Dept.

of ME

INDUSTRIAL ENGINEERING

Industrial engineering is concerned with design, improvement and installation of

integrated systems of men, materials, equipment and energy.
Main concern of industrial Engineering is productivity which implies

 More efficient use of resources

 Less wastage
 Higher level of output for a fixed level of input

Functions of an Industrial Engineer

1. Establishing the one best way of doing work (standard method)
2. Establishing the standard time for doing work
3. Developing a sound wage and incentive scheme
4. Preparing a detailed job description and job specification for each job and
evaluating them
6. Developing cost control Programs
7. Developing an optimal layout for smooth flow of work
8. Make economic analysis and justify their results
Industry
It is the place where the raw materials are converted or processed to
finished product. Industry coordinates men, materials, processes, machinery and
methods effectively to get the desired products.
Production and Productivity
Production is a process developed to transform a set of inputs like
men, materials, money, machinery and energy into a specified set of outputs
like finished products and services in desired quality and quantity
Production is a transformation of some set of inputs into desired outputs. It
is the volume of output irrespective of the quantity and quality of resources
employed to achieve that level of outputs.
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Input-Output Model

Productivity is regarded as efficiency in industrial system.it is the ratio between

outputs to input

Productivity = Output / Input

A production system is the set of interconnected input output elements and is
made up of three components made up of three component parts namely
inputs, process, outputs. A wide variety of inputs are transformed so that they
give out a set of outputs. The transforming process can be complicated and
the design of an actual input and output system for manufacturing may be
expensive and difficult.

INPUT-No of OUTPUT-No Productivity

Workers of Productivity of
products/day Plant-2 is
Plant-1 300 10 10/300=0.03 higher as
Plant-2 200 20 20/200=0.1 compared to
plant-1

Comparison of Production and Productivity

1. Production refers to the quantity of the product. Productivity is the
efficiency of production.
2. Production can be increased by increasing the inputs without any
improvement in their effective utilization. Improvement in productivity increases
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production without increases in the inputs.

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3. Higher production does not necessarily improve productivity.

Importance of improved productivity
Benefits of higher productivity are

 Reduction in cost per unit leading to reduction in price of goods.

 Increase in wages
 Increase in profits to the company
 Better standards of living of people
 Beating the competition
 Job security and job satisfaction

Methods of increasing the productivity

 by increasing the output for a given input

 by right utilization of human resources through motivation and training
 by reducing scrap to the maximum extent
 by adopting preventive maintenance measures
 by using correct tooling and equipment
 by providing good working conditions
 by adopting latest technology such as automation, robotics etc
 by promoting Research and development activities
 by providing Incentive schemes

Types of production
1. Job(Unit) Production
2. Batch (Intermittent) Production
3. Continues Production

Job Production
Job production includes production of special products and model products
such as boilers, Turbo Generator, Special design engines etc.
Characteristics
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 Planning can be done only after the job order is obtained

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 product design takes a lot of time

 job order for each product is different
 highly skilled supervision and high degree of control is required
 highly skilled workers are necessary

Advantages

 Meets individual requirements

 No managerial problems
 Flexibility in production with regards to demand

Disadvantages

 Raw material cost is slightly high

 High labour cost
 Production stops if there is no order

Batch (Intermittent)Production
It consists of production of identical products in batches of small
quantity. But one lot is different from the other. Ex: manufacture of machine
tools, forging press etc.
Characteristics

 Products produced in a batch are identical

 Division of labour is possible
 Common types of production
 Flow of material is intermittent
 Process layout is well suited

Advantages

 Variety of products can be manufactured

 It is flexible and easily adaptable to changes in product design
 A hold up in one operation does not cause disruption of others
 Well suited for medium scale industries
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 Investment required for machinery and plant is small

 Since the operators handle a variety of jobs there is more job
satisfaction

Disadvantages

 Due to frequent changes in product design production planning is

complex and machine set-ups need frequent changes.
 Optimum machine loading is difficult to achieve
 Raw material and work in process inventories are high

Continuous Production
In continuous production, manufacturing process goes on regularly
throughout the day continuously. Ex: Textiles, Paper, Chemicals, Cement,
Automobiles etc.

