Plant design involves planning the physical requirements of a manufacturing facility including product design, process design, capital acquisition, sales planning, and plant location selection. Key factors in selecting a plant location include proximity to markets and raw materials, transportation infrastructure, availability of utilities, labor costs, and environmental impact. Location analysis methodologies help evaluate potential sites, such as using weighted factors to rate locations or calculating the center of gravity based on existing facility distances and production volumes.
This document discusses key aspects in designing food processing plants, including plant layout and feasibility studies. It covers:
1) Distinct design considerations for food industries due to seasonal raw materials, stringent hygiene, and social cost-benefit analysis.
2) Components of a feasibility study including market potential, technical requirements, and financial projections.
3) Key factors in plant layout including flow patterns, equipment arrangement to minimize costs, and secondary considerations like climate and waste disposal.
This document discusses plant layout and provides definitions, characteristics, and types of plant layouts. It defines plant layout as the physical arrangement of equipment and facilities within a plant. The main types of plant layouts discussed are functional layout, line layout, static product layout, group layout, and combination layout. Functional layout groups similar machines together by process. Line layout arranges machines in a linear sequence of operations. Group layout groups equipment for similar parts into cells. The document also covers factors that influence layout choices and tools used for layout planning.
Plant location decisions are strategic, long term and non-repetitive in nature.
Without sound and careful location planning in the beginning itself, the new plant may pose continuous operating disadvantages.
Location decisions are affected by many factors, both internal and external to the organization’s operations
Internal factors include the technology used, the capacity, the financial position, and the work force required.
External factors include the economic, political and social conditions in the various localities.
This document discusses different types of dryers and drying processes. It describes spray dryers, oven dryers, freeze dryers, vacuum dryers, rotary dryers, and drum dryers. For each type of dryer it provides a definition, describes the drying process, and lists some common applications. The key information provided includes how each dryer works by removing moisture from materials using methods like applying heat, reducing pressure, or rotating materials to facilitate drying.
The document discusses plant layout, which refers to the arrangement of physical facilities and allocation of space for various production activities and personnel within a plant. It describes different types of layouts including functional, line, static product, group, and combination layouts. Key factors to consider for effective layouts are the building, personnel needs, machinery, materials, movement requirements, waiting times, and ability to accommodate services and future changes. The layout impacts efficiency, costs, safety, and ultimately organizational profits.
This presentation related to molecular diffusion of molecules in gases and liquids. Also includes inter-phase mass transfer and various theories related to it like two film theory, penetration theory and surface renewal theory.
This document discusses downstream processing in biotechnology. It defines downstream processing as the steps occurring after fermentation to recover and purify products. The key unit operations in downstream processing include cell removal, concentration, and purification techniques like chromatography. The level of purification required depends on the intended use and market for the product. Common downstream processing techniques are outlined along with considerations for designing efficient bioseparation processes.
The document discusses unit operations in food processing. It defines a unit operation as a processing step where raw materials enter and a desired product exits. Important unit operations include heat transfer, drying, evaporation, separation processes, size reduction, mixing and shaping. Examples of specific unit operations used to produce many foods are provided, such as pasteurization, freezing, spray drying, centrifuging, grinding, blending and extrusion. The document focuses on freezing operations like plate, immersion, blast and fluidized bed freezing.
This document discusses key aspects in designing food processing plants, including plant layout and feasibility studies. It covers:
1) Distinct design considerations for food industries due to seasonal raw materials, stringent hygiene, and social cost-benefit analysis.
2) Components of a feasibility study including market potential, technical requirements, and financial projections.
3) Key factors in plant layout including flow patterns, equipment arrangement to minimize costs, and secondary considerations like climate and waste disposal.
This document discusses plant layout and provides definitions, characteristics, and types of plant layouts. It defines plant layout as the physical arrangement of equipment and facilities within a plant. The main types of plant layouts discussed are functional layout, line layout, static product layout, group layout, and combination layout. Functional layout groups similar machines together by process. Line layout arranges machines in a linear sequence of operations. Group layout groups equipment for similar parts into cells. The document also covers factors that influence layout choices and tools used for layout planning.
Plant location decisions are strategic, long term and non-repetitive in nature.
Without sound and careful location planning in the beginning itself, the new plant may pose continuous operating disadvantages.
Location decisions are affected by many factors, both internal and external to the organization’s operations
Internal factors include the technology used, the capacity, the financial position, and the work force required.
External factors include the economic, political and social conditions in the various localities.
This document discusses different types of dryers and drying processes. It describes spray dryers, oven dryers, freeze dryers, vacuum dryers, rotary dryers, and drum dryers. For each type of dryer it provides a definition, describes the drying process, and lists some common applications. The key information provided includes how each dryer works by removing moisture from materials using methods like applying heat, reducing pressure, or rotating materials to facilitate drying.
The document discusses plant layout, which refers to the arrangement of physical facilities and allocation of space for various production activities and personnel within a plant. It describes different types of layouts including functional, line, static product, group, and combination layouts. Key factors to consider for effective layouts are the building, personnel needs, machinery, materials, movement requirements, waiting times, and ability to accommodate services and future changes. The layout impacts efficiency, costs, safety, and ultimately organizational profits.
This presentation related to molecular diffusion of molecules in gases and liquids. Also includes inter-phase mass transfer and various theories related to it like two film theory, penetration theory and surface renewal theory.
This document discusses downstream processing in biotechnology. It defines downstream processing as the steps occurring after fermentation to recover and purify products. The key unit operations in downstream processing include cell removal, concentration, and purification techniques like chromatography. The level of purification required depends on the intended use and market for the product. Common downstream processing techniques are outlined along with considerations for designing efficient bioseparation processes.
The document discusses unit operations in food processing. It defines a unit operation as a processing step where raw materials enter and a desired product exits. Important unit operations include heat transfer, drying, evaporation, separation processes, size reduction, mixing and shaping. Examples of specific unit operations used to produce many foods are provided, such as pasteurization, freezing, spray drying, centrifuging, grinding, blending and extrusion. The document focuses on freezing operations like plate, immersion, blast and fluidized bed freezing.
Prepared by
Er. B. SREENIVASULA REDDY
Assistant Professor (Food Engineering)
College of Food Science and Technology
Chinnarangapuram, Pulivendula – 516390
YSR (KADAPA) District, Andhra Pradesh
The document describes the Bollman extractor, which is a type of basket extractor used for leaching solids. It consists of a vertical chamber with a series of perforated baskets attached to a chain conveyor. Dry solids are added to the top baskets and leached by a solvent solution as the baskets descend counter-currently. The wet solids are removed at the bottom and the recovered solvent is evaporated and stripped to extract oil. The Bollman extractor provides continuous counter-current contact between solids and solvent for effective leaching.
