Chapter 5

CHPTER FIVE
Plant Layout and Plant (facility) Design
Contents To Be Covered
1. Basics Of Plant Layout
2. Study of Plant Layout;
3. Ergonomics and
4. Industrial Safety
Basics Of Plant Layout
Plant layout is defined as a plan of, or the act of planning an
optimum arrangement of industrial facilities, including
 personnel,  materials handling equipment and
 operating equipment,  all other supporting services along
 storage space, with the design of the best structure to
• Facility contain these facilities
Is Something created to serve a particular function
to start a new product, And when
to change the product the market demand changes,
design, the plant, the product, the building
to reduce the cost; become obsolete,
accidents occur frequently,
the working environment is poor.
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Study of Plant Layout
• The objective of plant layout study is to
• ensure effective space utilization,
• minimize the cost of material handling (internal transports),
• foresee future developments of the plant according to a rational master
plan,
• improve workers convenience as well as safety and create job
satisfaction, and
• avoid unnecessary capital investment.
Types of Layout
Product Layout Fixed-Position Layout
Cellular manufacturing layout Combination or Hybrid layout
Product Layout: In this type of layout, only one product or one type of
product is produced in a given area.
The product must be standardized and manufactured in large quantities
in order to justify the product layout.
Process Layout
• Process Layout: Similar equipment and similar

operations are grouped together in the
process or functional layout. It is particularly
useful where low volume is required.
Fixed-Position Layout
Fixed-Position Layout: In this type of layout, the material or major
component remains in a fixed location, and tools, machinery, men as well
as other pieces of material are brought to this location. Typical examples
are ship building, construction industries, aircraft building and bench work
exercises. This type of layout is not frequently used in industrial
enterprises. For this reason we are not going to look into its advantage and
disadvantages.
Cellular manufacturing layout
Ergonomics
It is Derived from two Greek words:
Ergo” meaning work “Nomoics” meaning natural laws
• Ergonomics is an applied science concerned with the design of
workplaces, tools, and tasks that match the physiological, anatomical,
and psychological characteristics and capabilities of the worker.”
Vern Putz-Anderson
• “The Goal of ergonomics is to ‘fit the job to the person,’ rather than
making the person fit the job.” Ergotech
• “If it hurts when you are doing something, don’t do it.” Bill Black
Ergonomics
Ideally, ergonomics:
Makes the job safer by preventing injury and illness Makes the job easier by adjusting the
job to the worker
Makes the job more pleasant by reducing physical and mental stress and
Saves money $$$
Ergonomic Factors
There are Two Categories of Ergonomic Factors
–Environmental 2. Physical
Environmental factors may affect:
Hearing, Vision, General comfort and health
 Some examples of ergonomic environmental problems that effect the
work area are:
– Sick Building Syndrome
– Excessive noise
– Improper lighting
– Temperature extremes
Physical factors
Physical stressors place pressure or stress on parts of the body: Joints,
muscles, nerves, tendons, bones. Sometimes these injuries are referred
to as “Cumulative Trauma Disorders” (CTDs) or “Repetitive Strain
Injuries” (RSIs)
Cumulative = occurring gradually over a period of weeks, months, or
years
Trauma = bodily injury to nerves, tissues, tendons, or joints
Disorders = physical ailments or abnormal conditions
Examples of Cumulative Trauma Disorders include:
 Carpal Tunnel Syndrome
 Epicondylitis
 Tenosynovitis
 Bursitis
Three Main Ergonomic Principles
1. Work activities should permit worker to adopt

several different healthy and safe postures.
2. Muscle forces should be done by the largest
appropriate muscle groups available
3. Work activities should be performed with joints at
about mid-point of their (esp. head, trunk,)
Industrial Safety
• Industry; is the place where raw materials and customer demand is
accepted is as well as goods and services produced shipped or hand
over to the customer.
• Safety ; the condition of being protected from or unlikely to cause
danger, risk, or injury or denoting something designed to prevent
injury or damager: a safety barrier a safety helmet
• “Safety is the state of being “safe” (from French sauf), the condition
of being protected against physical, social, spiritual, financial,
political, emotional, occupational, psychological, educational or other
types or consequences of failure, damage, error, accidents, harm or
any other event which could be considered non-desirable. Safety can
also be defined to be the control of recognized hazards to achieve an
acceptable level of risk. This can take the form of being protected
from the event or from exposure to something that causes health or
economical losses. It can include protection of people or of
possessions.”
Safety
“Safety means keeping yourself and others free from harm or dangerous
hazards. It means taking care from any injury and accident. It also
means to avoid accidents by being careful with what you are doing.
• Keeping safety is different according different professions the way of
keeping safety in hospital is different from safety that takes care in
industry..
Industrial hazards:
It can be defined as any condition produced by
industries that may cause injury or death to
personal or loss of product or property.
Electric
al
Mecha Pollutio
nical n
Biologic HAZAR
al DS
Chemic
al
Physica
l
; Industrial safety
is keeping the working place or the company from any
industrial hazards that may cause injury or death to personal or
loss of product or property.
That is take any preventive action before the hazards are occur
and take decisive corrective action unfortunately if the
accident is happen.

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CHPTER FIVE

Plant Layout and Plant (facility) Design

• Process Layout: Similar equipment and similar

1. Work activities should permit worker to adopt

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