This document provides an overview of facility layout and maintenance management concepts. It discusses types of plant layouts including product oriented, process oriented, fixed position, and combination layouts. Factors affecting layout and objectives of layout design are outlined. Material handling equipment types are described including hoists, conveyors, surface equipment, robotics, and computer controlled conveyors. Flexible manufacturing systems are defined including components, types based on operations and flexibility level. Finally, the document covers maintenance management topics such as types of maintenance, reasons for maintenance, costs of maintenance activities, and advantages and disadvantages of different maintenance approaches.

1. Compiled By: Mr. Gokul O
Assistant Professor
Department of Mechanical Engineering
Sree Buddha College of Engineering, Pattoor
According to APJ Abdul Kalam Technological
University Syllabus
Subjbect- Industrial Engineering
Course code- ME404
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2. 2nd module
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3. Facility Layout
Layout refers to the configuration of departments, work
centers, and equipment, with particular emphasis on
movement of work (customers or materials) through the
system.
Layout decisions are important for three basic reasons:
1.
2.
require substantial investments of money and effort;
involve long-term commitments, which makes
mistakes difficult to overcome; and
have a significant impact on the cost and efficiency of
operations
3.

4. Factors affecting Plant Layout
1.
2.
3.
4.
5.
6.
7.
8.
9.
Plant location and building
Nature of Product
Type of Industry
Plant Environment
Spatial Requirements
Repairs and Maintenance
Balance
Management Policy
Human Needs
10.Types of machinery and equipment

5. The basic objective of layout design is to facilitate a
smooth flow of work, material, and information through
system. Supporting objectives generally involve the
following:
To
To
To
To
To
facilitate attainment of product or service quality.
use workers and space efficiently.
avoid bottlenecks.
minimize
eliminate
material handling costs.
unnecessary movements of workers or
materials.
To
To
minimize production time or customer service time.
design for safety.

