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
