05

Material handling equipment

&

plant layout

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 Material handling equipment
• Material handling is the general term robots, automated warehouses.
for the machines and equipment used
• There is a large amount of heavy labour
for the purpose of making cargo
involved at logistics worksites, such as
handling work more efficient
in loading and unloading and
• and using fewer labour resources in transporting cargo.
cargo handling work that places a large • Material handling device is a general
burden on workers. term for the machines used to make this
• These machines and equipment are logistics work more efficient.
called material handling devices. • These machines perform a variety tasks
• Material handling equipment used at including moving raw materials, work
logistics worksites include forklift, in progress, and completed products.
carts, pallets, conveyors, conveyance
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 Material handling equipment

Cart

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 Plant and Equipment layout
Equipment layout is the detailing of utilization of facilities for the
conceptual layout. manufacture of products,
It consists of the following information: • involving a most efficient economical
arrangement of machines, personnel,
flows space needed to for the equipment
storage space, and all supporting
and other facilities are shown and
services, within available floor space.
access,
• Plant layout is a plan of optimum
removal space clearing areas, arrangement of facilities
storage space and handling facilities are • including personnel, equipment’s
outlined. storage space, material handling
equipment
• Concept of plant layout
• and all other supporting services along
• Plant layout is a plan for effective with the decision of best structure to
contain these facilities
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 Sketch of plant layout

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 Advantages of plant layout
1. Streamline flow of materials equipment and space.
through the plant. 7. Increase employee morale.
2. Minimize material handling. 8. Minimize interference (i.e.,
3. Facilitate manufacturing progress interruption) from machines.
by maintaining balance in the 9. Reduce hazards affecting
processes. employees.
4. Maintain flexibility of arrangements 10.Hold down investment (i.e., keep
and of operation. investment at a lower level) in
5. Maintain high turnover of in- equipment
process inventory.
6. Effective utilization of men,
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 Types of Plant Layout
Two basic plans of the arrangement of manufacturing facilities are; Product layout and process layout.
The only alternative is the combination of product and process layouts in the same plant.
a) Product Layout (or Line Layout)
• Here all the machines are arranged in the sequence, as required to produce a specific product.
• It is a straight-line layout because machines are arranged in a straight line.
• The raw materials are fed at one end and taken out as finished product to the other end.

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Advantages and Disadvantages of Product Layout
Advantages • Disadvantages

1. Reduce material handling cost due to 1. Lack of flexibility of operations, as layout

mechanized handling systems and straight flow. cannot be adapted to the manufacture of many
other type of products.
2. Perfect line balancing which eliminates
bottlenecks and idle capacity 2. Large capital investment, because of special
purpose machines.
3. Short manufacturing cycle due to uninterrupted
flow of materials. 3. Dependence of whole activity on each part; any
breakdown of one machine in the sequence may
4. Simplified production planning and control; and result in stoppage of production
simple and effective inspection of work
4. Same machine duplicated for manufacture of
5. Small amount of work-in-progress inventory different products; leading to high overall
6. Lesser wage cost as unskilled workers can learn operational costs.
and manage production. 5. Delicate special purpose machines require costly
maintenance/repair
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 Types of Plant Layout 4
a) Process Layout (or Functional Layout)
• In this type of layout, all machines performing similar type of operations are grouped at one location
i.e., all lathes, milling machines etc. are grouped in the shop and they will be clustered in like groups.

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 Advantages and disadvantage of process layout
• Advantages • DISADVANTAGES OF
1. Greater flexibility with regard to work PROCESS LAYOUT
distribution to machinery and personnel. 1. Backtracking and long movements occur in
Adapted to frequent changes in sequence of handling of materials. As such, material
operations. handling costs are higher.
2. Lower investment due to general purpose 2. Mechanization of material handling is not
machines; which are less costly than special possible.
purpose machines.
3. Production planning and control is difficult.
3. Higher utilization of production facilities; which
can be adapted to a variety of products. 4. Most space requirement; as work-in-progress
inventory is high-requiring greater storage
4. Variety of jobs makes the work challenge and space.
interesting.
5. As the work has to pass through different
5. Breakdown of one machine does not result in departments; it is quite difficult to trace the
complete stoppage of work. responsibility for the finished product.