Introduction to plant design economicsSunita Jobli
The document discusses different approaches to conceptual process design for a chemical process. It describes the onion model heuristic approach, which designs the process sequentially from the inner layers outward - starting with the reactor design and building outward by adding separation/recycle systems, heat exchanger networks, and utilities. This approach keeps the process structure "irreducible" by only adding units if economically justified. In contrast, the hierarchical approach classifies design decisions into 5 levels and generates/assesses alternatives at each level. The mathematical programming approach formulates the entire design problem into equations to optimize the "superstructure" and reduce it to an optimal feasible solution.
size reduction,laws involved in size reduction ,application & millsM Swetha
size reduction basic principles,laws&machanism of size reduction with all mills .I gave a note on size separation .it is very useful for the teaching staff &students of B.pharmacy
This document discusses different types of conveyors used for transporting solid materials, including belt conveyors, bucket conveyors, screw conveyors, and pneumatic conveyors. It provides details on the basic principles and components of each type. Belt conveyors transport material horizontally or inclined on a motor-driven rotating belt. Bucket conveyors use motor-driven chains carrying buckets to move material vertically or horizontally. Screw conveyors enclose material in a trough that is moved along by a rotating screw. Pneumatic conveyors use high velocity air to fluidize and transport powder or granular materials through pipes.
Agitation and Mixing are two important unit operations used in industries such as Impellers agitators are widely used to circulate the liquid through the vessel in which the dispersion of liquids and gases into other liquids like mixing of stiff paste, elastomers and dry solids powders takes place.
Materials handling involves the movement, storage, and protection of materials. It aims to lower costs by reducing unit handling costs, cycle times, and damages while improving productivity, quality, and storage capacity. The selection of materials handling equipment depends on factors like the production problem, volume, layout, material properties, and capabilities/safety of personnel. Common equipment includes conveyors, cranes, industrial trucks, and auxiliary equipment. The design of handling systems is based on whether they are equipment-oriented, material-oriented, method-oriented, or function-oriented.
Material handling (Production Technology) naturesbuilder
The document discusses material handling in manufacturing organizations. Material handling involves the movement of raw materials, work-in-process inventory, and finished goods within and between facilities. It accounts for 15-20% of total product costs. The objectives of material handling are to minimize costs and delays, improve safety, prevent damage to materials, and reduce in-process inventory levels. Common material handling activities include unloading, storage, packaging, and shipping. The document also describes various material handling equipment like conveyors, cranes, forklifts, and principles for selecting appropriate equipment.
The document discusses different types of plant layouts. It describes four main types: product layout, process layout, fixed position layout, and combined layout. Product layout involves materials moving sequentially between workstations with minimal backtracking. Process layout groups similar machines together. Fixed position layout fixes major production facilities in one location and brings other facilities to them. Combined layout is used when multiple products are produced in batches using a mix of layout types. The objectives of layout include minimizing costs and space while improving efficiency, safety, and productivity.
Mass transfer is the movement of mass from one location to another, such as between phases or components. It occurs through various processes like absorption, evaporation, drying, and distillation. Mass transfer involves both diffusive and convective transport mechanisms. Diffusion is the movement of molecules from a region of higher concentration to lower concentration down a concentration gradient via random molecular motion. Convection involves the bulk flow of a fluid carrying dissolved or suspended materials. Fick's first law describes the rate of diffusion, while Fick's second law describes how concentration changes over time at a given point for diffusion.
This document defines material handling and discusses various aspects of material handling systems. Material handling is defined as the movement, storage, protection and control of materials throughout the manufacturing and distribution process. The key objectives of material handling systems are to move materials safely, efficiently and at low cost. The document also discusses different types of material handling equipment like industrial trucks, automated guided vehicles, conveyors and cranes/hoists and their applications. It provides definitions for common terms and lists 10 principles for effective material handling systems design.
This document provides an overview of plant layout, including definitions, objectives, principles, and types of layouts. It defines plant layout as the arrangement of facilities including personnel, equipment, storage, and services. The objectives are to maximize profit and efficiency by arranging facilities optimally. Principles include minimizing distance moved, following the flow of processes, utilizing space effectively, and ensuring safety. Common types of layouts are product, process, and fixed position layouts.
This document discusses rheology, the study of fluid flow and deformation. It describes two categories of flow - Newtonian and non-Newtonian. Newtonian fluids have a linear relationship between shear stress and strain rate, while non-Newtonian fluids have non-linear or time-dependent relationships. Examples of non-Newtonian fluids include ketchup, which requires stress to flow out of the bottle, and solutions that become thinner or thicker with changes in shear rate. The document outlines different types of non-Newtonian behavior and explores concepts like thixotropy, where viscosity depends on time under shear.
Pharmaceutical Dryers. Dryers are used in a variety of industries, such as the food processing, pharmaceutical, paper, pollution control and agricultural sectors. ... Direct dryers convectively heat a product through direct contact with heated air, gas or a combusted gas product.
This document contains lecture slides from Dr. M. Subas Chandra Bose and Mrs. Sabarunisha Begum on the topic of mass transfer operations. It discusses various mass transfer concepts like diffusion, gas absorption principles, and vapor-liquid operations including distillation. The slides provide definitions and examples of different mass transfer processes and operations. They also describe concepts like the transfer unit, differential distillation, flash distillation, and continuous rectification in binary systems.
Unit operation in Food Processing. Preliminary Unit operation
Cleaning, sorting & Grading - aims, methods and applications
2. Size Reduction and Sieve Analysis
Theory of comminution; Calculation of energy required during size reduction. Crushing efficiency; Size reduction equipment; Size reduction of fibrous, dry and liquid foods; effects of size reduction on sensory characteristics and nutritive value of food
Sieving: Separation based on size (mesh size); types of screens; effectiveness of screens
3. Mixing
Mixing, Agitating, kneading, blending, homogenization and related equipment
4. Separation Processes
Principles of Filtration, Sedimentation, Crystallization and Distillation and equipment used
The document discusses material handling principles and concepts. It defines material handling as the art and science of moving, packing, and storing materials. The main objectives of material handling are to reduce the number of handlings and overall costs. Other objectives include lowering unit handling costs, reducing cycle times, improving safety, and increasing storage capacity. The document outlines several principles for efficient material handling, such as eliminating unnecessary handling, keeping materials moving, using simple flow patterns, and carrying payloads in both directions. It also discusses automation, life cycle costs, unit loads, and the benefits of optimized flow patterns for material handling systems.
The document discusses various topics related to drying of solids, including the classification of dryers, principles of drying, temperature patterns in dryers, heat transfer during drying, phase equilibria, and the drying curve. It describes different types of dryers such as adiabatic dryers, non-adiabatic dryers, and cross-circulation dryers. It also discusses factors that influence the drying process such as the nature of the solid, methods of contacting the solid and gas, and how drying occurs in three phases - initial, constant rate, and falling rate periods.
Drying is an essential process that involves transferring heat to remove moisture from wet products. Common drying methods include vacuum tray drying, freeze drying, rotary drum drying, spray drying, and pneumatic conveyor drying. Vacuum tray drying works by removing moisture through a vacuum, while spray drying uses nozzles to spray liquid droplets into a heated gas stream to evaporate water. Freeze drying preserves biological activity by freezing and then applying a vacuum to directly sublimate ice. Rotary drum dryers use a heated, rotating cylinder to dry materials, and pneumatic conveyor dryers suspend particles in a heated air stream to dry reasonably solid feeds.
