PLANT LAYOUT DESIGN AND OHS

Course objective
After completion of the course, students will have knowledge about plant layout and design, which makes them able to design an optimum plant for production according to manufacturing process, raw material, and other resource.

1. Introduction to plant design and plant location (1 hours)
1. Definition of Plant Layout,
2. Types of Manufacturing Process - Plant Design


2. Plant location (2 hours)
1. Influence of Location on Plant Layout
2. Location Factors
3. Plant Size Selection Guide
4. Location Theory and Models


3. Industrial buildings (2 hours)
1. Relationship between the Buildings and Layout, Building Design and Construction
2. Bays
3. Floors
4. Walls and Windows
5. Roots and Ceilings.
6. Types of buildings
1. Single Story Buildings and Multistory Buildings - Construction Material.
7. Plant layout problem


4. Why Layout Problems Develop (4 hours)
1. Classes of Plant Layout Problems
2. Objectives
3. Classification of Layouts
4. Product Layout
5. Process Layout and Fixed Position Layout
6. Organization for Plant Layout.


5. Data collection (2 hours)
1. Use of Work Study in Plant Layout
2. Plant Layout Tools and Techniques.


6. Evaluation of layout (2 hours)
1. Measurement of Effectiveness.
2. Systematic Evaluation.
3. Optimizing Evaluation


7. Common problems in plant layout (2 hours)
1. Employee Services
2. Working Conditions
3. The Influence of Organization and Wage Incentives
4. Human Relations.


8. Material handling (5 hours)
1. Introduction
2. Factors in Material Handling Problems
3. Cost Factors in Material Handling.
4. Principles of Material Handling: Reduction in Time
5. Reduction in Handling
6. Maintenance and Repair.
7. First Cost and Operating Cost
8. Material Handling Equipments:
1. Conveying Equipments: Belt Conveyor, Apron Conveyor etc.
2. Hoisting Equipments: Cranes, Hoists etc.
3. Unit Load Handling.
9. Selection of Material Handling Equipments:
10. Factors Affecting Selection, Amount of Equipments Required
11. Determining Requirements by Transportation Techniques.


9. Case Study (5 hours)
1. Design/ Redesign a Layout of an Industry Focusing On Various Component and Process of Plant Layout Which Fulfills the Course Objective.
2. Students must mandatorily perform this task using CAD/CATIA/ Or Any Other relevant Software and Mathematical Modern Techniques and Standards.


10. Industrial Safety and Health (10 hours)
1. Fundamentals of system safety. Safety and accident prevention- causes and
2. Safety in product and process design.
3. Fault-tree analysis and risk assessment.
4. Occupational diseases, stress, fatigue.
5. Health, safety and the physical environment.
6. Engineering methods of controlling chemical hazards, safety and the physical environment: engineering methods of controlling chemical and physical hazards.
7. Code and regulations for worker safety and health.
8. Rules and Regulations of national and International organizations regarding hygiene and safety


11. Industrial psychology (10 hours)
1. Basic concept of psychology and human behavior in an organization.
2. Definition of psychology,
3. School of thought in psychology, research method and measurement in psychology,
4. Work meaning for a human and evolution of working in an industrial organization,
5. Individual differences and its utilization for work design

Practical: Survey of land

1. Linear measurement.
1. Direct method
2. Indirect method
2. Angular measurement
1. Prismatic compass
2. Theodolite
3. Leveling
1. Longitudinal and cross-sectional leveling.
2. Trigonometric leveling
4. Contouring
5. Traversing by different methods
6. Calculation of area by different methods
7. Layout of building using chain , tape, leveling machine and theodolite.

References

1. James,M. Moore, (1959"Plant Layout and Design", Mcmillan & Co.
2. Bolz, Harold A. George E., "Material Handling Handbook”
3. Apple ,J.M., (1977), "Plant Layout and Material Handling", John Wiley & Sons.

Evaluation Scheme
The Questions will cover all the chapters in the syllabus. The evaluation scheme will be as indicated in the table below: