The document discusses various types of plant layouts including process layout, product layout, fixed position layout, and cellular manufacturing layout. It describes factors that influence plant layout design such as material handling costs, worker effectiveness, and safety. The objectives of a good plant layout are to provide production capacity, reduce costs, increase productivity, and improve safety. Methods for selecting and designing plant layouts include travel chart analysis and long distance analysis.
The document discusses Lean implementation at SasMos HET Technologies Pvt. Ltd., an Indian company that manufactures electrical harnesses and interconnects for aerospace and defense industries. It provides an overview of the company's history, quality standards followed, and plans for growth and expansion. The document also reviews several research papers on applying Lean principles in manufacturing environments through tools like value stream mapping, standard work, and visual controls to reduce waste and improve productivity, quality, and throughput.
The document discusses facility layout and describes different types of layouts. It begins by defining facility layout as the allocation of space and arrangement of equipment to minimize operating costs. The objectives of a good layout are then outlined, such as reducing costs, improving efficiency, and increasing productivity. Key factors that influence layout decisions are also identified, including materials, products, workers, and machinery. The main types of layouts - process, product, and combination - are then described and their advantages and disadvantages compared. Specific examples of process and product layouts are provided.
This document provides an introduction to operations management. It discusses plant location factors and types of plant layouts, including product layout, process layout, and combination layout. It also covers network analysis tools like PERT and CPM. Additionally, it describes different types of production systems such as intermittent production (job production and batch production) and continuous production (mass production and process production). The key characteristics of each production system are defined.
Guidelines for Safe Pre-commissioning, Commissioning, and Operation of Proces...Karl Kolmetz
This seminar focuses on the core building blocks of the process unit equipment.
This program will emphasize process unit equipment fundamentals, safe
utilization of these fundamentals by operations and maintenance personnel, and
equipment troubleshooting techniques.
Refining Process Equipment Troubleshooting Karl Kolmetz
This document provides an overview of a training course on petroleum refining process equipment troubleshooting. The course aims to help operations teams understand fundamental process unit operations concepts in order to improve unit performance and on-stream time. It covers topics like distillation, furnaces, boilers, rotating equipment, piping, heat exchangers, and process control systems. Through lectures and case studies, participants will gain knowledge of troubleshooting principles, techniques, and best practices to identify and resolve issues in refineries and petrochemical plants. The course is intended for personnel involved in plant operations, maintenance, engineering, and technical services.
Advanced Relief Valve and Process Flare Systems TrainingKarl Kolmetz
This document provides information about an advanced training course on pressure relieving and flaring systems. The course aims to develop key concepts and techniques for optimizing these systems. It will cover topics such as flare headers, relief valves, knock out drums, flares, and safety guidelines. The target audience includes operations, engineering, and maintenance personnel who are involved in decision making for processing plants. Attendees will gain an in-depth overview of flaring systems and learn about equipment design, operations, environmental concerns, and troubleshooting techniques.
Advanced Training for Pressure Relieving and Flaring SystemsKarl Kolmetz
Each company needs to have people trained in key areas of safety. These
include;
1. Hazard Analysis
2. Relief Valve Design
3. Reliving Cases Design
4. Flare System Design
This seminar focuses on the core building blocks of the relieving and flaring
process systems, equipment and economics. This program will emphasize the
process unit operation fundamentals, safe utilization of these fundamentals by
operations, engineering, maintenance and support personnel.
Natural gas operations considerations on process transients design and controlISA Interchange
This manuscript highlights tangible benefits deriving from the dynamic simulation and control of operational transients of natural gas processing plants. Relevant improvements in safety, controllability, operability, and flexibility are obtained not only within the traditional applications, i.e. plant start-up and shutdown, but also in certain fields apparently time-independent such as the feasibility studies of gas processing plant layout and the process design of processes. Specifically, this paper enhances the myopic steady-state approach and its main shortcomings with respect to the more detailed studies that take into consideration the non-steady state behaviors. A portion of a gas processing facility is considered as case study. Process transients, design, and control solutions apparently more appealing from a steady-state approach are compared to the corresponding dynamic simulation solutions.
The document discusses Lean implementation at SasMos HET Technologies Pvt. Ltd., an Indian company that manufactures electrical harnesses and interconnects for aerospace and defense industries. It provides an overview of the company's history, quality standards followed, and plans for growth and expansion. The document also reviews several research papers on applying Lean principles in manufacturing environments through tools like value stream mapping, standard work, and visual controls to reduce waste and improve productivity, quality, and throughput.
The document discusses facility layout and describes different types of layouts. It begins by defining facility layout as the allocation of space and arrangement of equipment to minimize operating costs. The objectives of a good layout are then outlined, such as reducing costs, improving efficiency, and increasing productivity. Key factors that influence layout decisions are also identified, including materials, products, workers, and machinery. The main types of layouts - process, product, and combination - are then described and their advantages and disadvantages compared. Specific examples of process and product layouts are provided.
This document provides an introduction to operations management. It discusses plant location factors and types of plant layouts, including product layout, process layout, and combination layout. It also covers network analysis tools like PERT and CPM. Additionally, it describes different types of production systems such as intermittent production (job production and batch production) and continuous production (mass production and process production). The key characteristics of each production system are defined.
Guidelines for Safe Pre-commissioning, Commissioning, and Operation of Proces...Karl Kolmetz
This seminar focuses on the core building blocks of the process unit equipment.
This program will emphasize process unit equipment fundamentals, safe
utilization of these fundamentals by operations and maintenance personnel, and
equipment troubleshooting techniques.
