UNIT 1

PLANNING AND FUNCTIONAL REQUIREMENTS

CLASSIFICATION OF INDUSTRIES AND INDUSTRIAL STRUCTURES

INDUSTRY

Primary Secondary Tertiary

• Agriculture • Banking
• Finance
• Forestry
• Fishing Heavy
Light • Insurance
• Health

• 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

• Efficient and uninterrupted flow of materials.

• To reduce the repetition of the same material being handled without any useful purpose.
• To design the pathway, roadway, railway, material handling and plant layout
requirements of a factory.
• To avoid overcrowding of machines and workmen on a shop floor, thus avoiding
congestion and improving housekeeping.
 • Easy accessibility of both material and machines is also kept inn mind, while carrying
out a plant layout.
• Efficient lighting, ventilation, means of escape during emergencies like fire, explosion
etc.
IMPORTANCE OF PLANT LAYOUT

• Facilitates the production process.

• Minimizes material handing, time and cost.
• Allows flexibility of operations.
• Easy production flow.
• Makes economic use of the building.
• Promotes effective utilization of manpower.
• Provides for employee’s convenience.
• It is important as it affects flow of materials, labour efficiency supervision and control.
PRINCIPLES OF LAYOUT
1. PRODUCT
 The weight, size and mobility of the product will affect the layout.
 Heavy and large products require the movement of men and machines and equipment
to a fixed position necessitating the fixed position layout as in the case of ship
building and railway car building.
 Smaller products will require the machines and equipment to be arranged either
according to the product or process.
2. TYPE OF MANUFACTURE
 Continuous / Mass production industry - Product type layout
 Intermittent manufacture industry - Process type layout
3. VOLUME OF PRODUCTION
 Job production industry
 Mass production industry
 Batch production industry
4. THE PROCESS
Synthetic process – Sugar and Cement factory
 Analytical process – Petroleum refineries
Extractive process – Extraction of metals from their ores
5. MATERIALS HANDLING
 The plant layout should provide adequate aisles for the movement of materials and
allocate space for storage both in store and workstations. In some industries,
overhead cranes are to be provided.
6. MACHINES AND EQUIPMENTS
 Adequate space must be provided for all machines and equipments used for
manufacturing, materials handling and services.
7. SELECTION AND CONSTRUCTION OF BUILDINGS
 The type and shape of the building are to be selected properly in the initial stage itself.
 Once the building is constructed, only the layout is to be changed and not the building.
Factors are to be considered while planning a building,

•The nature of the manufacturing process.

•The plant labour.
 •Lighting, heating, ventilation and air conditioning.
•Service facilities.
•Future expansion.
•Appearances.
8. QUALITY
To maintain the quality in the products, it is necessary to have
Less material handling. Proper plant layout.
9. PLANT SITE
The plant layout in order to provide facilities for receipt of raw materials and
shipment of finished products depending on the transport facilities available outside
the factory.
10. LINE BALANCING
 Assume that there is a product line with 3 work station A,B and C also that each
machine at A B and C can process 100parts , 50parts and 25parts per hour respectively.
 If each machine were to produce only 25parts per hour then each hour the machines at
A and B would be idle for 45 and 30 minutes respectively.
  In process layout, these periods of idleness might be occupied by proper routing and
scheduling of work.
 In product layout, one machine at station A, two machines at station B and four
machines at station C could be kept busy and the product flow would be constant all
along the line.

TYPES OF PLANT LAYOUT

1.Manufacturing Units
2.Traders
3.Service Establishments
1. MANUFACTURING UNITS
PRODUCT OR LINE LAYOUT:
• The machines and equipments are arranged in one line as per the sequence of
operations required for the product.
• The materials move from one workstation to another sequentially without any
deviation.
 • The materials are fed into the first machine and finished goods travel from machine to
machine, thus output of one machine becoming input of the next. e.g: paper mill.
GENERAL PRINCIPLES
a) All the machine tools or other items of equipments must be placed at the point
demanded by the sequence of operations.
b) There should not be any points where one line crosses another line.
c) Materials may be fed where they are required for assembly but not necessarily at one
point.
d) All the operations including assembly, testing packing must be included in the line.