6. Types of Plant layouts
• Product oriented plant layout
Machinery and Materials are placed following the product
path.
• Process oriented plant layout (Functional Layout).
Machinery is placed according to what they do and
materials go to them.
• Fixed position plant layout
Product stays and resources move to it.
• Combined Layout
Combine aspects of both process and product layouts.
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7. Product oriented plant layout
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8. Product oriented plant layout
This type of plant layout is useful when the production
process is organized in a continuous or repetitive way.
Continuous flow : The correct operations flow is reached
through the layout design and the equipment and
machinery specifications.
Repetitive flow (assembly line): The correct operations
flow will be based in a line balancing exercise, in order to
avoid problems generated by bottle necks.
The plant layout will be based in allocating a machine as
close as possible to the next one in line, in the correct
sequence to manufacture the product.
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9. Product oriented plant layout
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10. Process oriented plant layout
(Functional Layout)
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11. Process oriented plant layout
(Functional Layout)
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12. Process oriented plant layout
(Functional Layout)
• This type of plant layout is useful when the production
process is organized in batches.
• Personnel and equipment to perform the same function are
allocated in the same area.
• The different items have to move from one area to another
one, according to the sequence of operations previously
established.
• The variety of products to produce will lead to a diversity of
flows through the facility.
• The variations in the production volumes from one period
to the next one (short periods of time) may lead to
modifications in the manufactured quantities as well as the
types of products to be produced.
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13. Fixed-Position Layouts
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14. Fixed-Position Layouts
• In fixed-position layouts, the item being worked
on remains stationary, and workers, materials,
and equipment are moved about as needed.
• Fixed-position layouts are widely used in farming,
firefighting, road building, home building,
remodeling and repair, and drilling for oil. In each
case, compelling reasons bring workers,
materials, and equipment to the “product’s”
location instead of the other way around.
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15. Fixed-Position Layouts
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16. Combination Layouts
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17. Combination Layouts
• Supermarket layouts are essentially process layouts, yet we find that
most use fixed-path material-handling devices such as roller-type
conveyors in the stockroom and belt-type conveyors at the cash
registers.
• Hospitals also use the basic process arrangement, although
frequently patient care involves more of a fixed-position approach, in
which nurses, doctors, medicines, and special equipment are brought
to the patient.
• Faulty parts made in a product layout may require off-line reworking,
which involves customized processing. Moreover, conveyors are
frequently observed in both farming and construction activities.
• Cellular manufacturing - Group technology
• Flexible manufacturing systems
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18. Material Handling
• Material handling means providing the right amount of the
right material, in the right condition, at the right place, at
the right time, in the right position and for the right cost, by
using the right method.
• It applies to the movement of raw materials, parts in process,
finished goods, packing materials, and disposal of scraps.
• The cost of material handling contributes significantly to the
total cost of manufacturing.
• A properly designed and integrated material handling system
provides tremendous cost saving opportunities and customer
services improvement potential.
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19. Principles of material handling
• Orientation Principle: It encourages study of all available system
relationships before moving towards preliminary planning. The study
includes looking at existing methods, problems, etc.
• Planning Principle: It establishes a plan which includes basic requirements,
desirable alternates and planning for contingency.
• Systems Principle: It integrates handling and storage activities, which is cost
effective into integrated system design.
• Unit Load Principle: Handle product in a unit load as large as possible.
• Space Utilization Principle: Encourage effective utilization of all the space
available.
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20. Principles of material handling
• Gravity Principle: Encourages usage of gravity principle in movement of
goods.
