Plant Engineering

DEPARTMENT OF PRODUCTION ENGINEERINGB. I. T., MESRA, RANCHI

PLANT ENGINEERING (PE 7121)

Module 1 Facility Design: Objectives and Principle, Facility Design Process, Facility Design problems and their Analysis.

Module 2 Plant Location: Factors affecting the Location and Site Selection, Multiplant Location

Module 3 Plant Layout: Objectives of Good Plant Layout, Types of Layout, and Factors affecting Plant Layout.

Module 4 Techniques and Tools of Layout: Concept of location theory and Models, Techno economic Analysis, Design and Types of Building, Types of Flow Pattern.

Module 5 Material Handling: Objectives and Principle, Diagnosis and Analysis of Handling Problems, Types of Loading, Inter relationship between material handling and Plant Layout.

Module 6 Material Handling Equipments and their Selection, Industrial Applications, Design of an Integrated Plant/Facility Layout.

Module 7 Plant Maintenance: Life Cycle Costing, Importance of maintenance in Plant, Types of Maintenance, Preventive and Breakdown Maintenance, Inspection Decision, Economics of Maintenance, Evaluation of Maintenance Policy, Terotechnology.

Text Books:

1. Plant Layout Design by Moore, J. M. MacMullar Co.

2. Industrial Engineering & Management of Manufacturing System by Dr. Surender Kumar,

Satya Prakashan.

Reference Books:

1. Production and Operation Management by Alan Muhlemann, John Oakland and Keith

Lockyer, MacMillan India Ltd.

2. Plant Layout and Materials Handling by Apple J. M., 3rd Edition, Wily, 1977.

3. Management of Maintenance and Engineering System in Hospitality Industries by

Borsenik F. D., 3rd Edition, Wily, 1991.

4. Industrial Management by O. P. Khanna, Dhanpat Rai & Sons.

5. Industrial Organisation and Engineering Economics by Banga.

Module - 1DEPARTMENT OF PRODUCTION ENGINEERING

B. I. T., MESRA, RANCHI


Facility Design: Objectives and Principle, Facility Design Process, Facility Design problems and their Analysis.Definition, necessity of facility design, conceptual framework of facility design, factors in the design of facilities, Main objects of facility design, principle of facility design, facility design problems and their analysisDESIGN PROCESS: Facility design process, systematic analysis of facility design, classification of facility design problems, Models Design.

QUESTIONS

1. What do you mean by facility design? Discuss the conceptual framework of facility

design.

2. Explain different facility design principles.

3. What are the objectives of facility design?

4. Explain facility design process.

5. Explain systematic analysis of facility design.

6. What are the major problems occur when going through a facility design?

7. Write short notes on: Facility design process.

8. What are the different factors that affect the design of facility?

9. Explain Deming’s cycle of facility design process.

10. What are the different stages of facility design process?

11. Classify the facility design problem into a major element.

Home Assignments

1. State the principle governing the design of following facilities:

(i) Storage facilities (ii) Fire protection (iii) Power in a large factory

2. What are the different models of facility design process?

3. Discuss the factors to be considered in deciding what type of factory building would

be best for a company. Discuss.

Reference Books:

1. Industrial Engineering & Management of Manufacturing System by Dr. Surender

Kumar, Satya Prakashan.

2. Production and Operation Management by Alan Muhlemann, John Oakland and

Keith Lockyer, MacMillan India Ltd.





Plant Location: Factors affecting the Location and Site Selection, Multiplant Location.Concept of location, location strategy, factors affecting the location and site selection, multiplant location

QUESTIONS

1. Discuss the importance of location theories and models. How do these theories help

in plant location and design?

2. What are the factors that are considered for selecting a site for a factory?

3. What are the factors that should be considered in building design?

4. For what type of factory single storey building is preferred to the multi storey

building? Justify the answer.

5. Discuss how for the site of a factory would influence the production cost.

4. Discuss briefly the factors to be considered for good plant location.

5. What is the difference between a good site and a good location?

6. How could a company go about picking a location, which would be good over the

years? Explain.

7. “The location choice problem is complex mainly because multiple objectives and

criteria are normally evident”. Discuss illustrate.

8. Explain any ‘location evaluation method’ considering any industry.

9. When should the factory be close to its source of raw materials rather than its market?

10. What are major aspects of plant location problem and what factors are particularly

important to each?

11. Suggest suitable locations for the plants of the following products:

(i) Ships (ii) readymade garments (iii) antibiotic medicines

Give reasons for your choice.

12. In seeking a good general location, why should the nature of the industries in the

communities be studied?

13. Are the locations of employee service facilities important to a layout? Why?

Home Assignments

1. Name and discuss the factors, which you need for the selection for the selection of a

plant site. What are the advantages and disadvantages of town and country situation?