Designing and Redesigning business process: Plant LocationMOHD AMAAN HASAN
The following is the small short and simple powerpoint presentation entitled "Designing and Redesigning business process: Plant Location" for the subject Small Business and Enterpreneurship falls under BBA course.
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.
Prepared by
Er. B. SREENIVASULA REDDY
Assistant Professor (Food Engineering)
College of Food Science and Technology
Chinnarangapuram, Pulivendula – 516390
YSR (KADAPA) District, Andhra Pradesh
The document describes the Bollman extractor, which is a type of basket extractor used for leaching solids. It consists of a vertical chamber with a series of perforated baskets attached to a chain conveyor. Dry solids are added to the top baskets and leached by a solvent solution as the baskets descend counter-currently. The wet solids are removed at the bottom and the recovered solvent is evaporated and stripped to extract oil. The Bollman extractor provides continuous counter-current contact between solids and solvent for effective leaching.
Introduction to plant design economicsSunita Jobli
The document discusses different approaches to conceptual process design for a chemical process. It describes the onion model heuristic approach, which designs the process sequentially from the inner layers outward - starting with the reactor design and building outward by adding separation/recycle systems, heat exchanger networks, and utilities. This approach keeps the process structure "irreducible" by only adding units if economically justified. In contrast, the hierarchical approach classifies design decisions into 5 levels and generates/assesses alternatives at each level. The mathematical programming approach formulates the entire design problem into equations to optimize the "superstructure" and reduce it to an optimal feasible solution.
size reduction,laws involved in size reduction ,application & millsM Swetha
size reduction basic principles,laws&machanism of size reduction with all mills .I gave a note on size separation .it is very useful for the teaching staff &students of B.pharmacy
This document discusses different types of conveyors used for transporting solid materials, including belt conveyors, bucket conveyors, screw conveyors, and pneumatic conveyors. It provides details on the basic principles and components of each type. Belt conveyors transport material horizontally or inclined on a motor-driven rotating belt. Bucket conveyors use motor-driven chains carrying buckets to move material vertically or horizontally. Screw conveyors enclose material in a trough that is moved along by a rotating screw. Pneumatic conveyors use high velocity air to fluidize and transport powder or granular materials through pipes.
Agitation and Mixing are two important unit operations used in industries such as Impellers agitators are widely used to circulate the liquid through the vessel in which the dispersion of liquids and gases into other liquids like mixing of stiff paste, elastomers and dry solids powders takes place.
Materials handling involves the movement, storage, and protection of materials. It aims to lower costs by reducing unit handling costs, cycle times, and damages while improving productivity, quality, and storage capacity. The selection of materials handling equipment depends on factors like the production problem, volume, layout, material properties, and capabilities/safety of personnel. Common equipment includes conveyors, cranes, industrial trucks, and auxiliary equipment. The design of handling systems is based on whether they are equipment-oriented, material-oriented, method-oriented, or function-oriented.
Material handling (Production Technology) naturesbuilder
The document discusses material handling in manufacturing organizations. Material handling involves the movement of raw materials, work-in-process inventory, and finished goods within and between facilities. It accounts for 15-20% of total product costs. The objectives of material handling are to minimize costs and delays, improve safety, prevent damage to materials, and reduce in-process inventory levels. Common material handling activities include unloading, storage, packaging, and shipping. The document also describes various material handling equipment like conveyors, cranes, forklifts, and principles for selecting appropriate equipment.
The document discusses different types of plant layouts. It describes four main types: product layout, process layout, fixed position layout, and combined layout. Product layout involves materials moving sequentially between workstations with minimal backtracking. Process layout groups similar machines together. Fixed position layout fixes major production facilities in one location and brings other facilities to them. Combined layout is used when multiple products are produced in batches using a mix of layout types. The objectives of layout include minimizing costs and space while improving efficiency, safety, and productivity.
Mass transfer is the movement of mass from one location to another, such as between phases or components. It occurs through various processes like absorption, evaporation, drying, and distillation. Mass transfer involves both diffusive and convective transport mechanisms. Diffusion is the movement of molecules from a region of higher concentration to lower concentration down a concentration gradient via random molecular motion. Convection involves the bulk flow of a fluid carrying dissolved or suspended materials. Fick's first law describes the rate of diffusion, while Fick's second law describes how concentration changes over time at a given point for diffusion.
This document defines material handling and discusses various aspects of material handling systems. Material handling is defined as the movement, storage, protection and control of materials throughout the manufacturing and distribution process. The key objectives of material handling systems are to move materials safely, efficiently and at low cost. The document also discusses different types of material handling equipment like industrial trucks, automated guided vehicles, conveyors and cranes/hoists and their applications. It provides definitions for common terms and lists 10 principles for effective material handling systems design.
This document provides an overview of plant layout, including definitions, objectives, principles, and types of layouts. It defines plant layout as the arrangement of facilities including personnel, equipment, storage, and services. The objectives are to maximize profit and efficiency by arranging facilities optimally. Principles include minimizing distance moved, following the flow of processes, utilizing space effectively, and ensuring safety. Common types of layouts are product, process, and fixed position layouts.
This document discusses rheology, the study of fluid flow and deformation. It describes two categories of flow - Newtonian and non-Newtonian. Newtonian fluids have a linear relationship between shear stress and strain rate, while non-Newtonian fluids have non-linear or time-dependent relationships. Examples of non-Newtonian fluids include ketchup, which requires stress to flow out of the bottle, and solutions that become thinner or thicker with changes in shear rate. The document outlines different types of non-Newtonian behavior and explores concepts like thixotropy, where viscosity depends on time under shear.
Pharmaceutical Dryers. Dryers are used in a variety of industries, such as the food processing, pharmaceutical, paper, pollution control and agricultural sectors. ... Direct dryers convectively heat a product through direct contact with heated air, gas or a combusted gas product.
This document contains lecture slides from Dr. M. Subas Chandra Bose and Mrs. Sabarunisha Begum on the topic of mass transfer operations. It discusses various mass transfer concepts like diffusion, gas absorption principles, and vapor-liquid operations including distillation. The slides provide definitions and examples of different mass transfer processes and operations. They also describe concepts like the transfer unit, differential distillation, flash distillation, and continuous rectification in binary systems.
Unit operation in Food Processing. Preliminary Unit operation
Cleaning, sorting & Grading - aims, methods and applications
2. Size Reduction and Sieve Analysis
Theory of comminution; Calculation of energy required during size reduction. Crushing efficiency; Size reduction equipment; Size reduction of fibrous, dry and liquid foods; effects of size reduction on sensory characteristics and nutritive value of food
Sieving: Separation based on size (mesh size); types of screens; effectiveness of screens
3. Mixing
Mixing, Agitating, kneading, blending, homogenization and related equipment
4. Separation Processes
Principles of Filtration, Sedimentation, Crystallization and Distillation and equipment used
The document discusses material handling principles and concepts. It defines material handling as the art and science of moving, packing, and storing materials. The main objectives of material handling are to reduce the number of handlings and overall costs. Other objectives include lowering unit handling costs, reducing cycle times, improving safety, and increasing storage capacity. The document outlines several principles for efficient material handling, such as eliminating unnecessary handling, keeping materials moving, using simple flow patterns, and carrying payloads in both directions. It also discusses automation, life cycle costs, unit loads, and the benefits of optimized flow patterns for material handling systems.
