inspection and packing.

Line 1, a certain container

style and size
Line 2, another container
style and size
Line 3, another container
style and size
Line 4, another container
style and size

Heat treat,

Inspect,

Package,

multiple

multiple

multiple

general

general

general

purpose

purpose

purpose

machines

machines

machines

Line 5, another container

style and size

Parts wash, general purpose

Raw materials

Finished Goods

Admin and operations offices

Support and building amenities
Receiving and shipping docks

17

Labels

A 16

Model and prototype shops, pilot plant

These operations will have both specialized and general purpose machines. They will be called on
to produce any product, with as little subcontracted as possible. If associated with production
operations, these shops should be able to match or simulate all production equipment.

Specialty shops will depend on the charter of the organization, and may contain one or more of the following:
Metal working, classic
Wood working
Plumbing
Metal working, Cad Cam
Plastics working, layup
Hydraulics
Electrical
Composites working, layup
Instrumentation
Electronic
Welding
Fill
Sheet metal, cut and form
Plating
Package
Sandblast
Paint
Label
Chemistry
Multi-layer printing
Exact measurement
Assembly
Signs, printing
Optics
Design and engineering offices, Cad Cam equipment
Model and prototype shops are not the place for Just in Time material delivery, no matter what .
the black belts say. The predictability of work, the horizon, is not clear enough to allow lead times..
Inventory should keep on hand a wide variety of materials, because the shop will be called on to
produce and modify on short notice. Reliable local sources if any can allow a smaller inventory.
Layout of machines should concentrate on fitting them into the space with regard to safety and
material handling, because the flow of materials will likely be unpredictable and irregular .
If possible leave ample access space for material, and for new equipment and technology.

18

Multi-story building, utilize vertical flow

Where possible, utilize vertical flow to move product.
A practical handling system is necessary to place material on the upper floor to start.

Upper Level

1)

Product
Weigh and
Compound

Lower Level

Product
Mix, drop
to lower

1)

Sub-assembly or
2)

Product
Package

Product
Fill
Fed from
Above

Product assembly

Parts preparation, feed to lower

2)

via chute, dumbwaiter, slide.

Fed from above

Test, pack

Raw materials, where they can be

placed to the upper floor readily.

Product assembly, fill, package

3)

3)
Feed to lower via chute, dumbwaiter
or slide.

19

Fed from above

Multi-story building, two elevators

Except for the fact that material must use an elevator, flow can be productive.
Many options are possible.

Elevator

Elevator

Many options are possible.

1) An elevator can be used to receive, or
to ship, or to do both.

1)

2) The floor can serve one department or

product line, or multiple entities.
3) The floor can receive from, or feed,
another location.

1) Flow can U-shaped, in and out the same

elevator.

2)
2) Flow can be straight line, essentially
from one elevator to the other.
3) Or both, for
different products.
Elevator

Elevator

20

Multi-story building, one elevator

The area near the elevator will be busy, and should be kept open.
Careful layout will be useful to maintain productivity.

Elevator

Elevator

1) The elevator will be used to receive and ship.

Flow can only be U-shaped,
in and out of the same
elevator, unless vertical feed .
is possible through chute,
slide, or dumbwaiter

2) Flow can only be U-shaped, in and out

of the same elevator, unless vertical feed .
is possible through chute, slide, or
dumbwaiter.

3) The floor can serve one department or

product line, or multiple entities. Use
will depend on size and ingenuity of
layout applied.

Cross flow is possible.

21

Stairs

Multi-story building, services on another floor

The operations floor can be effectively laid out because services and amenities are on another floor.
In this example, services are located on only a partial floor, under manufacturing.
Upper Level, Operations
Lower Level
Stairs
Plant
Plant
Product B
Maintenance
Utilities
Manufacturing
No lower
level, this
Mechanical
section
Maintenance

Stores,
Docks
Stockroom

Food
Service

Stairs

Stairs

Elevator

Elevator
Medical
Product A
Manufacturing
Quality offices and labs

R&D
Stairs

Stairs

22

Production
Engineering

Outside storage, liquid and dry bulk materials

Outside storage is often practical. Outside containers do not take up plant space, and they can
be filled by truck easily.
Be sure that permanent containers do not block future plant expansion
Road Access
Liquid
Tank

Waste
Tank

One corner of the production building.

Access

Extended dock,
at the level
of the plant

Recycle
Pallets

Oil

Feed
Tank
Road

Recycle
Drums

Fuel

Plant
Access

and recycle
locations.

Dumpster

23

Dry
Mat'l
Hopper

Outside storage, large components and product handling

Large weather-proof components sometimes can be kept outside.
Be sure that permanent containers do not block future plant expansion
Horizontal
racks for
long
components

One corner of the production building.

Horizontal
storage of tall
sections

Temporary
trailer

24

Constrained by adjoining property

Placement of permanent equipment is key when building expansion is blocked in some directions.
Locate permanent equipment along the sides that are already blocked.
Street

Street

Place permanent equipment along these walls.

Docks, utilities, plating, elevator and stairs, liquid waste disposal,
rest rooms, fire sprinkler risers, water treatment, motor control
centers, mezzanines

Available for
Expansion

Leave these walls available for expansion.

Available for expansion

25

Unconstrained by adjoining property

Placement of permanent equipment is key when building expansion is blocked in some directions.
Locate permanent equipment along the sides that are already blocked.

Available for expansion

Available for
Expansion

Initial building
Place permanent equipment along no
more than two walls, or centrally.
Probably locate docks first considering
street access, grade levels, appearance,
and distances. Then plan interior layouts
accordingly.

Available for expansion

26

Available for
Expansion