2. Discuss the principles considerations of location of:

(i) Sheet industry around Jharkhand

(ii) Plastic industry in Bombay

(iii) Textile industry in Bombay and Ahmedabad

3. State the factors governing the choice of a site for a manufacturing unit.

4. You are proposed to establish a steel foundry in Bihar, discuss the factors, which

should be considered in selecting a site.

Reference Books:



2. Production and Operation Management by Alan Muhlemann, John Oakland and

Keith Lockyer, MacMillan India Ltd.





Plant Layout: Objectives of Good Plant Layout, Types of Layout, and Factors affecting Plant Layout.OBJECTIVES OF GOOD LAYOUT: Strategic issue of layout, criteria of a good layout, symptoms of a bad layout, factors affecting the plant layout, advantages of a good layout, future expansion of factory.TYPES OF LAYOUT: product and process layout, suitability, advantages & disadvantages of different layouts, planning the layout, installation of layout, flexibility of layout.

QUESTIONS

1. What are the objectives of a good plant layout?

2. Enumerate the various factors to be considered in the design of plant layout.

3. What are the principles of plant layout?

4. What are the criteria of a good plant layout?

5. What are the advantages of good layout?

6. Explain the different factors affecting the plant layout?

7. Define plant layout. Why is it necessary to plan it well?

8. Distinguish fully between the product layout and the process layout.

9. Describe the major steps of planning a layout.

10. What are the symptoms of poor layout? Describe the characteristics of a theoretically

perfect plant layout.

11. Compare the advantages and disadvantages of a process layout to a product layout

with respect to-

(a) Material Handling cost (b) Utilization of machines

© Need for supervision (d) Room required to work in process

12. Describe various types of plant layouts giving their scopes in various industries.

13. When one speaks of suitable lighting, the level of illumination is only one of the

factors considered. What are some of the other factors, and why are they important?

14. Draw a sketch of layout and discuss.

15. What information is essential to the development of an efficient factory layout?

16. What factors would you consider in choosing between extension of factory or

working another shift when increased production becomes necessary?

17. How flexibility in layouts can be secured?

Home Assignments

1. Draw a layout of: (a) small repair shop (b) layout of service

2. What information is necessary for planning a plant layout or revising an existing one?

How will you proceed to prepare a plan for such a layout?

3. Is the location of employee service facilities important to a layout? Why?

4. What is the prime objective in layout for grocery stores?

5. When does it become necessary to improve the existing layout?

Reference Books:





4. Industrial Management by O. P. Khanna, Dhanpat Rai & Sons




Techniques and Tools of Layout: Concept of location theory and Models, Techno economic Analysis, Design and Types of Building, Types of Flow Pattern.TECHNIQUES AND TOOLS OF LAYOUT: use of Travel chart, operations sequence analysis, line balancing, analytical tool of plant layout, layout of small repair shop, layout of service, determination of space requirements.TYPES OF FLOW PATTERN: Effects of flow pattern on plant layout, factors governing flow patterns, types of flow pattern.

QUESTIONS

1. Explain in detail the advantages and limitations of using templates and models, when

preparing one detailed layout.

2. Discuss in brief different techniques of plant layout.

3. Write short notes on:

4. (a) Operation sequence analysis (b) Line balancing

© Store space requirement (d) Flow process chart

5. Explain ‘Travel chart’. What is the use of Travel chart?

6. What are different analytical tools of plant layout?

7. ‘Flow of material in the plant determines the type of layout, cost of material handling,

space needed and length of the production time’. Discuss.

8. Enumerate factors governing the flow pattern.

9. ‘The flow patterns affects on the cost of various phenomenon/things’. What are they?

10. What is the effect of specific suitable flow pattern on plant layout?

11. Discuss about the classification of flow patterns.

12. Discuss the merits and demerits of a single-storey and multi-storey Industrial

building.

13. For what type of factory single storey building is preferred to the multi-storey

building? Justify the answer.

14. What are the different building equipments? Discuss.

15. Draw some layout of industrial buildings with future expansion.

16. On which factors space requirement depend?

17. Explain the following types of flow pattern:

(i) Straight line flow (ii) L-shaped flow

(iii) U-shaped flow (iv) Circular flow (v) Serpentine flow

Home Assignments

1. What are the different factors of space requirement in any working place?

2. An industry requires manufacturing five different components on a vertical milling

machine. The plant operates one shift of 40 hours/week. The quantity required for

each component and machine capacity for producing each component are as follows:

Component Pieces required/week Machine capacity/hour

LM 25 4000 30

CD 14 6500 90

GRD 100 4350 60

XL 42 2000 50

AP 200 960 35

Taking into account the set up allowances, down time losses etc. machine produces

only 75% of its capacity and rejects are 3%. How many machines are required for the

purpose?

