Unit 1 Industrial Engineering & Management Notes in English

 These are short notes for revision purpose. please refer you Reference book & College study materials for complete study.

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1. Plant Engineering

Plant Engineering refers to the branch of engineering that deals with the design, installation, and operation of a manufacturing plant or facility. It involves creating an efficient and safe environment for production processes by considering aspects such as layout, location, machinery, and workforce management.

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1.1 Plant

A plant is a facility or a place where raw materials are processed into finished products. In industrial terms, it refers to the entire setup, including buildings, machinery, equipment, and personnel, that is used for manufacturing goods. The plant's design and efficiency are crucial for the success of the production process.

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1.2 Selection of Site of Industry

The selection of the site of an industry is one of the most critical factors for the success of any industrial plant. It involves considering various factors to ensure smooth and efficient operations.

Factors to Consider:

1. Proximity to Raw Materials: The site should be close to the raw materials needed for production to minimize transportation costs.
2. Access to Transportation: The site should be well-connected by roads, railways, ports, or airports for easy transportation of materials and finished goods.
3. Availability of Labor: The site should have access to a skilled and affordable labor force.
4. Utilities and Infrastructure: The site should have easy access to utilities such as water, electricity, and gas. Adequate infrastructure for waste disposal and environmental concerns should also be considered.
5. Climate and Environmental Factors: Weather conditions and environmental regulations should be factored in, as extreme climates can affect production.
6. Government Policies and Incentives: The presence of government incentives such as tax benefits, subsidies, and industrial zones can influence the choice of location.
7. Market Proximity: The location should be near the target market to reduce distribution costs and delivery time.
8. Cost of Land: The price of land in the chosen area should be reasonable for the size of the plant required.

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1.3 Plant Layout

Plant Layout refers to the arrangement of machines, equipment, workstations, storage, and other necessary facilities in the plant. A well-planned layout ensures smooth and efficient production processes, minimizes material handling costs, and improves safety.

Objectives of Plant Layout:

• Minimize material handling costs: Reduce unnecessary movement of materials.
• Improve workflow: Ensure smooth and efficient flow of materials, products, and information.
• Increase production efficiency: Minimize idle time and optimize machine usage.
• Ensure worker safety: Proper arrangement to reduce accidents and ensure a safe working environment.
• Space utilization: Maximize the use of available space while providing flexibility for future expansions.

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1.4 Principles of a Good Layout

A good layout must satisfy the following principles to be efficient and effective:

1. Minimize Material Handling: The layout should minimize unnecessary movement of raw materials, work-in-progress, and finished goods to reduce handling costs and time.
2. Efficient Flow of Work: The layout should ensure that there is a smooth flow from raw materials to the finished product without bottlenecks or delays.
3. Flexibility: The layout should be adaptable to future changes in production volume or product type.
4. Utilization of Space: Proper space planning should be done to ensure efficient use of available space, including storage and movement areas.
5. Safety and Comfort: A good layout should consider safety standards, ventilation, lighting, and the comfort of the workers.
6. Minimize Idle Time: The layout should minimize idle time of both machines and workers.
7. Effective Supervision: The design should allow managers and supervisors to easily monitor operations and intervene when necessary.

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1.5 Types of Plant Layout

There are several types of plant layouts, and each type is suitable for different kinds of production processes.

1.5.1 Process Layout

In a process layout, similar machines and equipment are grouped together based on the functions they perform. This layout is suitable for industries where a variety of products are produced in small batches, and flexibility is essential.

Advantages:

• Flexibility in handling different types of products.
• Easy to accommodate changes in product design.

Disadvantages:

• High material handling costs.
• More complex inventory management.

Examples: Hospitals, machine shops, and service industries.

1.5.2 Product Layout

In a product layout, machines and workstations are arranged in the order of the production process for a specific product. This type of layout is most suitable for mass production where the same product is produced in large quantities.

Advantages:

• Efficient use of resources and space.
• Reduced material handling costs.

Disadvantages:

• Lack of flexibility to produce different products.
• Equipment breakdown can halt the entire production line.

Examples: Automobile assembly lines, bottling plants.

1.5.3 Fixed Position Layout

In a fixed position layout, the product stays in one place, and workers, equipment, and materials are brought to the site. This layout is used for large, bulky, or heavy products that cannot be moved easily.

Advantages:

• Suitable for large products that cannot be moved (e.g., ships, airplanes).
• Reduced movement of large items.

Disadvantages:

• High labor costs due to the movement of workers and equipment.
• Limited production capacity due to the fixed nature of the layout.

Examples: Shipbuilding, construction of large structures.

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1.6 Techniques to Improve Layout

There are several techniques used to improve plant layouts and optimize efficiency:

1. Flow Process Chart: This tool helps visualize the flow of materials and workers through the plant. It helps identify any inefficiencies or bottlenecks in the process.
2. Systematic Layout Planning (SLP): This method systematically analyzes and plans the layout based on the relationships between departments, processes, and material handling requirements.
3. Block Diagram: A block diagram is used to represent the physical arrangement of departments or areas within the plant. It helps in understanding spatial relationships and planning space utilization.
4. Computer-Aided Design (CAD): CAD software can be used to create and simulate plant layouts. This allows for more accurate planning and quick modifications.
5. Just-In-Time (JIT) Inventory Management: By adopting JIT principles, companies can reduce inventory space, simplify storage needs, and improve the flow of materials through the plant.
6. Automated Material Handling Systems: Introducing automated systems such as conveyor belts, robotics, and cranes can reduce material handling costs and improve the flow of products within the plant.