Plant layout and material handling pdf free download

Inspection and Quality Control 9. Work Study Network Analysis Operations Research Plant Maintenance Replacement Analysis Management Concept Industrial Ownership Supervisory and Leadership Decision Making Industrial Psychology Personnel Management Union and Industrial Labour Relations Industrial Labour Legislation Materials, Purchase and Stores Management Having more than 10 Nuclear Power Plant exists in India.

Some of them I have listed below which is:. Your email address will not be published. Save my name and email in this browser for the next time I comment. Frictional energy is generated when the stirring tool comes in contact with the workpiece. This results in the generation of heat that is used to create a weld between two workpieces, hence the Blast furnaces were first introduced in China around the 1st century AD.

They were further introduced in European countries like Durstel, Germany, Lappyhttan in the 13th century. Due to an Skip to content. Page Contents. Ruchir Patel. A short summary of this paper.

Download Download PDF. Translate PDF. For implementation of this plan, he has to take various crucial decisions namely location of business, layout the arrangement of physical facilities , designing the product, production planning and control and maintaining good quality of product.

This lesson deals with various aspects of plant location and layout. Investment in analyzing the aspects of plant location and the appropriate plant layout can help an entrepreneur achieve economic efficiencies in business operations. These decisions lay the foundation of the business of small entrepreneurs. What is plant location? Plant location refers to the choice of region and the selection of a particular site for setting up a business or factory.

But the choice is made only after considering cost and benefits of different alternative sites. It is a strategic decision that cannot be changed once taken. If at all changed only at considerable loss, the location should be selected as per its own requirements and circumstances. Each individual plant is a case in itself. Businessman should try to make an attempt for optimum or ideal location. What is an ideal location? An ideal 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. For achieving this objective, small-scale entrepreneur can make use of locational analysis for this purpose. It consists the following: a Demographic Analysis: It involves study of population in the area in terms of total population in no.

He would also see the feasibility of accessing the trade area from alternative sites. Costs of establishment is basically cost incurred for permanent physical facilities but operational costs are incurred for running business on day to day basis, they are also called as running costs. Two sites A and B are evaluated in terms of above mentioned two costs as follows: Table 7.

Site B Rs. Cost of establishments: Land and Buildings Equipment Transport facilities Cost of operations: Materials, freight and carriage Taxes and insurance Labour Water, power and fuel Total The above cost statement indicates that site B is preferable to site A keeping in mind economic considerations only although in some respects site A has lower costs. Positive includes cheap overhead facilities like electricity, banking transport, tax relief, subsidies and liberalization.

Negative incentives are in form of restrictions for setting up industries in urban areas for reasons of pollution control and decentralization of industries. Heavy preference to homeland suggests that small-scale enterprise is not freely mobile. Low preference for Government incentives suggests that concessions and incentives cannot compensate for poor infrastructure. Table given below also suggests that the locational choice undergo change with differences in the levels of development across the regions hills and plains.

Therefore, an appropriate location is essential to the efficient and economical working of a plant. A firm may fail due to bad location or its growth and efficiency may be restricted. The factor least important to consider when selecting a location for a new furniture store is a.

The weather of the community b. The future of the community c. The other businesses in the community d. The age distribution of the population in the community 2. When selecting a site for a business it is important to a. Lease the property to avoid the problem of mortgage payments c. Rent or buy the property, whichever must be done in order to obtain the specific site d.

Make comparisons between the rentals of neighboring stores and property for sale 3. After going through the above section, choose any five key words and explain their meaning in your own words a………………………………………………………………………………… ………………………………………………………………………………….. Discuss with them to find out: a The factors considered by them in the location decision. Only the properly laid out plant can ensure the smooth and rapid movement of material, from the raw material stage to the end product stage.

Plant layout encompasses new layout as well as improvement in the existing layout. It may be defined as a technique of locating machines, processes and plant services within the factory so as to achieve the right quantity and quality of output at the lowest possible cost of manufacturing. It involves a judicious arrangement of production facilities so that workflow is direct. An ideal plant layout should provide the optimum relationship among output, floor area and manufacturing process.

An entrepreneur must possess an expertise to lay down a proper layout for new or existing plants. It differs from plant to plant, from location to location and from industry to industry. But the basic principles governing plant layout are more or less same. As far as small business is concerned, it requires a smaller area or space and can be located in any kind of building as long as the space is available and it is convenient.

Plant layout for Small Scale business is closely linked with the factory building and built up area. From the point of view of plant layout, we can classify small business or unit into three categories: 1. Manufacturing units 2. This is a GMP and safety requirement in the industry.

The other four sections need to be placed to provide maximum assistance to primary manufacturing while ensuring the food hygiene requirements. Thus, it is important to clearly define the above five basic sections of a food processing factory in a layout drawing. A colour scheme as shown in Figure 3 is also proposed in order to identify the basic sections. Food processing comprises many simultaneous activities and can have complex layouts. These can take many shapes. Therefore, the proposed colour scheme can potentially simplify the layout design process by enabling easy visualisation.

The traditional method of locating departments is based mainly on two optimisation factors, the adjacency or distance travelled. However, in this model, food safety or GMP becomes the main criterion for optimisation to locate departments. Other traditional factors are considered as secondary.