• Safety Principle: Encourages provision for safe handling equipment
according to safety rules and regulation.
• Computerization Principle: Encourages of computerization of material
handling and storage systems.
• System Flow Principle: Encourages integration of data flow with physical
material flow.
• Layout Principle: Encourages preparation of operational sequence of all
systems available.
• Cost Principle: Encourages cost benefit analysis of all solutions available.
• Maintenance Principle: Encourages preparation of plan for preventive
maintenance and scheduled repairs.
• Obsolescence Principle: Encourage preparation of equipment policy as to
enjoy appropriate economic advantage.
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21. Principles of material handling
• Standardization Principle: It encourages standardization of
handling methods and equipment.
• Ergonomic Principle: It recognizes human capabilities and
limitation by design effective handling equipment.
• Energy Principle: It considers consumption of energy during
material handling.
• Ecology Principle: It encourages minimum impact upon the
environment during material handling.
• Flexibility Principle: Encourages of methods and equipment
which are possible to utilize in all types of condition.
• Simplification Principle: Encourage simplification of methods
and process by removing unnecessary movements
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22. Material Handling Equipment
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23. HOIST MATERIAL HANDLING EQUIPMENT
It constitute a group of equipment which are employed
mainly for lifting or lowering of unit load or piece goods in
batches.
This group of equipment can be further sub classified into:
1.Pure Hoisting Machineries
Jack
Hand Hoists
Pulley Blocks
2. Cranes
3. Elevators
Lift
Bucket Elevators
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24. CONVEYING EQUIPMENT
• It comprises of a number of equipment which are
employed for handling principally bulk load (occasionally
piece goods or unit load may also be handled) in
continuous flow. Such machines do not have separate
lifting or lowering gear. This group of equipment also can
have further sub classifications as:
1. Belt conveyor
2. Roller conveyor
3. Skate wheel conveyor
4. Overhead trolley conveyors
5. In floor taw line.
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25. SURFACE / OVERHEAD EQUIPMENT
• These are the group of equipment which are
employed for handling unit load or bulk load
in batches on a horizontal surface. This group
of equipment may be further sub classified
into:
1. Truck and Lorries
2. Railway Cars and Wagons
3. Fork Lifts
4. Overhead mono-rail / Equipment
5. Scrapers and Skidders
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26. ROBOTICS IN MATERIAL HANDLING
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27. COMPUTER CONTROLLED
CONVEYORS
• A computer-controlled overhead conveyor system is
provided wherein all conveyor vehicles substantially
continually communicate with a control system to be
routed through the track network.
• The track is conceptually divided into zones each
identified by an optically read marker; and the vehicles
include scanners for reading the markers as the
vehicles traverse the track. The marker information is
communicated to the control system which controls
track switches and vehicle velocities to prevent
collisions and to direct the vehicles to desired
destinations
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28. AUTOMATED GUIDED VEHICLE
• An automated guided vehicle or automatic
guided vehicle (AGV) is a mobile robot that
follows markers or wires in the floor, or uses
vision, magnets, or lasers for navigation
• Repetitive movement of materials over
distance
• Regular delivery of stable loads
• Medium throughput/volume
• When on-time delivery is critical
and late deliveries are causing inefficiency
• Operations with at least two shifts
• Processes where tracking material is
important
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29. Types of Material Handling
Equipment Loads:
• It usually classified into:
1. Unit Load
2. Bulk Load
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30. Unit Load
• Unit loads are those which are counted by
numbers or units.
• A component of a machine, a complete machine, a
structural element, a beam, a girder, building block
are some examples of unit load.
• Sometimes certain quantities of free flowing
materials can be placed in a container and can be
handled as unit load. Hoisting equipment are
primarily used for handling unit load. Unit loads
are usually specified by it’s weight.
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31. Bulk Load
• When the load is in the form of particles or lumps of
homogeneous materials or powder like materials,
which cannot be counted by numbers, it is called as
Bulk load.
• Examples are: Sand, Cement, Coal, Mineral, Stone, Clay
etc.,
• A bulk material may be classified by the following
properties:
• 1. Bulk Density
• 2. Lump-Size
• 3. Flowability
• 4. Abrasiveness
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34. Chute
Roller Conveyor
Belt Conveyor
Trough Conveyor

