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Plant Layout

Plant Layout. Arc Welding Processes. Learning Activities Read Handbook Pp 1-16, Look up Keywords View Slides; Read Notes, Listen to lecture Do on-line workbook Do homework. Lesson Objectives When you finish this lesson you will understand:. Keywords:. PLANT LAYOUT PATTERNS

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Plant Layout

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  1. Plant Layout

  2. Arc Welding Processes • Learning Activities • Read Handbook Pp 1-16, • Look up Keywords • View Slides; • Read Notes, • Listen to lecture • Do on-line workbook • Do homework • Lesson Objectives • When you finish this lesson you will understand: Keywords:

  3. PLANT LAYOUT PATTERNS Functional Layout Group similar machines in centers which perform similar functions. Product Layout Group machines in a line to make a certain product - Assembly Line Group Layout (Variation of product layout) Machines are arranged so that specific parts can be made in a group - then moved to next station (maybe even another plant). Fixed Position Layout The part is assembled in one location - machines and materials brought together.

  4. Functional Layout Group Machines in centers which perform similar functions

  5. Example: Movable Crane Manufacture • Outside Storage: • Incoming Plate and Supplies • Finished Product Awaiting Delivery

  6. Plate moves to a plasma arc cutting with water table • parts cut for telescoping arms – up to 3 arms • parts cut for cab section • parts cut for carrier frames

  7. Plates sub arc welded into telescoping arms • note fixturing table • arms slide inside each other so must be straight • largest arm move to flame cut area and pivot hole cut • SMAW hardfacing done around pivot hole

  8. All arms moved to GMAW station where stiffeners are welded on

  9. Arms inspected for straightness and weld workmanship • Arms assembled inside each other

  10. All parts assembled and painted

  11. Strain gage attached for lift “proof” testing

  12. “Proof Testing” performed on each unit before storage or delivery

  13. Functional Layout Advantages Disadvantages

  14. Functional Layout Advantages Disadvantages • General purpose machines slower • Work routing, scheduling difficult • Material handling costs high • Material moves slowly • Partially finished inventory high – large storage space • Communication difficult • Some limit to size of parts • Best use of specialization of machines & employees • Flexible – variety of products • General purpose machines – less costly • Ability to follow diverse paths • Less vulnerable to shutdowns • Machine breakdown less of problem • Small batch product economy • Suitable for incentive pay

  15. Questions? • Turn to the person sitting next to you and discuss (1 min.):

  16. Load Path Method to Determine Plant Layout

  17. 90 15 75 13 45 2 16 20 5 3 5 10 12 10 5 35 3 90 20 5 33 5 18 5 499 Direct: 90+ 15+ 75+ 20+ 45+ 5+ 13+ 12+ 3+ 35+ 10+ 5+ 18+ 20+ 33+ 90+ 10= 82 Indirect: 16+ 5+ 2+ 5+ 3+ 5+ 5= Minimum Load Path Arrangement

  18. 1 2 4 8 Fit Into 3 13 6 12 5 Existing Building Space 11 7 9 10

  19. Beside Total Weight there are other considerations which should not be overlooked • Bulk • Fragility • Cooperation between departments • Common services = air, electric power loading • Isolation of noisy or hazardous department

  20. Load Path Homework

  21. Product Layout Group machines in a line to make a certain product - Assembly line Pallet from Group Layout

  22. Example: Wheel Rim Manufacture

  23. Coil handling equipment – slit coils are fed into blank cutter

  24. Blank cutter cuts pieces to exact length

  25. Flat strip blank is rolled into a cylinder

  26. Cylinder is flash welded

  27. Cylinder is flared on each end to expand to outside wheel dimensions

  28. Wheel is roll formed though 3 or 4 successive expansions to final wheel contour

  29. The spider which was stamped on another line is mated with the wheel and GMAW together

  30. Product Layout Advantages Disadvantages

  31. Product Layout Advantages Disadvantages • Best for products made in large quantities • Low cost per unit • Fast • Low material handling costs • Low storage & inventory • Simplified training of new workers • Fewer personnel • Large initial investment • Vulnerable to stoppage • Inflexible – new designs not introduced • Parts must fit exact – no rework along line • Not suitable for incentive pay • Absenteeism hard to handle • All stations must take same time

  32. Time Flow Analysis • Make a list of all the assembly elements • Time for each element (we will do a time study exercise later) • List which elements must precede the current task

  33. Optimize the time flow by assigning task elements to work stations such that: • The time at every work station is close to the same • The correct sequence of operations is maintained • The number of work stations is reasonable • The required number of parts per hour exit the line Example: Suppose to make a reasonable profit (we will do a cost analysis exercise later) we need 65 cars exiting the assembly line per hour. The slowest work station will dictate the entire line speed, thus the slowest station must take less time than 0,92 minutes

  34. Precedence Diagram 0.2 7 0.4 0.3 0.1 4 12 2 0.2 8 0.2 1 0.6 9 14 0.7 0.8 0.8 3 5 0.3 10 0.6 0.3 6 13 0.5 11 Work Stations 8,12, 14 1,3 2,4,7 5 6,10 9 11,13 0.8 0.9 0.9 0.9 0.8 0.8 0.9

  35. Questions? • Turn to the person sitting next to you and discuss (1 min.):

  36. Time Flow Homework

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