Characteristics

 Raw material enters at one point and leaves as a finished product at

another end
 Modern control techniques can be applied
 Good plant maintenance is essential
 Skilled and semiskilled labour may be employed
Advantages

 Handling of materials is reduced.

 Increased production
 Better quality of products
 Minimum wastage of material
 Cost per unit is less

Disadvantages

 Heavy losses in the event of reduced demand

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 Any disruption in the process flow results in stoppage of all production

at all stages leading to huge losses.
 Because of repetitive work nature, workers get bored

Continuous production can be classified into two

 Mass or line production

 Flow or process production

In mass production identical articles are produced in very large quantities

using automatic machines and equipment
Ex: Manufacture of Bolts, Nuts, Automobile parts etc.
In flow production the plant, equipment and machinery and layout are
designed to produce the required product. The arrangement is not flexible. It
is normally designed for only one product.
Ex: Cement factory, Paper mill

PRODUCTION PLANNING AND CONTROL (PPC)

Production is achieved by transforming the raw material into desired finished

products as per the customer demand. Before starting the actual production
process, we must plan it properly. It is necessary to decide in advance
What to produce?
Where to produce?
When to produce?
How much to produce?
What is the competitor’s strategy?
Planning decides the means and ways by which the production in best way
be carried out. The control phase take the activities are done as per the
plans and it maintain a planned production. So production planning and control
function involves the planning of various production activities and making them
to happen as per the program.
Principle involved in production planning and control is
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‚PLAN YOUR WORK AND THEN WORK YOUR PLAN‛

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Production planning and control together may be defined as the direction and
coordination of company’s resources towards the attainment of its production
goals in the most efficient manner
PPC ensures that the right item is produced in time, quantity and quality

Objectives of PPC

 To find the demand for a new product

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 To forecast the demand for an existing product

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 To execute in advance the cost of a new product

 To make the route sheet
 To prepare the schedules for production
 To control labour and material

Functions of PPC

Preplanning Functions
Forecasting
Order writing
Product Design

Planning Functions

Planning………Material, Method, Facility Planning

Routing………….Flow of Work
Scheduling-…….production time Table

Control Functions

Dispatching……..authorizing the start of operations

Expediting………..Follow up progress
Inspection…….Ensure Quality

Advantages of PPC

 It increases productivity
 It increase wage structure and hence more employee motivation
 It improve level of quality and maintain consistency in standard
 Optimum utilization of plant capacity
 Optimum utilization of services and facilities available in the industry
 It improves safety
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 Improved process efficiency

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PREPLANNING

Preplanning involves

Forecasting it the estimation of type, quantity and quality of future work

Order writing is the fixing authority to one or more persons to undertake a

particular job

Product design is the collection of information regarding specification, bill of

materials and preparation of drawings or blue print

FORECASTING

It is defined as the type, quantity and quality of future work. If forecasting is

not done carefully, it may completely effect the profitably and existence of the
firm.

Methods of Forecasting

1. Historic estimate
2. Trend line Technique
3. Sales Force Estimate
4. Co-relation technique

Historic Estimate
This technique is based on the assumption that what happens in the past will
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happen in future.ie history repeats itself. For example if a company sold 3500

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fans in last summer, it expects to sell the same 3500 numbers this year
also. This method is simplest and cheapest method of forecasting

Trend Line Technique

This is a statistical method. This technique is more accurate than historic
estimate when large data of past sale is available. But this is a time
consuming method.

Sales Force Estimate

This technique is based on the principle that the marketing and sales
personnel know best about future sales. Information is gathered from future
sales. Different sales managers at region level may send their report to the
company. This technique is useful when an industry is making a limited
number of products and there are a few large customers.

Ex: Commercial diesel generator sets.

Co-Relation Technique

Co-relation technique can be used if a relationship between sales and other

product or other economic and non-economic phenomenon exists. For example
the sales of a lubricating oil is related to the sale of automobile vehicles.