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 Types of Plant Layout 6
Suitability of product Layout
Product layout is suitable in the following cases; • Suitability of process Layout
1. Where one or few standardized products are manufactured. • Process layout is suitable in the following case, where;

2. Where a large volume of production of each item has to travel 1. Non-standardized products are manufactured; as the
the production process, over a considerable period of time. emphasis is on special orders.

3. Where time and motion studies can be done to determine the rate 2. It is difficult to achieve good labour and equipment balance.
of work.
3. Production is not carried on a large scale.
4. Where a possibility of a good balance of labour and equipment
exists. 4. It is difficult to undertake adequate time and motion studies.

5. Where minimum of inspection is required, during sequence of 5. It is frequently necessary to use the same machine or work
operations. station for two or more difficult operations.

6. Where materials and products permit bulk or continuous 6. During the sequence of operations, many inspections are
handling by mechanical parts. required.

7. Where minimum of set-ups is required 7. Process may have to be brought to work, instead of vice
versa because materials or products are too large or heavy to
permit bulk or continuous handling by mechanical means.
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 Types of Plant Layout 7
a) Combination Layout • The final assembly of the product is done in a
product type layout
• In practice, plants are rarely laid out either in
product or process layout form. b) Fixed Position Layout
• Generally, a combination of the two basic • It is also called stationary layout.
layouts is employed; to derive the advantages
• In this type of layout, men, materials and
of both systems of layout.
machines are brought to a product that remains
• For example, refrigerator manufacturing uses a in one place owing to its size.
combination layout.
• Ship-building,
• Process layout is used to produce various
• aircraft manufacturing,
operations like
• wagon building,
• stamping,
• heavy construction of dams,
• welding,
• bridges, buildings etc. are typical of examples
• heat treatment being carried out in different
of such layout
work centres as per requirement.
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 Plant
• Plant is “any machinery, equipment (including scaffolding), appliance, implement or
tool and any component or fitting thereof or accessory thereto”.

• Plant is machinery that processes material by way of a mechanical action which Cuts,
drills, punches or grinds Presses forms, hammers, joins, or moulds material Combines,
mixes, sort, packages, assembles, knits or weaves material.

• Plant also includes lifts, cranes, tractors, earth moving equipment, pressure
equipment, hoists, powered mobile plant, plant that lifts or moves people or materials,
amusement structures, high powered lasers, turbines, explosive powered tools,
scaffolds, chisels, saws, photocopiers, desks, filing cabinets and temporary access
equipment

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 Plant 2
Hazard thrown off or under plant

Hazard means the potential to 4. Cutting or piercing due to sharp

cause injury or illness. or flying objects

Examples of potential harm that 5. Friction burns

plant or associated systems of
6. Injury from high pressure fluids
work may cause to people at
work include 7. Injury from electricity

1. Injury from entanglement 8. Injury from explosion

2. Crushing by falling or moving 9. Slips trips and falls

objects, or plant tipping over

3. Crushing from people being

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 Plant 3
Risk Assessment 2. Substitution e.g., of the equipment or
substance
• Risk assessment is the process of determining
whether there is a risk associated with each of the 3. Engineering controls, controls, which
hazards identified, that is, whether there is any use engineering measures to change
likelihood of injury or illness the physical characteristic of plant
to eliminate or reduce risk.
Risk Control
E.g. guarding
• Is the process of implementing measures to reduce
the risk associated with a hazard.
4. Administrative controls, controls,
• When controlling risk, the hierarchy of control
which use systems of work to
should be considered in order of priority.
eliminate or reduce, risk e.g. supervision,
Hierarchy of Control training, and rotation .
• The Hierarchy of Control is the established
priority order for the types of measures to be used
5. Personal protective equipment,
to control risks.
(PPE)
1. Elimination of the hazard
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