The document discusses various topics related to drying of solids, including the classification of dryers, principles of drying, temperature patterns in dryers, heat transfer during drying, phase equilibria, and the drying curve. It describes different types of dryers such as adiabatic dryers, non-adiabatic dryers, and cross-circulation dryers. It also discusses factors that influence the drying process such as the nature of the solid, methods of contacting the solid and gas, and how drying occurs in three phases - initial, constant rate, and falling rate periods.
Drying is an essential process that involves transferring heat to remove moisture from wet products. Common drying methods include vacuum tray drying, freeze drying, rotary drum drying, spray drying, and pneumatic conveyor drying. Vacuum tray drying works by removing moisture through a vacuum, while spray drying uses nozzles to spray liquid droplets into a heated gas stream to evaporate water. Freeze drying preserves biological activity by freezing and then applying a vacuum to directly sublimate ice. Rotary drum dryers use a heated, rotating cylinder to dry materials, and pneumatic conveyor dryers suspend particles in a heated air stream to dry reasonably solid feeds.
Designing and Redesigning business process: Plant LocationMOHD AMAAN HASAN
The following is the small short and simple powerpoint presentation entitled "Designing and Redesigning business process: Plant Location" for the subject Small Business and Enterpreneurship falls under BBA course.
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.
The document discusses various aspects of setting up a manufacturing plant, including plant capacity, location, size, product mix, factory design, machinery and equipment, plant layout, and factors affecting plant layout. It also covers network analysis, which is a technique used in project management to systematically plan, manage, and control projects to successful completion. Key terms related to network analysis and the steps involved in network analysis are defined.
Capacity planning involves establishing the maximum output rate that a facility can achieve. It includes determining how much capacity to install, when to increase capacity, and how much to increase it. Location analysis identifies the best geographic location for facilities based on factors like proximity to suppliers, customers, labor, and community considerations. Methods for evaluating capacity and location alternatives include decision trees, break-even analysis, and load-distance models. Capacity planning and location decisions impact operations strategy and are important across the organization.
Punjab technical University - scheme and syllabus of Masters in Business Administration (MBA) Batch 2012 onwards, course code MBA 202, production & operation Management. UNIT 1. ch. 2 facility location, ch. 3 production Design and development, ch 4 process selection- Job, project, batch mass & process types of production system.
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.
Site Selection, nature of the location, Factors affecting the location, Selection of the location, Importance of the plant location, choice of site for selection, Gov policies on decentralization, Industrial estates, Comparision of location, Plant layout, Principles of Plant Layout, Objective of Plant Layout, Flow pattern, Technique used in plant layout, Sample of different layout
This document provides an overview of manufacturing facility planning. It discusses the importance of facility planning, its objectives, and classification. The key steps in the facility planning process are also outlined. These include defining objectives, specifying activities, determining relationships between activities, establishing space requirements, generating and evaluating alternative plans, selecting and implementing a plan, and maintaining/adapting the plan over time. The target audience is 4th year students studying manufacturing facility planning.
The document discusses plant location and plant layout. It defines plant location as choosing a region and specific site for setting up a business or factory based on costs and benefits of alternative locations. Plant layout refers to arranging machines, work areas, and service areas within a factory for efficient manufacturing. The key types of layouts are functional/process, product/line, and stationary. The document also covers objectives, advantages, techniques, and features of good plant layouts.
The document discusses various aspects of process planning including product selection, design, standardization, modularization, make-or-buy decisions, capacity planning, process analysis using tools like flow charts and assembly charts. It explains that process planning begins with product selection which is a strategic decision involving other functions. Key elements of product design are discussed. Standardization and modularization are approaches to achieve variety and control costs. Make-or-buy decisions consider factors like cost, capacity and quality. Capacity planning determines production needs to meet demand. Process analysis and re-engineering help improve operations.
The document discusses different types of plant layouts including product layout, process layout, and fixed position layout. It provides details on each layout type such as their key characteristics, advantages, disadvantages, and when each layout is most suitable. It also covers principles of a good plant layout and factors to consider in site selection and plant location decisions.
1) The document discusses factors that govern plant location decisions, including availability of raw materials, markets, labor, transportation, and utilities.
2) It outlines qualitative and quantitative techniques used for optimal plant location, such as factor weighting systems, break-even analysis, and transportation models.
3) Examples are provided to illustrate cost-volume analysis and factor rating systems to evaluate multiple potential plant locations.
The document discusses facility location planning methods. It describes the load-distance method which selects locations that minimize total weighted loads moving in and out of a facility based on distance. Distances are expressed using grid coordinates on a map. Alternative is using time instead of distance.
It then discusses reasons for facility location selection such as business growth, market expansion, or lease expiration. Facility location planning helps reduce transportation costs and identify proximity to materials and transportation.
The document outlines factors to consider in facility location selection such as materials, markets, transportation, utilities, and labor availability. It also discusses township selection criteria and compares urban, rural, and suburban factory locations. Finally, it describes the factor rating technique for facility location evaluation.
Facility planning determines how a company's fixed assets support its objectives. It is an ongoing process that includes determining space needs, generating alternative facility designs, evaluating options, selecting a plan, implementing it, and adapting it over time. The steps are: 1) define objectives, 2) specify activities, 3) map interrelationships, 4) determine space needs, 5) generate alternatives, 6) evaluate alternatives, 7) select a plan, 8) implement, 9) maintain and adapt, and 10) redefine objectives if needed. Facility planning increases productivity and reduces costs by streamlining activities and incorporating safety and environmental measures.
Capacity planning involves determining a facility's maximum output rate. Location analysis identifies the best geographic location for a facility. The two processes are interrelated and involve assessing needs, developing alternatives, and evaluating options using tools like decision trees, factor ratings, and break-even analysis. Key location factors include proximity to customers, suppliers, labor, and transportation costs. Capacity planning tools help managers choose between alternatives like expanding capacity in large or small increments over time.
This document provides an overview of plant layout concepts and methods. It begins with definitions and objectives of plant layout. It then discusses different types of layouts including process, product, and combination layouts. Several factors that influence layout decisions are outlined, followed by principles and objectives of good layouts. Methods for layout planning and design procedures are presented, including manual techniques like travel chart and systematic layout planning as well as computerized heuristics like ALDEP, CORELAP, and CRAFT. Classification of layouts and evaluation methods are also summarized.
The document discusses various aspects of production including different types of production processes, the role of technology, and the job of a production manager. It describes mass production, flexible production, and customer-driven production. Production managers are responsible for planning production, determining facility layouts, implementing plans through inventory control and supplier selection, and controlling the production process.
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.