Refining Process Equipment Troubleshooting Karl Kolmetz
This document provides an overview of a training course on petroleum refining process equipment troubleshooting. The course aims to help operations teams understand fundamental process unit operations concepts in order to improve unit performance and on-stream time. It covers topics like distillation, furnaces, boilers, rotating equipment, piping, heat exchangers, and process control systems. Through lectures and case studies, participants will gain knowledge of troubleshooting principles, techniques, and best practices to identify and resolve issues in refineries and petrochemical plants. The course is intended for personnel involved in plant operations, maintenance, engineering, and technical services.
Advanced Relief Valve and Process Flare Systems TrainingKarl Kolmetz
This document provides information about an advanced training course on pressure relieving and flaring systems. The course aims to develop key concepts and techniques for optimizing these systems. It will cover topics such as flare headers, relief valves, knock out drums, flares, and safety guidelines. The target audience includes operations, engineering, and maintenance personnel who are involved in decision making for processing plants. Attendees will gain an in-depth overview of flaring systems and learn about equipment design, operations, environmental concerns, and troubleshooting techniques.
Advanced Training for Pressure Relieving and Flaring SystemsKarl Kolmetz
Each company needs to have people trained in key areas of safety. These
include;
1. Hazard Analysis
2. Relief Valve Design
3. Reliving Cases Design
4. Flare System Design
This seminar focuses on the core building blocks of the relieving and flaring
process systems, equipment and economics. This program will emphasize the
process unit operation fundamentals, safe utilization of these fundamentals by
operations, engineering, maintenance and support personnel.
Natural gas operations considerations on process transients design and controlISA Interchange
This manuscript highlights tangible benefits deriving from the dynamic simulation and control of operational transients of natural gas processing plants. Relevant improvements in safety, controllability, operability, and flexibility are obtained not only within the traditional applications, i.e. plant start-up and shutdown, but also in certain fields apparently time-independent such as the feasibility studies of gas processing plant layout and the process design of processes. Specifically, this paper enhances the myopic steady-state approach and its main shortcomings with respect to the more detailed studies that take into consideration the non-steady state behaviors. A portion of a gas processing facility is considered as case study. Process transients, design, and control solutions apparently more appealing from a steady-state approach are compared to the corresponding dynamic simulation solutions.
Optimizing Petroleum Refining FCC Unit Operations TrainingKarl Kolmetz
The success of every company depends of each employee's understanding of
the key business components. Employee training and development will unlock
the companies' profitability and reliability. When people, processes and
technology work together as a team developing practical solutions, companies
can maximize profitability and assets in a sustainable manner. Training and
development is an investment in future success - give yourself and your
employees the keys to success
This document discusses plant layout and location. It begins by outlining the learning outcomes, which include understanding different types of layouts and factors affecting plant layout and location. It then defines facility layout and discusses the scope and objectives of layout planning. The document describes four main types of layouts - process, product, grouping technology, and fixed position layouts - and notes their advantages and disadvantages. It also discusses re-layout and explains the reasons and symptoms for needing one. Finally, it covers issues to consider for facility location, such as proximity to customers, costs, infrastructure, and business climate.
Introduction to Pressure Relieving and Flaring Systems Training CourseKarl Kolmetz
Each company needs to have people trained in key areas of safety. These
include;
1. Hazard Analysis
2. Relieve Valve Design
3. Reliving Cases Design
4. Flare System Design
This seminar focuses on the core building blocks of the relieving and flaring
process systems, equipment and economics. This program will emphasize the
process unit operation fundamentals, safe utilization of these fundamentals by
operations, engineering, maintenance and support personnel.
The document discusses plant layout, which refers to the physical arrangement of machinery, equipment and facilities within a plant. It aims to optimize material flow and minimize costs. The key types of layouts mentioned are process, product, fixed position, cellular and combination layouts. Factors influencing layout decisions include the product, machinery, industry type, location and managerial policies. The objectives of a good layout are also outlined, such as minimizing transportation and material handling costs.
Bridging The Gap Between Innovation And CommercializationNAES Corporation
1) Next-generation biofuels have the potential to provide cleaner energy but commercializing new technologies poses financial risks.
2) Developing careful plant operations strategies can help mitigate these risks and bridge the gap between innovation and commercialization.
3) An experienced operator like NAES Corporation can implement best practices in plant operations to optimize performance, ensure regulatory compliance, and maximize profitability, helping projects secure financing and reducing risks for developers.
The document provides an overview of process safety, outlining key differences from occupational safety. It describes process safety as involving the prevention of unintentional chemical releases that can seriously impact plants and the environment. The ten pillars of compliance for process safety management are then defined, including safety management systems, aging equipment, competence, safety instrumented systems, overfill prevention, containment, emergency response plans, performance indicators, and safety leadership. Major accidents that resulted from failures in management of change are also discussed.
Construction productivity refers to the efficient use of resources like manpower, materials, and machinery to produce construction outputs. It is important because the construction industry accounts for 3-8% of GDP in most countries. Proper planning, such as developing an accurate work breakdown structure (WBS), is key to improving construction productivity. The WBS breaks down work into manageable tasks to aid in scheduling, cost estimating, and monitoring progress. Other factors like selecting appropriate tower cranes, managing subcontractors effectively, and employing prefabricated site assembly techniques can also positively impact productivity. Skilled labor plays an important role in productivity, so human resource planning and management is necessary to obtain the right mix of skilled and unskilled workers for
Advances in Ethylene Unit Pyrolysis Furnace Design and Optimization Training ...Karl Kolmetz
This course will guide the participates to develop key concepts and techniques
for the optimization of Ethylene Unit Pyrolysis Furnace Design and Optimization.
These key concepts can be utilized to make operating decisions that can improve
your unit’s performance.