35. Slat Chain Conveyor
Pallet
Container
Screw Conveyor

36. Stretch Wrap Industrial Robot
Hoist
Lift
Pillar Crane

37. Bridge Crane
Dolly
Tilt Floor Hand Truck
Gantry Crane

38. Pallet Truck
Trailer
Fork Lift Truck

39. FLEXIBLE MANUFACTURING
SYSTEMS (FMS)
A flexible manufacturing
system is an automated
machine cell, consisting
of a group of processing
workstations, inter
connected with
automated material
handling and storage
system.
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40. Flexibility
• It is an attribute that allows a mixed model manufacturing system
• Should cope up with a certain level of variations in part or product
style, without having any interruption in production due to
changeovers between models.
• Flexibility measures the ability to adapt “to a wide range of possible
environment”.
• To be flexible, a manufacturing system must posses the following
capabilities
• Identification of the different production units to perform the
correct operation
• Quick change over of operating instructions to the computer
controlled production machines
• Quick change over of physical setups of fixtures, tools and other
working units
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41. Basic components of FMS
1. Workstations
2. Automated Material Handling and Storage
systems
3. Computer Control System
4. Human Resources
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42. Workstations
Following are the types of workstations typically
found in an FMS:
1. Load/Unload Stations.
2. Machining Stations.
3. Assembly Station.
4. Other Stations and Equipment.
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43. Automated Material Handling and
Storage systems
Functions
1.Independent movement of work parts between
stations.
2.Handle a variety of work part configurations.
3.Temporary storage.
4.Convenient access for loading and unloading
work parts.
5.Compatible with computer control.
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44. Computer Control System
• The FMS includes a distributed computer system that is
interfaced to
– the workstations,
– Material handling system, and
– Other hardware components.
• A typical FMS computer system consists of a central
computer and microcomputers.
• Microcomputers controlling the individual machines
and other components.
• The central computer coordinates the activities of the
components to achieve smooth overall operation of
the system
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45. Human Resources
• Human are needed to manage the operations of
the FMS. Functions typically performed by human
includes
• Loading raw work parts into the system,
• Unloading finished parts (or assemblies) from the
system,
• Changing and setting tools,
• Equipment maintenance and repair,
• NC part programming in a machining system, and
• Programming and operation the computer system.
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46. TYPES OF FLEXIBLE MANUFACTURING
SYSTEMS
1. DEPENDING UPON KINDS OF OPERATION
I. Processing operation.
II. Assembly operation.
2. DEPENDING UPON NUMBER OF MACHINES
I. Single machine cell (SMC).
II. Flexible manufacturing cell (FMC.
III. Flexible Manufacturing System (FMS)
3. DEPENDING UPON LEVEL OF FLEXIBILITY
I. Dedicated FMS.
II. Random order FMS
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47. TYPES OF FMS
1. DEPENDING UPON KINDS OF OPERATION
I. Processing operation. Such operation transforms
a work material from one state to another moving
towards the final desired part or product. It adds
value by changing the geometry, properties or
appearance of the starting materials.
II. Assembly operation. It involves joining of two or
more component to create a new entity which is
called an assembly/subassembly
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48. Maintenance Management
• Maintenance is work that is carried out to
preserve an asset in order to enable its
continued use and function, above a minimum
acceptable level of performance, over its
design service life, without unforeseen
renewal or major repair activities
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49. Reasons for Maintenance
• Physical Integrity
To keep the assets in good working order so as to minimize disruptions and
downtimes.
• Risk Management
To keep the assets in a state of good repair for the owners’ health and safety.
• Aesthetic Preservation
To keep the assets from deteriorating in appearance and becoming unsightly.
• Responsible Stewardship
To ensure that the assets achieve their full potential service life.
• Duty of Care
To satisfy a legislated duty that is owed to owners, occupants and guest on the
property.
• Duty to Mitigate
To prevent unnecessary damage to assets that may result in their premature
failure.
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50. Types Of Maintenance
1.Breakdown maintenance
2.Preventive maintenance
• Periodic maintenance ( Time based maintenance -
TBM)
• Predictive maintenance
• Condition Monitoring
3.Corrective maintenance
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51. Break Down Maintenance
It means that people waits until equipment fails and
repair it. Such a thing could be used when the equipment failure
does not significantly affect the operation or production or
generate any significant loss other than repair cost.
Preventive maintenance
`It is a daily maintenance ( cleaning, inspection, oiling and
re-tightening ), design to retain the healthy condition of
equipment and prevent failure through the prevention of
deterioration, periodic inspection or equipment condition
diagnosis, to measure deterioration. It is further divided into
periodic maintenance and predictive maintenance. Just like
human life is extended by preventive medicine, the equipment
service life can be prolonged by doing preventive maintenance.
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52. Periodic maintenance
Time based maintenance consists of periodically
inspecting, servicing and cleaning equipment and
replacing parts to prevent sudden failure and process
problems
Predictive maintenance
This is a method in which the service life of
important part is predicted based on inspection or
diagnosis, in order to use the parts to the limit of their
service life. Compared to periodic maintenance,
predictive maintenance is condition based maintenance.
It manages trend values, by measuring and analyzing data
about deterioration.
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53. Condition Monitoring
• Condition monitoring is the process of determining the
condition of machinery while in operation.
• The key to a successful condition monitoring programme
includes:
–1. Knowing what to listen for
–2. How to interpret it
–3. When to put this knowledge to use
• Successfully using this programme enables the repair of
problem components prior to failure.
• Condition monitoring not only helps plant personnel
reduce the possibility of catastrophic failure, but also allows
them to order parts in advance, schedule manpower, and
plan other repairs during the downtime.
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54. Corrective maintenance
• It improves equipment and its components so
that preventive maintenance can be carried
out reliably. Equipment with design weakness
must be redesigned to improve reliability or
improving maintainability
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55. Costs of maintenance activity
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56. Advantages AndDisadvantages
Break Down Maintenance
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57. Advantages And Disadvantages
Preventive Maintenance
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58. Advantages And Disadvantages
Predictive Maintenance
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59. Advantages And Disadvantages
Condition Monitoring
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60. Advantages And Disadvantages
Corrective Maintenance
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