This document discusses plant location and layout. It defines plant location as choosing the region and site for a business or factory after analyzing costs and benefits of alternatives. Key factors in selecting a location include transportation, raw materials, labor, market access, and infrastructure. The document also defines plant layout as arranging production facilities to achieve efficient workflow. Types of layouts include product layout, process layout, and combined layout. Product layout arranges machines in sequence of operations. Process layout groups similar machines together. Location and layout are important strategic decisions that influence production costs.
Computer Applications in Power Systems 2023 SECOND.pdfhussenbelew
The document discusses real-time applications of computers in power systems. It describes how SCADA systems are used for monitoring, control, and management of electric power grids. Key functions of SCADA include data acquisition, remote control, supervision, historical data analysis, and various control applications specific to power generation, transmission, and distribution. Real-time monitoring and control allow for faster response to disturbances, optimized system operation, and more reliable power delivery.
The document discusses various aspects of power system reliability including adequacy, security, and stability. It defines adequacy as relating to having sufficient generation and transmission facilities to meet customer demand. Security pertains to how the system responds to disturbances like loss of generation or transmission. Stability refers to generators staying synchronized during disturbances. The document also discusses reliability assessment techniques like loss of load probability and expectation indices used to evaluate generation adequacy. Distribution reliability is assessed using indices that consider customer interruptions and outage times.
1) Research methodology involves systematically studying a problem and applying scientific processes to understand it. This may involve gathering new data or analyzing existing data.
2) There are various types of research including descriptive, analytical, applied, fundamental, quantitative, qualitative, conceptual, and empirical research. Research can also be one-time, longitudinal, diagnostic, exploratory, or experimental.
3) The scientific method relies on empirical evidence and objective consideration to formulate theories, make probabilistic predictions, and aim to solve problems through proper observation and experimentation. Research requires clearly defining the problem, designing the methodology, and justifying conclusions.
1) Water turbines are used to convert the kinetic and potential energy of falling water into mechanical energy for power generation.
2) There are two main types of water turbines - reaction turbines which operate submerged in water and impulse turbines which utilize the kinetic energy of a water jet.
3) Common types include the Francis turbine suited for medium heads, the Kaplan turbine for low heads and large flows, and the Pelton wheel impulse turbine for high heads.
Off grid electrical power systems can be single-source using solar, wind, hydro, or generators, or hybrid combining sources. Hybrid systems supply AC or DC power using conversion devices. Generated electricity is stored in batteries to provide power at night or without sun/wind. Rural electrification brings power to remote areas, allowing mechanization to increase farming productivity and reducing costs. It allows activities after dark like education, and improves safety, healthcare, and reduces isolation with telecoms.
The document discusses the components, sizing, and design of a solar photovoltaic (PV) system for a residence in Ethiopia. It describes measuring solar radiation, the major system components including solar panels, charge controller, inverter, batteries, and loads. It then sizes each component for the specific site based on energy demand calculations and equipment specifications. Components are selected, such as eight 180W solar panels, a 60A charge controller, 3000W inverter, and eight deep cycle batteries. A block diagram shows how all the parts connect and work together to power the home.
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Presentation of IEEE Slovenia CIS (Computational Intelligence Society) Chapte...University of Maribor
Slides from talk presenting:
Aleš Zamuda: Presentation of IEEE Slovenia CIS (Computational Intelligence Society) Chapter and Networking.
Presentation at IcETRAN 2024 session:
"Inter-Society Networking Panel GRSS/MTT-S/CIS
Panel Session: Promoting Connection and Cooperation"
IEEE Slovenia GRSS
IEEE Serbia and Montenegro MTT-S
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3-6 June 2024, Niš, Serbia
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TIME DIVISION MULTIPLEXING TECHNIQUE FOR COMMUNICATION SYSTEMHODECEDSIET
Time Division Multiplexing (TDM) is a method of transmitting multiple signals over a single communication channel by dividing the signal into many segments, each having a very short duration of time. These time slots are then allocated to different data streams, allowing multiple signals to share the same transmission medium efficiently. TDM is widely used in telecommunications and data communication systems.
### How TDM Works
1. **Time Slots Allocation**: The core principle of TDM is to assign distinct time slots to each signal. During each time slot, the respective signal is transmitted, and then the process repeats cyclically. For example, if there are four signals to be transmitted, the TDM cycle will divide time into four slots, each assigned to one signal.
2. **Synchronization**: Synchronization is crucial in TDM systems to ensure that the signals are correctly aligned with their respective time slots. Both the transmitter and receiver must be synchronized to avoid any overlap or loss of data. This synchronization is typically maintained by a clock signal that ensures time slots are accurately aligned.
3. **Frame Structure**: TDM data is organized into frames, where each frame consists of a set of time slots. Each frame is repeated at regular intervals, ensuring continuous transmission of data streams. The frame structure helps in managing the data streams and maintaining the synchronization between the transmitter and receiver.
4. **Multiplexer and Demultiplexer**: At the transmitting end, a multiplexer combines multiple input signals into a single composite signal by assigning each signal to a specific time slot. At the receiving end, a demultiplexer separates the composite signal back into individual signals based on their respective time slots.
### Types of TDM
1. **Synchronous TDM**: In synchronous TDM, time slots are pre-assigned to each signal, regardless of whether the signal has data to transmit or not. This can lead to inefficiencies if some time slots remain empty due to the absence of data.
2. **Asynchronous TDM (or Statistical TDM)**: Asynchronous TDM addresses the inefficiencies of synchronous TDM by allocating time slots dynamically based on the presence of data. Time slots are assigned only when there is data to transmit, which optimizes the use of the communication channel.
### Applications of TDM
- **Telecommunications**: TDM is extensively used in telecommunication systems, such as in T1 and E1 lines, where multiple telephone calls are transmitted over a single line by assigning each call to a specific time slot.
- **Digital Audio and Video Broadcasting**: TDM is used in broadcasting systems to transmit multiple audio or video streams over a single channel, ensuring efficient use of bandwidth.
- **Computer Networks**: TDM is used in network protocols and systems to manage the transmission of data from multiple sources over a single network medium.
### Advantages of TDM
- **Efficient Use of Bandwidth**: TDM all
Using recycled concrete aggregates (RCA) for pavements is crucial to achieving sustainability. Implementing RCA for new pavement can minimize carbon footprint, conserve natural resources, reduce harmful emissions, and lower life cycle costs. Compared to natural aggregate (NA), RCA pavement has fewer comprehensive studies and sustainability assessments.
2. Chapter Outline
Definition of Plant Design
Plant/Facility location
Selection of General and Specific Territories
Analytical Plant Location Methodology
Definition of Plant Layout
Types of Plant Layout
Ergonomics 2
3. Plant Design
Plant design is a broad function-taking place
in the origin of an enterprise.
• It is the planning of finances, the plant
location and all the planning necessary for
the physical requirements of an overall
design of a plant.
• The basic decision that must be taken for
effective plant design include:
4. Plant design cont’d
o Product design
o Process design
o Capital acquisition
o Sales planning
o Make or buy
o Product price range
o Plant location
o Plant layout
o Diversification
o Building type selection 4
5. Plant design …..Cont’d
i) Product Design:
The design of the product is the foundation upon which a
plant layout is built.