Many aspects of fired heaters operations and management can be improved
including, energy utilization, product improvements, furnace tube life, and safety.
This cannot be achieved without first an understanding of basic fundamental
principles of design and operation. These principles need to be understood in
advance of operating and trouble shooting a process unit operation for the
manager or problem solving to be effective.
Designing Facility Layout and Effective Material Handling for a Ceramic Insul...IRJET Journal
This document discusses designing an effective facility layout and material handling system for a ceramic insulator plant. It begins with an abstract that introduces the focus on improving material movement within the plant by first studying the manufacturing process and then designing a new optimum layout. It then describes using the systematic layout planning (SLP) methodology, which involves three stages of analysis, search, and selection. In the analysis stage, inputs were collected, operations were charted, relationships between workstations were understood, and diagrams were created. Potential new layouts were developed using ALDEP software and considering practical limitations. The evaluation of different layout options aims to reduce material handling efforts.
This document provides an overview of plant layout and material handling. It begins with definitions and discusses the scope and principles of plant layout. The objectives and factors influencing plant layout are explained. Different types of layouts are classified and their advantages and disadvantages are outlined. The document also discusses layout planning tools and techniques, the layout design process, and manual and computerized layout design procedures. Heuristics for solving layout problems are introduced.
TAS Middle East believes owners focus on five criteria when selecting a central plant system: design, construction quality, operating performance, initial cost, and operating cost. TAS has invested in research to develop standardized, efficient central plant designs ranging from 400 to 8,000 tons to reduce costs. Their packaged central plant systems are pre-engineered in a controlled factory environment, which allows for reliable design, quality construction, and safer installation compared to field-constructed plants. Packaged systems also help manage initial costs by minimizing risks from change orders compared to customized field construction involving multiple suppliers. TAS guarantees operating efficiency and completion date through their standardized, pre-engineered designs and quality manufacturing processes.
The document provides an introduction to plastics processing methods. It discusses that plastics processing involves converting plastic raw materials into semi-finished or finished products through techniques like deformation of polymer melts, rubbers, solutions, and more. The main processing methods include injection molding, extrusion, blow molding, compression molding, and thermoforming. The selection of the right processing method depends on factors like the product design, material properties, production quantities, quality requirements, and costs. The document provides an overview of various common processing methods and their basic workings.
The document provides an overview of plastics processing methods. It defines plastics processing as converting plastic raw materials into semi-finished or finished products. It then classifies common primary and secondary processing methods and discusses their basic principles and limitations. Key primary methods include injection molding, extrusion, blow molding, compression molding, and transfer molding. The document also covers how factors like material properties, part design, costs, and quality requirements influence the selection of the appropriate processing method.
The document provides an introduction to plastics processing methods. It discusses that plastics processing involves converting plastic raw materials into semi-finished or finished products through techniques like deformation of polymer melts, rubbers, solutions, and more. The main processing methods include injection molding, extrusion, blow molding, compression molding, and thermoforming. The selection of the right processing method depends on factors like the product design, material properties, production quantities, quality requirements, and costs. The document provides an overview of various common processing methods and their basic workings.
Scale up of industrial microbial processes Shubham Vats
This document discusses the scale up of industrial microbial processes. It begins with an introduction to the importance of biotechnology and scale up. The key points are:
1. Scale up is increasing production size and involves transferring microbial fermentation processes developed at lab scale to large scale for commercial purposes.
2. There are typically two stages of scale up - a pilot plant (100-10,000L fermenters) to translate the lab process and a demonstration plant (10,000-100,000L fermenters) to validate the process for full scale.
3. Successful scale up requires considering factors like inoculum preparation, fermenter design, sterilization, oxygen supply, and foaming
This document discusses various maintenance policies and strategies. It describes different types of maintenance tasks including breakdown maintenance, planned maintenance (preventive maintenance, corrective maintenance, predictive maintenance, condition-based maintenance, and reliability-centered maintenance). Preventive maintenance aims to eliminate breakdowns and deviations from optimal operating conditions. Predictive maintenance uses equipment operating data to optimize plant operations. Condition-based maintenance techniques include vibration monitoring, thermography, tribology, and electrical motor analysis. The document also covers lubrication methods like hydrostatic, hydrodynamic, boundary, and extreme pressure lubrication. Automatic lubrication systems include single line parallel, dual line parallel, single line progressive, mist lubrication, and multi-port direct lubrication systems.
ARC Advisory Group's 2014 European Industry Forum in the Netherlands included this interesting presentation from Willem Hazenberg of Stork on control system migration.
Facility layout and design aims to optimize the arrangement of equipment, materials, and personnel within a facility. Key considerations for layout include minimizing materials handling costs, reducing bottlenecks, and improving workflow efficiency. Common layout types include flow-line, process, fixed position, group technology, and cellular manufacturing layouts. Proper analysis of production requirements, material flows, and interdepartmental relationships is necessary to evaluate alternative layouts and select the optimal design.
The document discusses renewing the practice of process control engineering in the hydrocarbon processing industry (HPI). It argues that a key issue has been a lack of a standardized method for quantifying the financial value and performance of process control systems. The author proposes that the purpose of process control tools and technologies should be to optimize plant operations for maximum expected profit. This requires identifying process variables that affect profits, determining their optimal setpoints based on risk/reward tradeoffs, and controlling operations tightly at these setpoints. Adopting this standardized method would allow practitioners to properly evaluate and justify instrumentation, set operating conditions correctly, and strengthen plant performance.