Existing layouts present in the food industry were observed and evaluated in designing the model layout. Many layouts indicate that the high risk and low risk areas are protected from the external environment by only a solid wall.

This can lead to pest ingression, cross contamination, and direct contamination. Most of the time, the utility system is located away from the high risk area; hence, heating, ventilating and air conditioning HVAC ducting, steam lines, and compressed air lines should move to this area through wall openings.

This poses a risk to the food processing plant. These risk factors can be significantly controlled by surrounding the primary manufacturing area with the secondary manufacturing area. The secondary manufacturing area then has to be surrounded with other sections of the factory. This prevents the external contaminants from reaching the primary and secondary manufacturing areas. This reduces the risk due to biological, chemical, or physical contamination.

Finally, the utility, administration, and warehouse areas should be attached to the secondary manufacturing area. The diamond model layout shown in Figure 4 ensures correct material and personnel movement within the factory.

As indicated in Figure 5 , the material flow is from left to right. The raw material and packing material received at the stores in left side are converted to finished goods and transferred to the stores at the right end of the layout.

Personnel entry to the facility is from the administration area at the bottom as shown in Figure 6. Thus, this model minimises cross contamination and streamlines personnel and goods movement on the factory floor. The model in Figure 4 clearly shows the five key areas of a food processing factory. These five areas encompass all functions of typical food processing factories. The space allocation for each of these sections varies from the actual space requirements as per the manufacturing process.

This is performed when the framework is applied to identify the space requirements in the layout. The product that arrives from the secondary manufacturing area is exposed to the facility environment in the primary manufacturing area, drastically increasing the contamination risk and thus it should be the most protected area of the manufacturing process.

Hence the above model locates the primary manufacturing area at the centre of the layout to isolate it from the outside environment as much as possible. The product usually enters the primary area through pressurised air locks. Personnel also must enter through air locks and undergo gowning changes. They need to wear head covers, shoe covers, masks, and gloves as appropriate to the manufacturing process before entering the primary manufacturing area.

Hand-wash stations also need to be established at the entry to the primary manufacturing area. Furthermore, entrances to this area need to have air curtains to prevent outside air from entering the high risk area.

As mentioned, the product is exposed at the high risk primary manufacturing area [ 11 ]. Thus, the air in this section must be conditioned as a standard. The particle count in air is controlled through high efficiency particle absorption HEPA filters and relative humidity is controlled as per the process norms. The air pressure is also maintained at a slightly higher level than that of the secondary manufacturing area to prevent particulates from getting into the primary manufacturing area.

The product is first exposed to the facility environment in the secondary manufacturing area. The raw material enters the secondary manufacturing area from the stores.

The product being manufactured at the primary manufacturing area is usually in its primary packing when it reaches the secondary manufacturing area, and the secondary manufacturing area is the entity in which the final packing of the product takes place. Then the product in its final packing is sent to the finished goods warehouse. Hence, air locks need to be placed between the stores and secondary manufacturing area to prevent contamination through leaking air.

These air locks also prevent pests from entering the secondary manufacturing area [ 11 ]. The personnel entry to the secondary manufacturing area is from the administration area and that too needs to be through air locks.

It is also usually equipped with a gowning regime to change to designated clothes before entering the secondary manufacturing area. Thus, the gowning area needs to be appropriately placed in the administration section of the layout. The air quality of the secondary manufacturing area is maintained as specific to the manufacturing process. The same pressure difference is maintained between the primary and secondary manufacturing areas so that the air flows to the low risk area from the high risk area [ 11 ].

Here, it is also good practice to maintain positive pressure e. The positive pressure prevents outside air from reaching the secondary manufacturing area. This prevents possible contamination of the product. The warehouse holds raw material and packing material for the manufacturing process and finished goods. The warehouse is divided into two sections: Store A and Store B. Store A keeps the raw material and packing material. All these materials are in the quarantine area until they pass the quality check.

Then these materials are released for manufacturing. Store B holds finished goods. The finished goods are released from the store once the quality checks are over. The environmental conditions in the store areas can differ to suit the products being manufactured.

For example, these can be cold rooms, chilled rooms, or air conditioned according to the requirement for raw material and finished goods. The goods movement from the stores is in one direction. There is no back tracking or criss-crossing of material movement on the layout. As shown in Figure 5 for material movement, the raw and packing material entering Store A move through the manufacturing process and reach Store B as finished goods.

Therefore, in order to prevent cross contamination, personnel movement needs to be restricted or controlled and thus changing room facilities need to be placed at appropriate locations. This area hosts all utilities and the engineering department of the organisation. Utility equipment includes components such as air handlers for the heating, ventilating and air conditioning HVAC system, boilers, air compressors, chillers, and water purification plants that support the manufacturing process.

According to the observations, there is no need for frequent direct access to the secondary packing area from the utility area. Therefore, sealed type emergency exit doors can be fixed if required.

This area holds the facilities such as the main administration office, changing rooms for employees, canteens, washrooms, toilets, and first aid rooms. Employees use the changing room in the administration area and wear the factory uniform and sanitise their hands before entering the secondary manufacturing area.

Employees enter the stores from a separate entrance after changing their uniforms. This area is not treated as a production area. Offices are also located in this area and the layout can be designed so that the offices have a direct view of the manufacturing area through glass panels.