Design for function: in order to create a satisfied
customer or to attract customers, a product must
perform the function for which its customer intends to.
Design for manufacturing: a product that solves the
functional problem nicely, but is impossible to
manufacture, is worthless.
Design for selling: a product that functions
well and easy to make, but wanted by no one is
useless.(Design of distribution/selling) system
6. Cont’d…
(ii) Process Design (Determination of the Production
Process:)
• Encompass the selection of a process, choice of
technology, process flow analysis and layout of the
facilities
(iii) Capital Acquisition: Obtaining capital for the
initial establishment;
♣ Raising funds to cover operating costs;
♣ Secure funds for expansion.
The primary sources of capital are:
♣ Personal savings;
♣ Loans and sales of bonds;
♣ Profit plowback
7. Cont’d
(iv) Sales Planning:
It is important to know the market demand with the
understanding of seasonal variation.
(v) Make or Buy:
The determination of unit cost is usually the first step
in a make-buy analysis. In such analysis management
is interested in:
♣ Reducing unit material and processing costs;
♣ Minimizing cash investment;
♣ Improving product.
8. Cont’d
(v) Plant Size:
The size of a plant dependent upon the volume of
output proposed for it.
vi) Product Price Range:
The choice of competent price range will influence the
quality, quantity and the manufacturing process of the
product.
vii) Plant Location:
Selecting a location involves large commitments of
capital as a result it must be done with utmost care.
9. viii) Plant Layout:
It is the plan of, or the act of planning, a good
workable disposition of industrial facilities,
like operating equipment, storage space,
materials handling equipment and all other
supporting services, along with the design of
the best structure to contain these facilities.
9
11. Plant design …..Cont’d
ix) Building Type Selection:
Selection of the type of building will take place before,
or during the plant layout phase.
x) Diversification:
To diversify doesn't mean widening the scope of the
presently manufactured line, but rather mean entering a
completely new field(planning new products).
xi) Organization Development:
The manner in which the overall objectives of an
enterprise are clearly defined, the objectives of various
subdivisions are determined and clearly specified
influences the arrangement of plant facilities.
12. Plant/Facility Locations
What is plant location?
Refers to the choice of region and the selection of a
particular site for setting up a business or factory.
To get advantage by virtue of location.
It is a strategic decision that cannot be changed
once taken.
A facility is something built or established to serve a
purpose and facilities location is the determination
of the site for that facility. It is part of a larger study
area called facility’s management, which involves
both the location of the facility and the composition,
or internal layout of the facility once located.
12
13. Plant/facility Location …Cont.
There are analytical procedures to aid in the process
but the decision must also included factors that are
difficult and impossible to quantify.
What is an ideal/best location?
♣ Is one where the cost of the product is kept to
minimum, with a large market share, the least risk
and the maximum social gain.
♣ It is the place of maximum net advantage or which
gives lowest unit cost of production and distribution.
14. Plant location …(Cont…)
Do you think the location of Gypsum
Board or Dejen Cement factory in East
Gojjam is correct?
Why?
14
16. Selection of General Territory
♣ Calls for information of a more general nature
Factors that affect the choice of territory includes:
i. Location of market/Proximity to Market:
Market oriented plants; Space required for output
>>> space required for input.
i.e. Car manufacturing, Appliances.
ii. Cost of construction:
iii. Location of raw material: Raw material oriented factories;
weight of input >>> weight of output.
16
17. Selection of general territory…(Cont..)
iv. Transport
♣ The transport of materials and products to and
from plant will be an overriding consideration in
site selection.
♣ If practicable, a site should be selected so that it
is close to at least two major forms of transport:
road, rail, waterway or a seaport.
17
18. Selection of general territory…(Cont..)
v. Labors and wages:
♣ Quality of labor force
♣ Availability of labor force
♣ Unemployment rate
♣ Labor unions
♣ Attitudes towards work and labor turnover
♣ Motivation of workers and work force
management
vi. Energy: other than electric power, in some plants
it is necessary to use gas, coal, fuel-oil, etc…
18
19. Selection of a Specific Site
Factors affecting includes:
i. Community: the plant has to be located according to
the master plan of the city or region.
ii. Transport: it is important to consider the
transportation infrastructure of the area.
iii. Availability of utility, electricity, water,……
Aluminum plant is strongly dependent to the
electricity
Blast furnace requires a high flow of water
iv. Future development: the plant has to be in position
to develop or change product quantity, type and size.
19
20. Selection of a Specific Site…(Cont)
iv. Wind direction: if the industry produces smoke, gas,
odor, etc…
v. Condition of the site: the grounds has to have a good
resistance to the load induced by the foundation of the
building.
vi. Complementary plants: an industry to produce as
intended, may need material, service and assistance
from other plants.
viii. Cost of living
Health care
Education
Construction costs. 20
21. Principal factors must be considered selecting a
suitable plant site, can be summarized:
1. Raw material
availability.
2. Marketing area.
3. Availability of suitable
land.
4. Transport facilities.
5. Availability of labors.
21
6. Availability of utilities (Water,
Electricity).
7. Environmental impact and effluent
disposal.
8.Local community considerations.
9.Climate.
10.Political strategic considerations.
11. Taxations and legal restrictions
22. Analytic Plant Location Methodology
22
1. Location Rating Factor analysis
Steps for location factor analysis;
1. Identify important factors
2. Weight factors (0.00 - 1.00)
3. Subjectively score each factor (0 - 100)
4. Sum weighted scores
23. Plant Location Methodology
Location Factor Rating: Example
23
1. Labor pool and climate
2. Proximity to suppliers
3. Wage rates
4. Community environment
5. Proximity to customers
6. Shipping modes
7. Air service
LOCATION FACTOR
.30
.20
.15
.15
.10
.05
.05
WEIGHT
80
100
60
75
65
85
50
Site 1
65
91
95
80
90
92
65
Site 2
90
75
72
80
95
65
90
Site 3
SCORES (0 TO 100)
Weighted Score for “Labor pool and climate” for
Site 1 = (0.30)(80) = 24
24. Plant Location Methodology
Location Factor Rating
24
Site 3 has the highest
factor rating
24.00
20.00
9.00
11.25
6.50
4.25
2.50
77.50
Site 1
19.50
18.20
14.25
12.00
9.00
4.60
3.25
80.80
Site 2
27.00
15.00
10.80
12.00
9.50
3.25
4.50
82.05
Site 3
WEIGHTED SCORES
Best Site is 3
25. Plant Location Methodology:
2. Center of Gravity Method
The center of gravity method is used for locating
single facilities that considers existing facilities,
the distances between them, and the volumes of
goods to be shipped between them.
This methodology involves formulas used to
compute the coordinates of the two-dimensional
point that meets the distance and volume criteria
stated above.