The document summarizes a study on determining the optimal disassembly sequence of a cell phone to minimize the number of workstations and idle times. Data on disassembling 25 parts of a Samsung cell phone by 3 workers was analyzed using a sequencing algorithm in operations research. The analysis found the total estimated time was 154 minutes, with idle times of 9, 15 and 13 minutes for each worker respectively. This allows placing workers to minimize idle times in a disassembly line.
Zodiac Signs and Food Preferences_ What Your Sign Says About Your Tastemy Pandit
Know what your zodiac sign says about your taste in food! Explore how the 12 zodiac signs influence your culinary preferences with insights from MyPandit. Dive into astrology and flavors!
Optimizing Petroleum Refining FCC Unit Operations TrainingKarl Kolmetz
The success of every company depends of each employee's understanding of
the key business components. Employee training and development will unlock
the companies' profitability and reliability. When people, processes and
technology work together as a team developing practical solutions, companies
can maximize profitability and assets in a sustainable manner. Training and
development is an investment in future success - give yourself and your
employees the keys to success
This document discusses plant layout and location. It begins by outlining the learning outcomes, which include understanding different types of layouts and factors affecting plant layout and location. It then defines facility layout and discusses the scope and objectives of layout planning. The document describes four main types of layouts - process, product, grouping technology, and fixed position layouts - and notes their advantages and disadvantages. It also discusses re-layout and explains the reasons and symptoms for needing one. Finally, it covers issues to consider for facility location, such as proximity to customers, costs, infrastructure, and business climate.
Introduction to Pressure Relieving and Flaring Systems Training CourseKarl Kolmetz
Each company needs to have people trained in key areas of safety. These
include;
1. Hazard Analysis
2. Relieve Valve Design
3. Reliving Cases Design
4. Flare System Design
This seminar focuses on the core building blocks of the relieving and flaring
process systems, equipment and economics. This program will emphasize the
process unit operation fundamentals, safe utilization of these fundamentals by
operations, engineering, maintenance and support personnel.
The document discusses plant layout, which refers to the physical arrangement of machinery, equipment and facilities within a plant. It aims to optimize material flow and minimize costs. The key types of layouts mentioned are process, product, fixed position, cellular and combination layouts. Factors influencing layout decisions include the product, machinery, industry type, location and managerial policies. The objectives of a good layout are also outlined, such as minimizing transportation and material handling costs.
Bridging The Gap Between Innovation And CommercializationNAES Corporation
1) Next-generation biofuels have the potential to provide cleaner energy but commercializing new technologies poses financial risks.
2) Developing careful plant operations strategies can help mitigate these risks and bridge the gap between innovation and commercialization.
3) An experienced operator like NAES Corporation can implement best practices in plant operations to optimize performance, ensure regulatory compliance, and maximize profitability, helping projects secure financing and reducing risks for developers.
The document provides an overview of process safety, outlining key differences from occupational safety. It describes process safety as involving the prevention of unintentional chemical releases that can seriously impact plants and the environment. The ten pillars of compliance for process safety management are then defined, including safety management systems, aging equipment, competence, safety instrumented systems, overfill prevention, containment, emergency response plans, performance indicators, and safety leadership. Major accidents that resulted from failures in management of change are also discussed.
Construction productivity refers to the efficient use of resources like manpower, materials, and machinery to produce construction outputs. It is important because the construction industry accounts for 3-8% of GDP in most countries. Proper planning, such as developing an accurate work breakdown structure (WBS), is key to improving construction productivity. The WBS breaks down work into manageable tasks to aid in scheduling, cost estimating, and monitoring progress. Other factors like selecting appropriate tower cranes, managing subcontractors effectively, and employing prefabricated site assembly techniques can also positively impact productivity. Skilled labor plays an important role in productivity, so human resource planning and management is necessary to obtain the right mix of skilled and unskilled workers for
Advances in Ethylene Unit Pyrolysis Furnace Design and Optimization Training ...Karl Kolmetz
This course will guide the participates to develop key concepts and techniques
for the optimization of Ethylene Unit Pyrolysis Furnace Design and Optimization.
These key concepts can be utilized to make operating decisions that can improve
your unit’s performance.
Many aspects of fired heaters operations and management can be improved
including, energy utilization, product improvements, furnace tube life, and safety.
This cannot be achieved without first an understanding of basic fundamental
principles of design and operation. These principles need to be understood in
advance of operating and trouble shooting a process unit operation for the
manager or problem solving to be effective.
Designing Facility Layout and Effective Material Handling for a Ceramic Insul...IRJET Journal
This document discusses designing an effective facility layout and material handling system for a ceramic insulator plant. It begins with an abstract that introduces the focus on improving material movement within the plant by first studying the manufacturing process and then designing a new optimum layout. It then describes using the systematic layout planning (SLP) methodology, which involves three stages of analysis, search, and selection. In the analysis stage, inputs were collected, operations were charted, relationships between workstations were understood, and diagrams were created. Potential new layouts were developed using ALDEP software and considering practical limitations. The evaluation of different layout options aims to reduce material handling efforts.
This document provides an overview of plant layout and material handling. It begins with definitions and discusses the scope and principles of plant layout. The objectives and factors influencing plant layout are explained. Different types of layouts are classified and their advantages and disadvantages are outlined. The document also discusses layout planning tools and techniques, the layout design process, and manual and computerized layout design procedures. Heuristics for solving layout problems are introduced.
TAS Middle East believes owners focus on five criteria when selecting a central plant system: design, construction quality, operating performance, initial cost, and operating cost. TAS has invested in research to develop standardized, efficient central plant designs ranging from 400 to 8,000 tons to reduce costs. Their packaged central plant systems are pre-engineered in a controlled factory environment, which allows for reliable design, quality construction, and safer installation compared to field-constructed plants. Packaged systems also help manage initial costs by minimizing risks from change orders compared to customized field construction involving multiple suppliers. TAS guarantees operating efficiency and completion date through their standardized, pre-engineered designs and quality manufacturing processes.