3. Discuss about ‘Computerized approaches and quantitative techniques for facility

planning and design’.

4. On which factors space requirement depend?

Reference Books:









Material Handling: Objectives and Principle, Diagnosis and Analysis of Handling Problems, Types of Loading, Inter relationship between material handling and Plant Layout.

QUESTIONS

1. “Material handling is a necessary evil” – Discuss.

2. Explain the term material handling and discuss the objectives of good material

handling system.

3. What is material handling? What does it achieve?

4. Discuss briefly the steps needed to analyze a material handling problem.

5. Enumerate some of the guiding principles of material handling.

6. ‘Flow of material in the plant determines the type of layout, cost of material,

space needed and length of the production time’. Discuss.

7. How the space requirement is effected by factors in material handling system such

as characteristics, quantity, unit load, equipment manpower etc. Discuss.

8. What is material handling? How the following factors affect the choice of

material handling equipment.

(i) Required path of travel (ii) Nature of material

9. Discuss the functions and principle of good material handling system.

10. Explain material flow cycle.

11. What is the different type of loads?

12. What are the different types of materials moved in the factory?

13. What are the different aspects material handling systems?

HOME ASSIGNMENTS

1. Explain the guiding principles of material handling system.

2. How to solve a material-handling problem? Explain different steps for it.

3. How you can diagnosis and analyze a material handling problem?

4. What do you mean by material handling efficiency?

Reference Books:









Material Handling Equipments and their Selection, Industrial Applications, Design of an Integrated Plant/Facility Layout.

QUESTIONS

1. What are the factors to be considered while selecting material handling

equipment?

2. Describe briefly different types of material handling equipments.

3. How the following factors effect the choice of material equipment

(i) Required path of travel (ii) Nature of material

4. Taking the case of a particular industry, mention some of the material handling

equipments used there.

5. How material-handling equipments can be classified?

6. Categories material handling equipments.

7. In which applications cranes and hoists are useful?

8. List out some area where industrial trucks are most useful.

9. List out the few mechanical handling equipment.

10. How selection of material handling equipments depends upon the facility of

design?

HOME ASSIGNMENTS

1. Design a shop, which is almost considered as a flexible manufacturing

system.

2. Give some argument that before designing a facility, equipment must selected

in mind.

3. Draw some attention on using mechanical equipment.

Reference Books:




Plant Maintenance: Life Cycle Costing, Importance of Maintenance in Plant, Types of Maintenance, Preventive and Breakdown Maintenance, Inspection Decision, Economics of Maintenance, Evaluation of Maintenance Policy, Terotechnology.

QUESTIONS1. What do you mean by plant maintenance?

2. What are the objectives of plant maintenance?

3. What is the importance of maintenance?

4. What are the duties – function and responsibilities of plant maintenance

engineering department?

5. What is corrective/breakdown maintenance? What are the typical causes of

equipment breakdown?

6. What are the advantages and disadvantages of breakdown maintenance?

7. What is meant by scheduled maintenance?

8. What is preventive maintenance? What are the objectives of preventive

maintenance? Write down the elemental steps/procedure of preventive

maintenance?

9. Write short notes on ‘predictive maintenance’?

10. Why maintenance is needed in a plant? What are its objectives?

11. Name different types of maintenance used in industry? Give merits and demerits

of each.

12. What is the procedure for breakdown maintenance? Explain in brief.

13. What are the factors influencing a good maintenance policy?

14. Explain in brief the different techniques for a proper maintenance in a small

plant?

15. What are the difference between a breakdown maintenance and preventive

maintenance?

16. Explain what type of maintenance can be used in the following cases

economically.

(a) in case of small scale industry (b) in case of medium scale industry

© in case of large scale industry

17. Why planned maintenance policy is desirable in any type of industry? Explain.

18. Explain with an example that the maintenance cost is not a negative cost for a

successful running of an industry.

19. Mention some of the causes of equipment breakdown.

20. What do you mean by ‘stand-by-machines’?

HOME ASSIGNMENTS

1. Write a note on ‘economics of maintenance’. How it is related to crew size.

2. Discuss in brief the elements of good maintenance.

3. “No maintenance work can proceed effectively without on information system”. –

Discuss.

4. How will you evaluate the efficiency of maintenance?

5. How can you distinguish between maintenance activities from production

activities?

6. Mention some of the problems they are associated with maintenance of

equipments.

7. What are the basic steps to be followed for the implementation of preventive

maintenance?

8. “Some maintenance engineers contend that the preventive maintenance on items

is absolutely unnecessary”. Comments on this opinion.

9. How can the effectiveness of a maintenance department be evaluated?

Reference Books:






Plant Engineering

Documents

Transcript of Plant Engineering