PROCESS PLANNING
It is the preparation of detailed working plan. It means the planning of
production process. It determines the economical method of performing the
activity.
Process planning procedure
1. Select the most economical process. It depends on delivery date, quality,
and quantity

2. Selection of material
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3. Selection of work holding devices, other special attachments

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4. Selection of cutting tools and inspection gauges

5. Time calculation
6. Preparation of process sheet

With the help of process sheet, it is possible to estimate the following

1. Requirement of men, materials, machine
2. Time required for manufacturing of products

Break Even Analysis for Machine Selection

A particular product can be produced by two or more machine. We have to

select the machine in which the cost of production is less.
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Total cost = fixed cost + Variable cost

From the graph we can see that total cost of 2 machines is same for Q
quantity of product. This is known as break even quantity. If the quantity to
be produced is less than Q, machine 2 is selected, because machine 2 gives
least cost for quantity less than Q. Similarly if the quantity to be produced is
more than Q, machine 1 is selected, because machine 1 gives the least cost
for quantity more than Q

ROUTING

Routing may be defined as the selection of path which each part of the
product will follow while being transformed from raw materials to finished
products. Path of the product will also give sequence of operation to be
adopted while being manufactured. In other way, routing means determination
of most advantageous path to be followed from department to department and
machine to machine till raw material gets its final shape

Routing procedure
1. The finished product is analysed and broken into number of components
required for the product
2. Bills of material are prepared from the parts list and decide what is to be
produced in the plant and what is to be purchased from outside
3. Available machine capacities and machine characteristics are find out
4. Necessary operation through which raw materials has to undergone are
listed
5. Path of material is decided.
6. Prepare a route sheet
7. The economic lot size is determined
8. Determine the scrap factors and places where scrap is very likely to occur
are identified. The cost of each production of each component is estimated.
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Route Sheet
route shet is used to specify the several operations to be performed, their
path, sequence of operations, the department in which each operations isto be
performed and type of machine isto be used in each case.

Difference between Process Sheet and Route Sheet

1. Sequence of operations listed in route sheet is to be strictly followed while

that in process sheet can be changed
2. In process sheet only the code of machine is given. In route sheet
identification number of the particular machine is given
3. Process sheet is prepared during the preplanning level.ie well in advance
of production activity. But route sheet is prepared just a few days before the
commencement of production
4. Process sheet remains the same for a given product whenever it is
manufactured, whereas route sheet is to be modified for every repeated order.

SCHEDULING

Scheduling determines the starting and completion of various operations in the

manufacture of a product. A production schedule is similar to a railway time
table showing when the product will enter particular process and when it
leaves the same for next operation. On the basis of this the production time
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can be determined.

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Factors affecting schedule

Internal factors
a) Availability of equipment, machinery
b) Availability of material
c) Availability of workers
d) Stock of finished goods in the firm

External factors
a) Customers demand
b) Delivery dates
c) Dealers and retailers inventory

Types of scheduling
1. Master scheduling
2. Parts scheduling
3. Machine loading scheduling

Master scheduling
It is a weekly or monthly breakup of the production requirements for each
product. Whenever any order is received, it is accommodated first in the
master schedule considering the availability of the machines and labour.

Parts scheduling
It gives the number of units of different parts to be produced for a given
product.it is prepared on the basis of master schedule.

Machine loading scheduling

It gives the information of allocating load for various machines. It is a time
table for the working of various machines. This scheduling is prepared in the
basis of parts schedule
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Preparation of schedule charts in Gantt chart form

Gantt chart is a graphical representation of scheduling. Gantt chart can be

prepared for master scheduling, parts scheduling and machine loading
scheduling

Master scheduling in Gantt chart form

In the Gantt chart the schedule for the three different products for three
months. In this chart, the planned output is shown as hatched strips and the
actual output is recorded by white strips. The chart shows the actual output
of the product the end of February. Output of product A is same as per the
planned output. The actual output of B is less than the planned output. The
reason for the shortfall may be breakdown of machine, raw material shortage,

breakdown of machine etc. Remedial action is taken to achieve the planned

output. The actual output of C is more than that of the planed output

Part Schedule in Gantt chart form

A product may have a number of parts. Parts schedule gives the quantity of
various parts to be produced to assemble the products. Part schedule is
based on master schedule. This chart gives the schedule for three different
parts A, B, C of the product X.
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It shows the schedule of production for a period of one month. In the chart,
the planned output is shown by hatched strip. The actual output is recorded
by white strip. The actual output of parts A exactly equal to the planned
output. The output of C is more than the planned output.