The document provides an introduction to plastics processing methods. It discusses that plastics processing involves converting plastic raw materials into semi-finished or finished products through techniques like deformation of polymer melts, rubbers, solutions, and more. The main processing methods include injection molding, extrusion, blow molding, compression molding, and thermoforming. The selection of the right processing method depends on factors like the product design, material properties, production quantities, quality requirements, and costs. The document provides an overview of various common processing methods and their basic workings.
The document provides an overview of plastics processing methods. It defines plastics processing as converting plastic raw materials into semi-finished or finished products. It then classifies common primary and secondary processing methods and discusses their basic principles and limitations. Key primary methods include injection molding, extrusion, blow molding, compression molding, and transfer molding. The document also covers how factors like material properties, part design, costs, and quality requirements influence the selection of the appropriate processing method.
The document provides an introduction to plastics processing methods. It discusses that plastics processing involves converting plastic raw materials into semi-finished or finished products through techniques like deformation of polymer melts, rubbers, solutions, and more. The main processing methods include injection molding, extrusion, blow molding, compression molding, and thermoforming. The selection of the right processing method depends on factors like the product design, material properties, production quantities, quality requirements, and costs. The document provides an overview of various common processing methods and their basic workings.
Scale up of industrial microbial processes Shubham Vats
This document discusses the scale up of industrial microbial processes. It begins with an introduction to the importance of biotechnology and scale up. The key points are:
1. Scale up is increasing production size and involves transferring microbial fermentation processes developed at lab scale to large scale for commercial purposes.
2. There are typically two stages of scale up - a pilot plant (100-10,000L fermenters) to translate the lab process and a demonstration plant (10,000-100,000L fermenters) to validate the process for full scale.
3. Successful scale up requires considering factors like inoculum preparation, fermenter design, sterilization, oxygen supply, and foaming
This document discusses various maintenance policies and strategies. It describes different types of maintenance tasks including breakdown maintenance, planned maintenance (preventive maintenance, corrective maintenance, predictive maintenance, condition-based maintenance, and reliability-centered maintenance). Preventive maintenance aims to eliminate breakdowns and deviations from optimal operating conditions. Predictive maintenance uses equipment operating data to optimize plant operations. Condition-based maintenance techniques include vibration monitoring, thermography, tribology, and electrical motor analysis. The document also covers lubrication methods like hydrostatic, hydrodynamic, boundary, and extreme pressure lubrication. Automatic lubrication systems include single line parallel, dual line parallel, single line progressive, mist lubrication, and multi-port direct lubrication systems.
ARC Advisory Group's 2014 European Industry Forum in the Netherlands included this interesting presentation from Willem Hazenberg of Stork on control system migration.
Facility layout and design aims to optimize the arrangement of equipment, materials, and personnel within a facility. Key considerations for layout include minimizing materials handling costs, reducing bottlenecks, and improving workflow efficiency. Common layout types include flow-line, process, fixed position, group technology, and cellular manufacturing layouts. Proper analysis of production requirements, material flows, and interdepartmental relationships is necessary to evaluate alternative layouts and select the optimal design.
The document discusses renewing the practice of process control engineering in the hydrocarbon processing industry (HPI). It argues that a key issue has been a lack of a standardized method for quantifying the financial value and performance of process control systems. The author proposes that the purpose of process control tools and technologies should be to optimize plant operations for maximum expected profit. This requires identifying process variables that affect profits, determining their optimal setpoints based on risk/reward tradeoffs, and controlling operations tightly at these setpoints. Adopting this standardized method would allow practitioners to properly evaluate and justify instrumentation, set operating conditions correctly, and strengthen plant performance.
The document summarizes a study on determining the optimal disassembly sequence of a cell phone to minimize the number of workstations and idle times. Data on disassembling 25 parts of a Samsung cell phone by 3 workers was analyzed using a sequencing algorithm in operations research. The analysis found the total estimated time was 154 minutes, with idle times of 9, 15 and 13 minutes for each worker respectively. This allows placing workers to minimize idle times in a disassembly line.
Zodiac Signs and Food Preferences_ What Your Sign Says About Your Tastemy Pandit
Know what your zodiac sign says about your taste in food! Explore how the 12 zodiac signs influence your culinary preferences with insights from MyPandit. Dive into astrology and flavors!
The Genesis of BriansClub.cm Famous Dark WEb PlatformSabaaSudozai
BriansClub.cm, a famous platform on the dark web, has become one of the most infamous carding marketplaces, specializing in the sale of stolen credit card data.
Easily Verify Compliance and Security with Binance KYCAny kyc Account
Use our simple KYC verification guide to make sure your Binance account is safe and compliant. Discover the fundamentals, appreciate the significance of KYC, and trade on one of the biggest cryptocurrency exchanges with confidence.
Brian Fitzsimmons on the Business Strategy and Content Flywheel of Barstool S...Neil Horowitz
On episode 272 of the Digital and Social Media Sports Podcast, Neil chatted with Brian Fitzsimmons, Director of Licensing and Business Development for Barstool Sports.
What follows is a collection of snippets from the podcast. To hear the full interview and more, check out the podcast on all podcast platforms and at www.dsmsports.net
Part 2 Deep Dive: Navigating the 2024 Slowdownjeffkluth1
Introduction
The global retail industry has weathered numerous storms, with the financial crisis of 2008 serving as a poignant reminder of the sector's resilience and adaptability. However, as we navigate the complex landscape of 2024, retailers face a unique set of challenges that demand innovative strategies and a fundamental shift in mindset. This white paper contrasts the impact of the 2008 recession on the retail sector with the current headwinds retailers are grappling with, while offering a comprehensive roadmap for success in this new paradigm.
