Professional Documents
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Industrial Structures
Industrial Structures
INDUSTRY
• Mining • Police
• Extracting minerals •
Security
INDUSTRY SECTORS AND CLASSIFICATION
ACCORDING TO GOVERNMENT
1. PRIMARY SECTOR - Agriculture, mining and raw material extraction
2. SECONDARY SECTOR - Manufacturing
3. TERTIARY SECTOR - Service production.
MARKET BASED CLASSIFICATION
1. Global Industry Classification
2. Standard Classification
3. Industry Classification
PRODUCT BASED CLASSIFICATION
1. Chemical industry
2. Petroleum industry
3. Automotive industry
4. Paper industry
5. Food industry etc.
CLASSIFICATION OF INDUSTRIAL STRUCTURES
CLASSIFICATION OF BUILDING BASED ON OCCUPANCY ( NBC 2005 )
• Group A -Residential
• Group B -Educational
• Group C -Institutional
• Group D -Assembly
• Group E -Business
• Group F -Mercantile
• Group G -Industrial
• Group H -Storage
• Group J -Hazardous
Buildings under Group G shall be further sub-divided as follows
• Sub-division G-1 Buildings used for low hazard industries
• Sub-division G-2 Buildings used for moderate hazard industries
• Sub-division G-3 Buildings used for high hazard industries
INTRODUCTION TO PLANT LAYOUT
DEFINITION
Plant layout refers to the arrangement of physical facilities such as machinery, equipment
,furniture etc, within the factory building 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 material to the shipment of the finished product.
NECESSITY TO CONSIDER PLANT LAYOUT
When a new industry is started.
When there is a change in the design of the present product.
When a new product is added to the existing flow.
When there is an increase in production activities and hence reduction in the size of
department.
When there is a relocation of departments.
OBJECTIVES OF PLANT LAYOUT
• In this type of layout machines of a similar type are arranged together at one place, hence
these layouts have drilling department, milling department , welding department etc.
• The work has to be allocated to each department in a such a way that no machines are
chosen to do as many different job as possible.
• The work, which has to be done, is allocated to the machines according to loading
schedules with the object of ensuring that each machine is fully loaded.
GENERAL PRINCIPLES
a) The distance between departments should be as short as possible for avoiding long
distance movement of materials
b) The departments should be in sequence of operations
c) The arrangement should be convenient for inspection and supervision
ADVANTAGES
• Lower initial capital investment in machines and equipments. There is high degree of
machine utilization , as a machine is not blocked for a single product.
• The overhead costs are relatively low.
• Change in output design and volume can be more easily adapted to the output of variety
of products.
• Breakdown of one machine does not result in complete works storage.
• Supervision can be more effective and specialized.
• There is a greater flexibility of scope for expansion.
DISADVANTAGES
•Material handling costs are high due to backtracking.
•More skilled labour is required resulting in higher cost.
•Time gap or lag in production is higher.
•Work in progress inventory is high needing greater storage space.
•More frequent inspection is needed which results in costly supervision.
SUITABILITY
Process layout is adopted when,
•Products are not standardized.
•Quantity produced is small.
•There are frequent changes in design and style of product.
•Machines are expensive.
FIXED POSITION OR LOCATION LAYOUT
• In this type of layout, the major product being produced is fixed at one location.
Equipment labour and components are moved to that location.
• All facilities are brought and arranged around one work corner. This type of layout is not
relevant for small scale entrepreneur.
• It saves time and cost involved on the movement of work from one workstation to
another.
• The layout is flexible as change in job design and operation sequence can be easily
incorporated.
• It is more economical when several orders in different stages of progress are being
executed simultaneously.
• Adjustments can be made to meet shortage of materials or absence of workers by
changing the sequence of operations.
DISADVANTAGES
• Production period being very long, capital investment is very heavy.
• Very large space is required for storage of material and equipment near the product.
• As several operations are often carried out simultaneously, there is possibility of
confusion and conflicts among different work groups.
SUITABILITY
• Manufacture of bulky and heavy products such as locomotives, ships , boilers ,
generators, wagon building, aircraft manufacturing, etc.
• Construction of building flyovers, dams.
• Hospital, the medicines, doctors and nurses are taken to the product.
COMBINED LAYOUT
• Certain manufacturing units may require all the three processes namely Intermittent
process (job shops) , continuous process ( mass production shops)and the representative
process (miscellaneous shops).
• Example : Industries involving the fabrication of parts and assembly, fabrication tends
to employ the process layout while the assembly areas often employ the product
layout.
• In soap industry, the machinery manufacturing soap is arranged on product line but
ancillary services like heating, water treatment plant etc are arranged on functional basis.
FACTORS INFLUENCING PLANT LAYOUT
1.Factory building.
2.Nature of product.
3.Production process.
4.Type of machinery.
5.Repairs and maintenance.
6.Human needs.
7.Plant environment.
Thus, the layout should be conducive to health and safety of employees.
It should ensure free and efficient flow of men and materials.