26. Plant Location Methodology:
Center of Gravity Method Formulas
C =
d V
V
x
ix i
i
Cx = X coordinate of center of gravity
Cy = Y coordinate of center of gravity
dix = X coordinate of the ith location
diy = Y coordinate of the ith location
Vi = volume of goods moved to or from ith location
C =
d V
V
y
iy i
i
27. Question: What is the best location for a new Z-Mobile
warehouse/temporary storage facility considering only distances
and quantities sold per month?
Plant Location Methodology:
Center of Gravity Method Formulas
Center of gravity method example
– Several automobile showrooms are located
according to the following grid which represents
coordinate locations for each showroom.
S howroom No ofZ-Mobile s
s old pe r month
A 1250
D 1900
Q 2300
X
Y
A
(100,200)
D
(250,580)
Q
(790,900)
(0,0)
28. Plant Location Methodology: Example of Center of Gravity
Method: Determining Existing Facility Coordinates
S howroom No ofZ-Mobile s
s old pe r month
A 1250
D 1900
Q 2300
X
Y
A
(100,200)
D
(250,580)
Q
(790,900)
(0,0)
To begin, you must identify the
existing facilities on a two-
dimensional plane or grid and
determine their coordinates.
You must also have the
volume information on the
business activity at the
existing facilities.
29. Plant Location Methodology: Example of Center of Gravity
Method: Determining the Coordinates of the New Facility
C =
100(1250) + 250(1900) + 790(2300)
1250 + 1900 + 2300
=
2,417,000
5,450
=
x 443.49
C =
200(1250) + 580(1900) + 900(2300)
1250 + 1900 + 2300
=
3,422,000
5,450
=
y 627.89
Showroom No ofZ-Mobile s
sold pe r month
A 1250
D 1900
Q 2300
X
Y
A
(100,200)
D
(250,580)
Q
(790,900)
(0,0)
You then compute the new coordinates using the formulas:
Z New
location
30. Revise Previous lectures
1. What is plant location?
2. What is an ideal/best location?
3. List principal factors must be considered
selecting a suitable plant site.
4. What are the steps of location Rating Factor?
30
31. Plant layout
“It is a plan of, or the act of planning, an optimum
arrangement of industrial facilities; including personnel,
operating equipment, storage space, material handling
equipment, and all other supporting services, along with
the design of the best structure to contain these
facilities.”
James M. Moore
Plant layout is the most effective arrangement and
coordination of the physical plant facilities to allow
greatest efficiency in the combination of men, materials
and machines necessary for operation of any unit of a
plant or business 31
32. • Plant layout refers to the arrangement of physical
facilities such as machines, equipment, tools,
furniture etc.
• In such a manner so as to have quickest flow of
material at the lowest cost and with the least amount
of handling in processing the product from the receipt
of raw material to the delivery of the final product.
• The layout design affects the cost of producing goods
and delivering services for many years into the future
32
33. In Class Exercise:
Taking the definition of plant layout in to
consideration, if you are asked to design layout
what major principles you will follow?
33
34. PRINCIPLES OF PLANT LAYOUT
1. Principle of overall integration. The layout is best
which integrates(compromise) the men, material,
machinery, supporting activities and any other
considerations.
2. Principle of minimum distance moved. By placing
subsequent operations adjacent to each other, saving
can be made reducing the distance of these moves.
3. Principle of flow. It means that material will move
progressing from one operation to the next towards
completion
4. Principle of cubic space. Economy is obtained by
using effectively all available space both vertical and
horizontal.
5. Principle of satisfaction and safety. It means that
layout is best which makes work satisfying and easy for
workers.
34
35. PRINCIPLES OF PLANT LAYOUT CONT’D
6. Principle of Flexibility. It means that the best
layout is one which can be adopted and
rearranged at minimum cost with least
inconveniences
7. Principle of expansion. Expand in future without
disturbing the existing layout and production
schedules.
8. Principle of versatility. Layout should be adoptable
to changes in product design, sales requirement and
process improvement.
9. Principle of orderliness. Clean work areas with
suitable equipment for removing scrap, wastes etc.
35
36. The objectives of a good plant layout
1. Integrate the production centers
♣ Integrates (men, materials and machines) in to a
logical, balanced and effective production unit.
♣ It permits the arrangement of the equipment to
provide greater utilization.
♣ It helps to increase the output by shortening the
manufacturing time.
2. Reduce material handling. The equipment may be arranged
in such a manner to minimize material handling and
transportation.
36
37. The objectives of a good plant layout …(cont)
3. Effective utilization of available space. The
layout determines the location of departments and
production centers, their proximity to each other to
various services, and hence the efficient utilization of the
available space. More over, a good layout utilizes space,
both vertical and horizontal in the best possible manner.
4. Worker convenience and job satisfaction.
Ergonomics? human factor engineering
Working places-safe, well ventilated and free from dust,
noise, fumes, odor, and other hazardous conditions helps to
increase the efficiency of the workers and improve their
morale.
37
38. The objectives of a good plant layout …(cont)
5. Flexibility.
• The best layout is one, which can be adopted and re-
arranged at a minimum cost with least inconvenience.
6. Avoid unnecessary capital investment. Capital investment
in equipment can sometimes be reduced by the proper
arrangement of machines and departments.
7. Stimulate effective labor utilization. Every year millions of
productive man-hours are wasted because of poor layout.
Proper layout does not guarantee, but certainly stimulates,
the effective utilization of manpower.
38
39. Types of plant layout
Plant layout can be classified as:
1. Process or functional layout
2. Product or line layout
3. Mixed or combined layout
4. Fixed position layout
5. Group technology layout
39
40. 1. Process (Job Shop) Layouts
♣ Equipment that perform similar processes are
grouped together. e.g., all lathes, milling
machines, etc. are grouped in the shop will be
clustered in like groups.
♣ Used when the operations system must handle a
wide variety of products in relatively small
volumes (i.e., flexibility is necessary)
40
42. Characteristics of Process Layouts
♣ General-purpose equipment is used
♣ Changeover is rapid
♣ Material flow is intermittent
♣ Material handling equipment is flexible
♣ Operators are highly skilled
♣ Technical supervision is required
♣ Planning, scheduling and controlling functions are
challenging
♣ Production time is relatively long
♣ In-process inventory is relatively high
42
43. 2. Product (Assembly Line) Layouts
♣ Operations are arranged in the sequence required to make
the product.
♣ Used when the operations system must handle a narrow
variety of products in relatively high volumes.
♣ Operations and personnel are dedicated to producing one or
a small number of products.
43
44. Characteristics of Product Layouts
♣ Special-purpose equipment are used
♣ Changeover is expensive and lengthy
♣ Material flow approaches continuous
♣ Material handling equipment is fixed
♣ Operators need not be as skilled
♣ Little direct supervision is required
♣ Planning, scheduling and controlling functions are
relatively straight-forward
♣ Production time for a unit is relatively short
♣ In-process inventory is relatively low
44
45. 3. Mixed or combined layout
♣ Pure process or pure line layouts are rare.
The combination of these is very commonly
used in industry.
♣ The combined layout incorporates the
benefits of the process and product layout.