Anny Serafina Love - Letter of Recommendation by Kellen Harkins, MS.AnnySerafinaLove
This letter, written by Kellen Harkins, Course Director at Full Sail University, commends Anny Love's exemplary performance in the Video Sharing Platforms class. It highlights her dedication, willingness to challenge herself, and exceptional skills in production, editing, and marketing across various video platforms like YouTube, TikTok, and Instagram.
The APCO Geopolitical Radar - Q3 2024 The Global Operating Environment for Bu...APCO
The Radar reflects input from APCO’s teams located around the world. It distils a host of interconnected events and trends into insights to inform operational and strategic decisions. Issues covered in this edition include:
3 Simple Steps To Buy Verified Payoneer Account In 2024SEOSMMEARTH
Buy Verified Payoneer Account: Quick and Secure Way to Receive Payments
Buy Verified Payoneer Account With 100% secure documents, [ USA, UK, CA ]. Are you looking for a reliable and safe way to receive payments online? Then you need buy verified Payoneer account ! Payoneer is a global payment platform that allows businesses and individuals to send and receive money in over 200 countries.
If You Want To More Information just Contact Now:
Skype: SEOSMMEARTH
Telegram: @seosmmearth
Gmail: seosmmearth@gmail.com
Top mailing list providers in the USA.pptxJeremyPeirce1
Discover the top mailing list providers in the USA, offering targeted lists, segmentation, and analytics to optimize your marketing campaigns and drive engagement.
How to Implement a Strategy: Transform Your Strategy with BSC Designer's Comp...Aleksey Savkin
The Strategy Implementation System offers a structured approach to translating stakeholder needs into actionable strategies using high-level and low-level scorecards. It involves stakeholder analysis, strategy decomposition, adoption of strategic frameworks like Balanced Scorecard or OKR, and alignment of goals, initiatives, and KPIs.
Key Components:
- Stakeholder Analysis
- Strategy Decomposition
- Adoption of Business Frameworks
- Goal Setting
- Initiatives and Action Plans
- KPIs and Performance Metrics
- Learning and Adaptation
- Alignment and Cascading of Scorecards
Benefits:
- Systematic strategy formulation and execution.
- Framework flexibility and automation.
- Enhanced alignment and strategic focus across the organization.
Building Your Employer Brand with Social MediaLuanWise
Presented at The Global HR Summit, 6th June 2024
In this keynote, Luan Wise will provide invaluable insights to elevate your employer brand on social media platforms including LinkedIn, Facebook, Instagram, X (formerly Twitter) and TikTok. You'll learn how compelling content can authentically showcase your company culture, values, and employee experiences to support your talent acquisition and retention objectives. Additionally, you'll understand the power of employee advocacy to amplify reach and engagement – helping to position your organization as an employer of choice in today's competitive talent landscape.
Taurus Zodiac Sign: Unveiling the Traits, Dates, and Horoscope Insights of th...my Pandit
Dive into the steadfast world of the Taurus Zodiac Sign. Discover the grounded, stable, and logical nature of Taurus individuals, and explore their key personality traits, important dates, and horoscope insights. Learn how the determination and patience of the Taurus sign make them the rock-steady achievers and anchors of the zodiac.
2. Chapter10 2
Plant Layout
Plant Layout
This Technical Measures Document refers to Plant Layout.
Other relevant Technical Measures Documents are:
•Design Codes - Plant
•Design Codes – Pipe work
•Plant Modification / Change procedures
•Maintenance procedures
When a new plant is erected The question of placement of
machinery at different places,the location of the
store,Plating shop,painting shop is very important.
A good deal of expertise is used by management to secure a
proper layout for new or existing plant.
3. Chapter10 3
Plant Layout
Meaning,Definition & scope
A plant Layout refers to the arrangement of machinery &
other industrial facilities such as receiving & shipping
departments,Employer amenities for achieving quickest and
smoothest production at least cost
The subject of plant layout not only covers the initial
layout,but encompasses improvement in ,or revision of
existing layout
A more simple definition is given by Knowles & Thomson
they say the plant layout involves
“Planning & arrangement of machinery & other industrial
facilities & services for the first time in completely new plant
The improvement of layout already in use ,in order to
introduce new methods
4. Chapter10 4
Objectives of good
Plant Layout
Provide enough Production Capacity
Reduce material handling cost
Reduce hazards to personnel
Increase employee moral
Reduce accidents
Utilize available space
Provide ease of production
Provide ease of maintenance
Provide ease of supervision
Improve productivity
Allow high machine utilization
5. Chapter10 5
Factors Influencing
Plant Layout
General principles
Plant layout is often a compromise between a number of
factors such as:
•The need to keep distances for transfer of materials between
plant/storage units to a minimum to reduce costs and risks;
•The geographical limitations of the site;
•Interaction with existing or planned facilities on site such as
existing roadways, drainage and utilities routings;
•Interaction with other plants on site;
•The need for plant operability and maintainability;
•The need to locate hazardous materials facilities as far as
possible from site boundaries and people living in the local
neighborhood;
6. Chapter10 6
Factors Influencing
Plant Layout
•The need to prevent confinement where release of
flammable substances may occur;
•The need to provide access for emergency services;
•The need to provide emergency escape routes for on-site
personnel;
•The need to provide acceptable working conditions for
operators.