Future expansion and diversification may also be considered while planning factory layout.
APPLICABILITY OF PLANT LAYOUT
PRODUCT APPLICABILITY
DETERGENT POWDER A MULTI-STOREY BUILDING- Materials are stored and poured into the
boiler at different stages on different floors.
TALCUM POWDER Here, machinery is arranged vertically i.e from top to bottom. Thus
material is poured into the first machine at the top and powder comes out at
the bottom located at ground floor,
NEWSPAPER PLANT The plant layout must be simple and direct so as to eliminate distance,
delay and confusion. There must be perfect coordination of all
departments and machinery or equipments as materials never fail.
FIVE STAR HOTEL Lodging, bar, restaurant, kitchen, stores ,swimming pool, laundry ,parking
areas etc should all find an appropriate place in the layout. Importance
must be given to cleanliness, elegant appearance, convenience and compact
looks, which attract customers.
CINEMA HALL Emphasis on comfort and convenience of the cinemagoers. The projector,
screen, sound box , fire fighting equipment ,ambience etc should be of
utmost importance.
SOURCES OF NOISE
1.Impact.
2.Friction.
3.Air.
4.Reciprocation.
5.Other noises.
NOISE CONTROL MEASURES ( for noise level above 95 dB)
1.SUBSTITUTION OR SELECTION PROCESS
a) Welding instead of riveting.
b) Hot working of metal instead of cold working.
c) Belt drives instead of gear drives.
2. SEGREGATION OR ISOLATION OF PROCESSES
If substitution is not possible, the machines which produce high levels of noise can be
separated and enclosed in an isolated room. EXAMPLE: Compressors or Generators.
3. CONTROL AT SOURCE
The noise levels can be reduced by,
• Proper selection of machinery.
• Use of isolators ( rubber pad, resilient material), mufflers or silencers.
• Proper maintenance of machines.
• Proper installation or erection.
4. PERSONAL PROTECTION
Workers employed in high noise level areas should be provided with suitable
protective equipment such as ear plug or ear muff, to reduce the intensity.
5.CHANGE OF JOB OR CHANGE OF PERSONS
• Instead of allotting the same job for the same person for a prolonged period, suitable
changes in allotting the workmen for short intervals of time can solve the problem.
• Avoiding the same worker to get exposed for longer duration ( more than 4 hours) in
the noisy atmosphere will help in protecting the worler’s hearing ability.
LEGAL PROVISIONS INVOLVING HIGH NOISE LEVELS
According to Factory Act 1948 and Factory rules, the following provisions have been
made pertaining to high noise levels:
• In every factory, suitable engineering control or administrative measures shall be
taken to ensure, as far as reasonably practicable, that no worker is exposed to sound
levels exceeding the maximum permissible noise exposure levels given below:
•Every worker employed in areas where the noise exceeds the maximum permissible exposure
levels specified above shall be subjected to an auditory examination by a certifying surgeon
within 14 days of his first employment and thereafter shall be re-examined atleast once in every
12 months.
VIBRATION
Vibration of a body is the movement of the body about its mean position and can be linear,
circular, periodic or non periodic.
The movement of atoms cause cause vibration of a body and vibration stops when atoms come
to halt at mean position.
Vibration that causes noise can be very harmful for us and mechanical vibration cause fast
wear and tear of machinery parts.
Vibration has two measurable quantities : Amplitude or Intensity and Frequency .
FREQUENCY
A vibrating object moves back and forth from its normal stationary position. A complete cycle
of vibration occurs when the object moves from one extreme position to the other extreme and
back again.
The number of cycles that a vibrating object completes in one second is called frequency.
The unit of frequency is hertz (Hz). One hertz equals one cycle per second.
AMPLITUDE
A vibrating object moves to a certain maximum distance on either side of its stationary
position.
Amplitude is the distance from the stationary position to the extreme position on either side
and is measured in meters (m).
The intensity of the vibration depends on amplitude.
ACCELERATION
Acceleration is a measure of how quickly speed changes with time. The measure of
acceleration is expressed in m/s2.
The magnitude of acceleration changes from zero to a maximum during each cycle of
vibration.
RESONANCE
Every object tends to vibrate at one particular frequency called the natural frequency.
If we apply a vibrating force on the object with its frequency equal to the natural frequency, it
is a resonance condition.
HOW DOES THE VIBRATION EXPOSURE OCCUR?
The effect of vibration exposure depends on the frequency of vibration.
Each organ of the body has its own resonant frequency, if exposure occurs at or near any of
these resonant frequencies , the resulting effect is greatly influenced.
1.Anti -Vibration Tools : Anti - vibration chain saws reduces the acceleration levels by a factor of 10
2.Anti - Vibration Gloves : Conventional protective gloves ( cotton and leather) are made using a
layer of visco – elastic material.
COMPONENTS OF FIRE
1.Fuel ( combustible material)
2.Oxygen ( available in the atmospheric air)
3.Heat ( ignition sources)