A line layout for two

products
ADVANTAGES
 • Low cost of material handling, due to straight and short route and absence of
backtracking
• Smooth and uninterrupted operations
• Continuous flow of work
• Lesser investment in inventory and work in progress
• Optimum use of floor space
• Shorter processing time or quicker output
• Less congestion of work in the process
• Lower cost of manufacturing per unit
DISADVANTAGES
• High initial capital investment in special purpose machine
• Heavy overhead charges
• Breakdown of one machine will hamper the whole production process
• Lesser flexibility as specially laid out for particular product
SUITABILITY
Product layout is useful under following conditions,
• Mass production of standardized products
• Simple and repetitive manufacturing process
• Operation time for different process is more or less equal
• Reasonably stable demand for the product
• Continuous supply of materials
PROCESS 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.

Fixed position layout regarding shipbuilding

ADVANTAGES

• 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.

CONTROL OF INDUSTRIAL NOISE AND HEAT

1. INDUSTRIAL NOISE
An undesirable sound can be termed as a ‘NOISE’. Indian Factory Act 1948 has
included noise induced hearing loss as one of the notifiable diseases.
 A worker can claim compensation from the management under the Workmen
Compensation Act 1923 for the hearing loss induced by his exposure to high noise
levels.
MEASUREMENT OF NOISE
The unit of sound is called a ‘decibel’ and is denoted by the symbol ‘dB’.
As per medical authorities, any sound above 85 dB exposed for more than 8 hours
can cause danger to a person’s hearing ability.
INTENSITY
SOUNDS -
1. Speaking at very low voice - 20 dB
2. Normal conversation 60 dB
3. Machines like press,lathe etc 80 dB
4. Air plane 120 dB

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.

SEGMENTAL VIBRATION - Affects an organ , part or ‘segment’ of the body.

 WHOLE BODY VIBRATION - Affects the entire body or number of organs in the body.

HOW CAN YOU MEASURE VIBRATION?

 A complete assessment of exposure to vibration requires the measurement of vibration
acceleration in m/s2.
 Vibration exposure direction , frequencies and duration of exposure are also determined.
 Measuring acceleration can also give information about velocity and amplitude of vibration.
CONTROLLING MEASURES OF VIBRATION

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.

SAFE WORK PRACTICES

 Employ a minimum hand grip consistent with safe operation of the tool or process.
 Wear sufficient clothing ,including gloves to keep warm.
 Avoid continuous exposure by taking rest periods.
  Rest the tool on the work piece whenever practical.
 Refrain from using faulty tools.
 Maintain properly sharpened cutting tools.
INDUSTRIAL FIRE AND PREVENTION

COMPONENTS OF FIRE
1.Fuel ( combustible material)
2.Oxygen ( available in the atmospheric air)
3.Heat ( ignition sources)

HEAT OR IGNITION SOURCES

1. Electrical Equipment.
2. Friction.
3. Open flames.
4. Smoking and Matches.
5. Hot Surfaces.
 6. Static Electricity.
CLASSIFICATION OF FIRE
CLASS DESCRIPTION

A Burning of solid materials such as wood, paper, clothes, rubber etc

B Burning of liquids like oil, grease, paint, petrol, kerosene etc

C Fires of gases like acetylene, ethane, methane and other gases

D Sodium, potassium, Magnesium and similar chemicals produce fire

E Fires due to electrical equipment.

FIRE EXTINGUISHING AGENTS

1. Water.
2. Carbon - di – oxide.
3. Dry chemical powder.
4. Inert gases, etc.
TYPES OF FIRE EXTINGUISHERS
Fire buckets - suitable for CLASS A small fires
Portable fire extinguisher - suitable for various classes of small fires
Soda acid type extinguisher - suitable for CLASS A and not suitable for CLASS B and E
Foam extinguisher - suitable only for CLASS B fires
Carbon di oxide extinguisher - suitable for CLASS E fire
Dry chemical powder extinguisher - suitable for CLASS C, D and E
FIRE FIGHTING EQUIMENTS – TYPES AND USES
FIRST AID TREATMENT OF BURNS AND SCALDS
•BURN - Hot surfaces, electric current , corrosive chemicals etc cause burn injuries.
•SCALD - Steam, boiling water, hot oil etc., produce scald injuries
GENERAL FIRE PRECAUTIONS
• When a person catches fire he should be approached with a rug or blanket and wrap it around
him to smoother the flame.
• No lotions of any kind should be applied on the burnt area.
• In the case of burns due to corrosive chemicals, the burnt parts should be flooded with water.
• The burnt area should be covered with dry sterile dressing and a bandage may be applied.
• The affected area should be immobilized by suitable means.
• Physical shock of the person is treated by giving him tea or coffee and reassuring him till
medical aid is started.
• In major cases the patient should be sent to hospital as quickly as possible.

Lighting – Refer IS: 6060 - 1971

Ventilation – Refer IS: 3130 - 1975
THANK YOU