The most important factors of plant layout as far as safety
aspects are concerned are those to:
•Prevent, limit and/or mitigate escalation of adjacent events
(domino);
•Ensure safety within on-site occupied buildings;
•Control access of unauthorized personnel;
7. Chapter10 7
Factors Influencing
Plant Layout
•Facilitate access for emergency services.
In determining plant layout designers should consider the
factors in outlined in the following sections.
Inherent (Essential) safety
The major principle in Inherent Safety is to remove the
hazard altogether. The best method to achieve this is to
reduce the inventory of hazardous substances such that a
major hazard is no longer presented. However, this is not
often readily achievable and by definition no COMAH
facility will have done so. Other possible methods to achieve
an Inherently Safer design are:
8. Chapter10 8
Factors Influencing
Plant Layout
•Intensification to reduce inventories;
•Substitution of hazardous substances by less hazardous
alternatives;
•Attenuation to reduce hazardous process conditions i.e.
temperature, pressure;
•Simpler systems/processes to reduce potential loss of
containment or possibility of errors causing a hazardous
event;
•Fail-safe design e.g. valve position on failure.
Plant layout considerations to achieve Inherent Safety are
mainly those concerned with domino effects (see below).
9. Chapter10 9
Factors Influencing
Plant Layout
The Dow / Mond Indices
These hazard indices are useful for evaluating processes or
projects, ranking them against existing facilities, and
assigning incident classifications. They provides a
comparative measure of the overall risk of fire and explosion
of a process, and are useful tools in the plant layout
development stage since they enable objective spacing
distances to be taken into account at all stages.
The methodology for undertaking a rapid ranking method
that is based on the Dow / Mond index is detailed in ILO,
Major Hazard Control: A practical manual, 1988.
Although these are useful rule-of thumb methodologies for
first consideration of plant layout, they do not replace risk
assessment.
10. Chapter10 10
Factors Influencing
Plant Layout
The distances derived between plant units using these
systems are based upon engineering judgment and some
degree of experience rather than any detailed analysis.
Domino effects
Hazard assessment of site layout is critical to ensure
consequences of loss of containment and chances of
escalation are minimized. Domino may be by fire, explosion
(pressure wave and missiles) or toxic gas cloud causing loss
of control of operations in another location.
Fire
A fire can spread in four ways:
•Direct burning (including running liquid fires);
•Convection;
•Radiation;
11. Chapter10 11
Factors Influencing
Plant Layout
•Conduction.
The spread of fire from its origin to other parts of the
premises can be prevented by vertical and horizontal
compartmentation using fire-resisting walls and floors.
Further information may be found in BS 5908 : 1990.
Consideration should also be given to the spread of
flammable material via drains, ducts and ventilation systems.
Delayed ignition following a release may result in spread of
flames through such systems via dispersed flammable gases
and vapors.
Protection against domino effects by convection, conduction
and radiation can be achieved by inherent safety principles
12. Chapter10 12
Principles of
Plant Layout
The principle of Minimum travel
The principle of sequence
The principle of usage
The principle of compactness
The principle of safety
The principle of satisfaction
The principle of minimum investment
13. Chapter10 13
Types of
Plant Layout
Process lay out,job lay out,functional lay out
Product layout or line processing lay out
Fixed position lay out
Cellular Manufacturing lay out
Combinational or hybrid layout
16. Chapter10 16
Types of
Plant Layout
PROCESS LAYOUT IN A
FUNCTIONAL APPROACH:
X X X
Machine machine
group 1 group 2
Movement of
product
Machine
group 3
Machine
group ‘n’
‘Random’ movement takes
place as products are
moved according to process
requirements.
There is no ‘flow’ as such -
each product will have its
particular process
requirements and will
move to each machine
group as when required
17. Chapter10 17
Types of
Plant Layout
FIXED POSITION LAYOUT
Product
Operators perform processes
on the ‘fixed’ product. There
may be more than one
operation performed on the
product at the same time.
Each operation adds to the
product until it is completed
18. Chapter10 18
Types of Plant Layout
Fixed position layout
Air Craft Assembly
Raw material
Machine &
Equipment
Labor
Finished
product
Air craft
19. Chapter10 19
Types of
Plant Layout
PROCESS LAYOUT IN A
PRODUCT FAMILY CELL
X X X X X X X
group 1 group 2 group 3 group 4
24. Chapter10 24
Special arrangements for particular type
of plants (JOB PROCESSES )
1.Investment in automation is for general purpose
technology rather than product specific investment.
2.Many different products are run throughout the plant and
materials handling has to be modified and adjusted to suit
many different products and types
3.Detailed planning will evolve around sequencing
requirements for each product, capacities for each work
centre and order priorities: because of this scheduling is
relatively complicated, in comparison to repetitive ‘line’
manufacture.
25. Chapter10 25
Special arrangements for particular type
of plants (BATCH PROCESSES )
1. Automation, especially for lower volumes
of batch manufacturing, tends to be general
purpose, rather than dedicated to a particular
product whose volume does not demand product-
specific investment in automation.
2. Scheduling is complicated and has to be
completely reviewed on a regular, on-going basis -
this applies to new products, ‘one-off’s’ that may
be required, together with relatively high volume,
standard products: all of these types will need to
be scheduled.
26. Chapter10 26
Special arrangements for particular type
of plants (BATCH PROCESSES )
3.Operators have to be able to perform a number
of functions - this is obviously true of ‘job’ types
processes. In batch, though, this flexibility is
crucial in that it will allow operators to move to
various workstations as required.
4. Where automation is being used, set-up
time should be short: the ideal set up times is
quick enough to accommodate run lengths of just
one unit, switching over to other models and
volumes as, and when, required.
27. Chapter10 27
Special arrangements for particular type
of plants (Line PROCESSES )
1. Process times should be fast - which is critical
in order to satisfy delivery speed requirements
2. There should be simplification in
production planning and control and the tasks
themselves should also be simplified for each
workstation.
3. There should be small amounts of work in
process: in fact, work in process (which, in
accounting terms, can be viewed as an asset) is a
liability to the company which can ruin cash-flow
and stifle quick response to market requirements
28. Chapter10 28
Special arrangements for particular type
of plants (Line PROCESSES )
4. Materials handling between stations should be
placed as closely as possible to each other.
5.Materials flow and control are critical : Just-in
Time lends itself most noticeably to ‘line’ or very
high volume batch production. Stock-outs have to
be avoided although, at the same time, excess
stock is a waste and a liability, rather than an asset
(materials can be viewed as an asset on the
balance sheet which is misleading and alien to
world class manufacturing.
29. Chapter10 29
Special arrangements for particular type
of plants (Continuous PROCESSES )
1.The volume of a product is very high and the
process is dedicated to making, typically, only one
product.
2.Huge investment in dedicated plant is often
required.
3.Much automation tends to be evident and labour
input is one of ‘policing’ rather than being highly
skilled as an integral input to the overall process.
30. Chapter10 30
Importance of layout
1.Economics of handling
2. Effective use of available area
3. Minimization of product delay
4.Improved Quality control
5.Minimum Equipment investment
6.Avoidance of bottleneck
7.Better production control
8.Improve employee moral
31. Chapter10 31
Layout Planning
Steps in layout Planning and design
Product
Analyst Process
Equipment
Direct labor
Building design
Plant layout
Indirect
labor
Facilities
Expected Volume
Of Production
Phase1
Phase2
32. Chapter10 32
Layout Tools and techniques
Various tools & techniques are available for
planning layouts
The most common is to use two dimensional
template.
Templates are patterns which consists of a thin
plate of wood or metal which serves as a gauge or
guide in mechanical work.A plant layout template
is a scaled representation of a physical object in a
layout
33. Chapter10 33
Criteria for selection &
Design layouts
Facility layouts must integrate work center
location ,office,computer facilities.Two of major
criteria for selecting and designing and layout are:
Material handling cost: These costs are
minimized by using mechanized handling of
materials
Worker effectiveness:Good layouts provide
workers with satisfying job & permit them to
work effectively at highest skill levels
34. Chapter10 34
Criteria for selection &
Design layouts
The various methods used for selecting the best
layout are
Travel Chart method
The travel chart which is also known as from to chart is
helpful in analyzing overall flow of material
It shows number of moves made between the
department& identifies most active department
The solution is provided by trial & error method &
which attempts to minimize non adjacent flow by centrally
locating the Active department
35. Chapter10 35
Criteria for selection &
Design layouts
Travel Chart method(Procedure)
Step1 Determine which departments have the most
frequent links with other department This can be done in
totaling entries in each row and column
Step2 Try to locate Most active department in the central
position in the outline
Step3 by trial & error method locate other departments
so that non adjacent flows are minimized
Step4 If all the non adjacent moves are eliminated ,the
solution is complete.
36. Chapter10 36
Criteria for selection &
Design layouts
A
F
D
B
C
E
7
4 6
5
3
10
2
7
8
4
10
Departments marked as A,B,C……..Moves marked as 1,2,3…
37. Chapter10 37
Criteria for selection &
Design layouts
The various methods used for selecting the best layout are
Long Distance Analysis method
When designing a new assembly plant or retrofitting an
existing plant, it is critical to determine where all the
materials will be received, stored and used.
Variable width and color material flow diagrams created
by Factory FLOW are especially useful for presenting this
information.
Factory FLOW automatically finds the shortest route
from origin to destination along an aisle network for all
materials/parts involved.
38. Chapter10 38
Criteria for selection &
Design layouts
Once routes are determined. Factory FLOW draws the
routes, outputs travel distances, times, and costs to report
files and scales the thickness of flow lines according to the
flow intensity of each part.
The input data required by Factory FLOW is the kind of
basic from-to information typically already available in a
database or spreadsheet.
Among other output reports, Factory FLOW generates
detailed reports on manpower requirements by equipment
type. Factory FLOW's from-to chart shows the flow
intensities and distances between ail from-to locations
analyzed.
39. Chapter10 39
Criteria for selection &
Design layouts
The distance intensity chart plots each part's move
intensity against its travel distance on an X-Y graph.
With the help of powerful personal computer systems
and user friendly graphical environments, material flow
studies of over 10,000 parts within facilities of over 5
million square feet can be accomplished by a novice user
in under an hour.
40. Chapter10 40
Systematic Layout Planning
Systematic Layout Planning(SLP) method is used in
some production system such as service system,where the
amount of material that flows between department may not
be critical for developing a good facility layout.
This method develops a chart known as “Relationship
chart”or “Richard Muther’s half Matrix.
Important ratings are indicated by a,e,i,o,u,x known as
“nearness code”
a- absolutely necessary,e-essential
I-important,o-o.k
U-unimportant
X-undesirable
41. Chapter10 41
Systematic Layout Planning
Assembly
Fabrication
Job Planning
Pattern Shop
Shipping
Testing
Wiring
o
u
o
u
e
i
e
u
u
e
a
Richard Muther’s half Matrix
42. Chapter10 42
Systematic Layout Planning
Richard Muther’s half Matrix
Job
Planning
Fabrication Assembly
Shipping
Pattern Shop Wiring
Testing
1
2
3 4
5
6
7
Job A
Job B
Job A
Job B