45
46. Combined layout
Receiving
Raw mat. Fabrication
storage line-part B
Fabrication Planer
line-part A
Finished Lathe
goods Drill
storage Mill
Mill
Drill
Grinder
Mill
Assembly line Automatic
46
Small number of
high volume
products
47. 4. Static or fixed position layout
47
Is adopted when work piece is
very big or too heavy to move
from one position to the other
and is consequently fixed in one
place.
49. 5. Group technology(Cellular)
layout
Production volumes for individual products
are not sufficient to justify product layouts.
Grouping products into logical product
families, a product layout can be justified
for the family.
49
50. Group technology layout cont’d
“Group technology is the technique of
identifying and bringing together related or
similar parts in a production process in order to
utilize the inherent economy of flow
production methods.”
Group Technology layout is also called
manufacturing cell layout.
The arrangement of a facility so that
equipment used to make similar parts or
families of parts is grouped together.
50
51. Group technology layout…(cont)
Example:
A plant producing 10,000 part numbers may be able to
group the parts into 50 or 60 families. Each family
would possess similar design and manufacturing
characteristics.
Hence, the processing of each member of a given
family would be similar, and this results in
manufacturing efficiencies in the form of:
Reduced set-up,
Lower in-process inventories,
Better scheduling,
Improved tool control,
Standard process plan.
51
53. Group Technology
53
Drilling
D D
D D
Grinding
G G
G G
G G
Milling
M M
M M
M M
Assembly
A A
A A
Lathing
Receiving and
shipping
L
L L
L L
L L
L
(a) Jumbled flows in a job shop without GT cells
55. Class of layout Problems
Building new plant
Move to existing plant
Rearrange existing layout
Minor changes
55
56. Common Reasons for the design of Layouts
Changes In Design of Products/services
Introduction of New Products/services
Market Demand change
Changes In Technology/equipment
Poor Worker environment
Market Relocation
Cost Reduction
56
62. What is Ergonomics???
• Ergonomics is concerned with the interaction
between human and technology
• Ergonomics integrates knowledge delivered
from the human science to match systems,
environments, jobs, and products to the
physical and mental abilities and limitation of
people
62
63. Ergonomics is the study of the man in relation
to his work
Sometimes it is called by the name ‘human
engineering or human factors engineering”
“The application of human biological sciences
along with engineering sciences to achieve
optimum mutual adjustment of men and his
work.
The benefits being measured in terms of
human efficiency and well-being.”
63
Ergonomics
64. Human engineering (ergonomics) has two
broader objectives:
1.To enhance the efficiency and effectiveness
with which the activities (work) is carried out so
as to increase the convenience of use, reduced
errors and increase in productivity.
2.To enhance certain desirable human values
including safety reduced stress and fatigue and
improved quality of life.
64
Objectives of Human Engineering
65. Ergonomics aims at providing comfort and
improved working conditions so as to
channelize the energy, skills of the workers
into constructive productive work.
This accounts for increased productivity,
safety and reduces the fatigue.
65
Cont.…
66. 66
Ergonomic
• Ergonomics, also known as human engineering or human
factors engineering, the science of designing machines,
products, and systems to maximize the safety, comfort,
and efficiency of the people who use them.
• Ergonomists draw on the principles of industrial
engineering, psychology, anthropometry (the science of
human measurement), and biomechanics (the study of
muscular activity) to adapt the design of products and
workplaces to people’s sizes and shapes and their physical
strengths and limitations.
67. Ergonomic
• Ergonomists also consider the speed with
which humans react and how they
process information, and their capacities
for dealing with psychological factors,
such as stress or isolation.
67
68. 68
Ergonomic
• Ergonomist view people and the objects they use
as one unit, and ergonomic design blends the best
abilities of people and machines.
• Humans are not as strong as machines, nor can
they calculate as quickly and accurately as
computers.
• Unlike machines, humans need to sleep, and they
are subject to illness, accidents, or making
mistakes when working without adequate rest.
69. Ergonomic
• But machines are also limited—cars cannot repair
themselves, computers do not speak or hear as
well as people do, and machines cannot adapt to
unexpected situations as well as humans.
• An ergonomically designed system provides
optimum performance because it takes advantage
of the strengths and weaknesses of both its
human and machine components. 69
70. 70
Definition: Ergonomic
IEA (International Ergonomics Association)
”the scientific discipline concerned with the
understanding of the interactions among
human and other elements of a system, and
the profession that applies theory, principles,
data and methods to design in order to
optimize human well-being and overall system
performance”
71. 71
Typical losses from failure to apply
ergonomic
1. Lower production output
2. Increased lost time
3. Higher medical & material cost
4. Increased absenteeism
5. Low quality work
6. Injuries, strains
7. Increased probability of accidents & errors
72. Introduction
Safety, hazard and risk are frequently-used terms in chemical process safety
Definitions
• Safety or loss prevention: the prevention of accidents through the use of
appropriate technologies to identify the hazards of a chemical plant and
eliminate them before an accident occurs.
– Loss Prevention: Prevention of injury to people, damage to
environment, loss of equipment, inventory or production
– Safety : Strategy of accident prevention
• Hazard: a chemical or physical condition that has the potential to cause
damage to people, property, or the environment.
• Risk: a measure of human injury, environmental damage, or economic loss
in terms of both the incident likelihood and the magnitude of the loss or
injury.
72
73. Introduction
Chemical plants contain a large variety of hazards:
1. There are the usual mechanical hazards that cause worker
injuries from tripping, falling, or moving equipment.
2. There are chemical hazards. These include fire and
explosion hazards, reactivity hazards, and toxic hazards.
73
74. Introduction
As will be shown later,
chemical plants are the safest
of all manufacturing facilities.
However, the potential always
exists for an accident of
terrible proportions.
Despite substantial safety
programs by the chemical
industry, headlines of the type
shown in Figure 1-1 continue
to appear in the newspapers.
74
75. Safety Programs
A successful safety program requires several ingredients.
These ingredients are:
• System
• Attitude
• Fundamentals
• Experience
• Time
• You
75
76. Safety Programs
• Why the program needs a System:
1. to record what needs to be done
2. to do what needs to be done
3. to record that the required tasks are done
• Attitude: positive attitude
willingness to do some of the thankless work that is required for success
• Experience: Everyone must learn from the experience of history; read and
• understand case histories of past experience
• Time: Every one should recognize that safety takes time; this include
1. time to study 2. time to do the work
3. time to record results 4. time to share experience
76
77. The most effective means of implementing a safety program is to make it
everyone’s responsibility in a chemical process plant
Distinction between a good and an outstanding safety program
- A good safety program identifies and eliminates
existing safety hazard
- An outstanding safety program has management systems to prevent the
existence of a safety hazard
Most Importantly!! Safety cannot be
Prioritized - it must be condition
of employment!
77
78. Revise previous class
1. Principles of plant layout
2. Types of plant layout
3. Common Reasons for Redesign of Layouts
4. Class of layout Problems
78
79. Assignment
Read & prepare brief description report about
Type of layouts;
Process layout
Product layout
Combined layout
Fixed position layout
Group technology layout
79