Machine loading scheduling

Machine loading scheduling is the process of allocating work load for various
machines. This schedule is prepared on the basis of parts schedule.

DISPATCHING
Dispatching is concerned with getting the work started. It ensures that plans
are properly implemented. It is the physical handling over of a manufacturing
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order to the operating facility or worker through release of orders.

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Functions of dispatching
1. Assigning the individual machines or workplaces and man
2. Movement of materials, tools, jigs, fixtures etc. to the point of their use
3. Initiating the work by giving the worker all work orders, instructions,
drawings etc.
4. Guiding and controlling the materials and operations on the basis of route
sheets and schedules.
5. Controlling the progress of all operations
6. Issuing inspection orders after each operation

FOLLOW UP (EXPEDITING)
After dispatching function, it is compulsory that the progress of the job to be
regulated. Here a follow up team reports the daily progress of the work in
each shop in a pre-planned Performa

Following are the main purposes of follow up team

1. To see materials are reached the shop in time so that production can be
started as per schedule
2. To see that a particular product is passing through all its operations from
raw materials to final product as per schedule
3. To see that all parts are ready for assembling purpose in actual quantities
and at required time as per schedule
4. To see the causes of delays due to equipment breakdown, lack of proper
tools, gauges, jigs, fixture etc
5. To see the causes of major rejections
6. To see the errors due to routing, scheduling and dispatching

INSPECTION
Inspection is carried out for conforming that quality is of predetermined
standard. During inspection defective parts are rejected so that only products
of good quality should reach to the customers
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VALUE ENGINEERING

Value engineering or value analysis is a special type of cost reduction

technique. A component, to be a part of a product, must perform some
function and serve some purpose. Value analysis examines the design, function
and cost of each and every component in order to produce it economically
without decreasing its utility, function and reliability
A simple example of tooth paste tube or talcum powder container may be
taken for illustrating the concept of value analysis. The function of collapsible
tube of tooth paste or container of talcum powder is only to contain the
product. Earlier they were made of sheet metal or aluminum which is costly.
They are now a days being replaced by plastic tube to contain tooth paste
and hard board containers to contain talcum powder.

Objectives of Value Engineering

1. To simplify the product
2. To use new and cheaper materials
3. To modify and improve product design
4. To use efficient process
5. To increase utility of product
6. To reduce the cost of product
7. To save money by increased profits

Advantages of Value Engineering

1. It is much faster cost reduction technique
2. It eliminate unnecessary functions
3. It requires little expenditure
4. It increases systems efficiency
5. It provides a method of generating ideas and alternatives for possible
solution to a problem.
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Applications of Value Engineering

Hardware projects
1. Defense equipment
2. Automobile industry
3. Material handling industry
4. Air craft manufacturing
5. Import substitutes

Software projects
1. Marketing information system
2. Production information system
3. Inventory control procedure

Non traditional Areas

1. Urban slum development
2. Staff welfare program
3. Staff motivation

PLANT LOCATION
One of the key features of a production process is the efficiency with
which the products (services) are transferred to the customers. This fact will
include the determination of where to place the plant or facility. Plant location
means deciding a most appropriate economic and suitable site, area, place
etc. where the plant or factory will start functioning. The selection of location
is a key-decision as large investment is made in building plant and Machinery.
It is not advisable or not possible to change the location very often.

Factors Affecting Plant Location

Input Considerations

a) Material – Quantity, quality cost and regular supply

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b) Land – site availability and costs, costs of construction

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c) Equipment – Availability and cost

d) Plant utilities – Gas, electricity, coal, water, etc.
e) Labour – Availability, supply, skill, wage rates.
f) Capital – Equity and debt potential, banking facilities

Processing Considerations
a) Production analysis – Educational and research facilities
b) Process analysis – Engineering and consultancy.
c) Forecasting and scheduling-Data resources and capabilities
d) Production control – Inventory storage and future expansion
e) Maintenance - service and repair facility
f) Cost control – Accounting and credit facilities
g) Presence of related industry.
h) Facilities for disposal of waste

Output Considerations
a). Distribution - Distribution and storage facility.
b). Transportation – Facilities and costs.
c). Present and future market potential.
d). Local rates and taxes

Other Considerations
a). Community attitude towards industry and company.
b). Public and community services – educational, recreational, housing.
c). Stock holders interest
d). Political situations
e). Environmental standards

Selection of Site in an Urban (City) Area

Advantages:
1. Power and water is easily available
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2. Good market for small manufactures

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3. Transportation of incoming and outgoing materials is convenient and cheap

4. Availability of adequate supply of labour force
5. Good communication facilities like telephone, fax, internet etc.
6. Houses for workers are easily available

Dis- advantages:
1. Area being limited, it may not be possible to arrange the equipment to the
best of advantages
2. Cost of building factory will be high
3. High taxes
4. Land for future expansion is not available rates
5. More problems about labour and employer relation

Selection of Site in a Rural Area

Advantages:

1. The cost of land is less than in a city area and usually easier to provide
space for future expansion
2. The cheapness of land enables greater freedom in selecting the most
economic design for the buildings
3. Healthy surrounding and pleasant atmosphere
4. Less labour issues
5. Lesser taxes and restriction

Dis- advantages:

1. Sufficient power and water facilities may not be available

2. Skilled workers are not easily available
3. Government facilities may not be sufficient
4. Transport and housing facilities may not be satisfactory
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5. Repairing work may become difficult, because of less industry in that area

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PLANT LAYOUT
Plant Layout
Plant layout refers to the arrangement of the physical facilities including
work centers for the manufacturing of a product. It is the spatial arrangement
of the physical resources used to produce a product

Objectives of Plant Layout

1. To facilitate production process

2. To Minimise material handling
3. To maintain flexibility in the operations
4. To economically use all floor space
5. To provide optimum utilization of machines and equipment
6. To reduce risk hazards
7. To bring about higher productivity

Principle of Plant layout

1. Principle of integration: A good layout is one that integrates men, materials,

machines and supporting services and others in order to get the optimum
utilization of resources and maximum effectiveness.
2. Principle of minimum distance: This principle is concerned with the minimum
travel (or movement) of man and materials. The facilities should be arranged
such that, the total distance travelled by the men and materials should be
minimum

3. Principle of cubic space utilisation: The best layout is that in which all the
available space (vertically and horizontally) is most effectively and
economically used. In addition to use 2 dimensional space i.e. floor space, we
can follow three dimensional space utilization i.e the available space in the
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wall and the ceiling can be effectively utilized for storing the material. If we

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can use mechanical handling devices like cranes, a lot of space can be
saved

4. Principle of flow: A good layout is one that makes the materials to move
in forward direction towards the completion stage, i.e., there should not be
any backtracking.

5. Principle of maximum flexibility: The good layout is one that can be altered
without much cost and time, i.e., future requirements should be taken into
account while designing the present layout.

6. Principle of safety, security and satisfaction: A good layout is one that gives
due consideration to workers safety and satisfaction and safeguards the plant
and machinery against fire, theft, etc.
7. Principle of minimum handling: A good layout is one that reduces the
material handling to the minimum.

Factors influencing Layout

 Type of product ,method of production, production process

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 Production capacity

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 Type of industry like analytic, synthetic ,conditioning or extractive

 Grouping of machines
 Material flow pattern
 Space requirement of machines, material handling, storage and other
facilities
 Safety factors
 Health and other factors like ventilation, natural light, removal of smoke,
fumes etc.
 Provision of future expansion
 Storage system ie centralized or decentralized or a combination of both

TYPES OF PLANT LAYOUT

1. Fixed position layout

2. Product layout (Line Layout)
3. Process layout (Functional Layout)
4. Combination layout

Fixed Position Layout

In this type of layout the material or major components remain in a
fixed location and tools, machinery, men and other materials are brought to
this location. This type of layout is suitable when one or a few pieces of
identical heavy products are to be manufactured and when the assembly
consists of large number of heavy parts, the cost of transportation of these
parts is very high.

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Applications
Manufacture of huge aircrafts, Ship vessels, pressure vessels etc.

Advantages
1. Helps in job enlargement and upgrades the skills of the operators.
2. The workers identify themselves with a product in which they take interest
and pride in doing the job.
3. Greater flexibility with this type of layout.
4. Layout capital investment is lower.
5. Less material movement

Disadvantages
1. Machines and tool etc take more time to reach to the work place
2. Highly skilled workers are required
3. Complicated jigs and fixtures may be required in fixing jobs, tools etc

Product Layout (Line Layout)

In product layout, machines and equipment are arranged in the sequence of

manufacturing operations required for the product. The material is moved from
one work station to another Sequentially without any backtracking or deviation.

It is called line layout because machines are mostly arranged in straight line.
The raw materials are fed at one end and taken out as the finished product
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on the other. A product layout may assume a straight line shape, a V-shape
or circular shape.

Applications
Large automobile assembly plants, food processing chains, continuous process
industries etc.

Advantages
1. The flow of product will be smooth and logical in flow lines.
2. Minimum material handling cost.
3. Simplified production, planning and control systems are possible.
4. Less space is needed for placing machines
5. Manufacturing cycle is short due to uninterrupted flow of materials.
6. Unskilled workers can learn and manage the production.

Dis advantages
1. A breakdown of one machine in a product line may cause stoppages of
machines in the downstream of the line.
2. A change in product design may require major alterations in the layout.
3. Comparatively high investment in equipment is required.

PROCESS LAYOUT (FUNCTIONAL LAYOUT)

Process layout is recommended for batch production. All machines performing

similar type of operations are grouped at one location in the process layout
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e.g., all lathes, milling machines, etc. are grouped in the shop will be
clustered in like groups. Thus, in process layout the arrangement of facilities
are grouped together according to their functions. A typical process layout is
shown in Fig. The flow paths of material through the facilities from one
functional area to another vary from product to product. Usually the paths are
long and there will be possibility of backtracking.

Applications
Suitable for job order, non-repetitive and non-standardized production, distribution
warehouses, hospitals, medical clinics are often designed in this manner

Advantages
1. Higher degree of machine utilisation
2. Break down of one machine does not result in complete work stoppage
3. Adaptable to produce varieties of products
4. Supervisors will become highly knowledgeable about the functions under
their department
5. Adaptable to changes in sequence of operation
Dis advantages
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1. Material handling becomes extremely difficult

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2. Large floor are is required

3. It needs more inspection and efficient co-ordination
4. Lowered productivity due to number of set-ups
5. Throughput (time gap between in and out in the process) time is longer

Combination Layout

A combination of process and product layouts combines the advantages

of both types of layouts. A combination layout is possible where an item is
being made in different types and sizes. In such cases machinery is arranged
in a process layout but the processing group is then arranged in a sequence
to manufacture various types and sizes of product. Figure shows a
combination of type layout for manufacturing different sized gears.

Application
Manufacture of files, hacksaw, circular metal saw, wood saw etc.

Advantages
It has combined advantage of both line as well as functional layout

Dis advantages
1. If proper line balancing is not done it may crate delay or bottle neck
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2. Possibility of over loading and underutilization of some machines are there.

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PLANT MAINTENANCE
Plant maintenance consists of all activities needed to keep the plant,
machines, tools and equipment, services including building and fitting in
standard living condition

Objectives
1. To safeguard the investment by minimizing the rate of wear and tear
2. To preserve and prolong the working life of a plant and machinery
3. To keep the productive assets in efficient working condition
4. To Minimise idle life and loss of production due to breakdown
5. To Minimise industrial accidents through regular inspection and repair of
safety devices etc.

TYPES OF MAINTENANCE
Maintenance may be classified into following categories

1. Preventive maintenance
2. Predictive maintenance
3. Breakdown or Corrective maintenance
4. Scheduled maintenance,

Preventive Maintenance
It is also called planned maintenance or systematic plant maintenance. It
locates weak spots (such as bearing surfaces, parts under excessive vibrations,
etc.) in all equipment, provides them regular inspection and minor repairs
thereby reducing the danger of unanticipated breakdown. The underlying
principle of preventive maintenance is that “Prevention is better than Cure”.
Preventive maintenance is a means to increase the reliability of their
equipment.

Advantages
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1. Cost effective in many capital intensive processes.

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2. Increased component life cycle.

3. Reduced equipment or process failure

Disadvantages
1. Catastrophic failures still likely to occur.
2. Includes performance of unneeded maintenance

Predictive Maintenance
This is a modern concept having excellent future prospects. It makes
use of human senses or other sensitive instruments such as Audio gauges,
Vibration analyzers, Amplitude meters, Pressure, temperature and resistance
strain gauges, etc., to predict troubles before the equipment fails. Unusual
sounds coming out of rotating equipment predict an upcoming trouble, an
electric cable excessively hot at one point predicts a trouble. These can be
sensed observed and detected at right time and necessary repairs and faulty
parts are replaced. In predictive maintenance, equipment conditions are
measured periodically or on a continuous basis and this enable maintenance
men to take a timely action such as equipment adjustments, repair or
overhaul. Predictive maintenance extends the service life of equipment without
fear of failure.

Advantages
1. Increased component operational life/availability.
2. Decrease in equipment or process downtime.
3. Better product quality.
6. Improved worker and environmental safety.

Disadvantages
1. Increased investment in diagnostic equipment
2. Increased investment in staff training
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Breakdown or Corrective Maintenance

Breakdown maintenance is basically the ‘run it till it breaks’ maintenance mode.

The repairs are made after the equipment is out of order and it cannot
perform its normal function any longer, e.g., an electric motor will not start, a
belt is broken, etc. Under such conditions, production department calls on the
maintenance department to rectify the defect. The maintenance department
checks into the difficulty and makes the necessary repairs. After removing the
fault, maintenance engineers do not attend the equipment again until another
failure or breakdown occurs.

Advantages
1. Involves low cost investment for maintenance.
2. Less staff is required.

Disadvantages
1. Increased cost due to unplanned downtime of equipment.
2. Increased labour cost, especially if overtime is needed.
3. Possible secondary equipment or process damage from equipment failure.

Scheduled Maintenance

Scheduled maintenance is conducted by a predetermined and pre planned

schedule. Normally this is done according to the recommendations of supplier
of the equipment. For example, 2 wheeler suppliers gives the time table or
schedule to change the oil, to check the lubrication system, ignition system,
battery maintenance etc. Scheduled maintenance practice incorporates inspection,
lubrication, repair and over-haul of certain equipment which if neglected can
result in breakdown. Inspection, lubrication, and servicing of this equipment are
included in the predetermined schedule. Scheduled maintenance practice is
generally followed for overhauling of machines, cleaning of water and other
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tanks, white-washing of buildings, etc.

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Advantages

1. Usually made up of tasks that don’t require extensive training, such as

lubricating and retightening screws
2. Lower long term costs compared with breakdown maintenance

Disadvantages

1. Planning time is required

2. Parts are often replaced before end of life, which costs more than waiting
until they fail

MATERIAL HANDILING
Material handling is the art and science of moving, packaging and storing the
material in any form, and includes the preparation, placing and positioning the
material to facilitate their movement or storage
The cost of material handling accounts for 30% to 65% of the total cost of
covering the raw material into finished product. Material handling adds to the
cost of the product. Therefore, reduction in material costs will make the
product more competitive. The material handling system should be so designed
as to maximize efficiency and minimize cost.

Since the material handling is concerned with the movement of materials,

every movement has following elements
1. Picking upload
2. Transporting the load
3. Setting the load down

Function of Material handling (Objectives of material handling)

1. Unloading the raw materials from transport vehicles, moving and

positioning of purchased materials for storage and delivering the
material as close to the point of use
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2. Material handling adds to the cost of the product. Try to eliminate

material handling wherever possible
3. Arrange the production sequence and plant layout in such a way that
the material handling is eliminated or reduced
4. Select the proper equipment for movement, loading, unloading and
storage
5. Select the shortest route of material movement
6. Select multipurpose handling equipment wherever possible
7. Make use of gravity based material movement equipment wherever
possible
8. Ensure safety of men, material and equipment during handling
9. Carry out handling cost studies and cost control and cost reduction
methods
10. Carry out preventive maintenance for reducing their down time

Principle of Material Handling

The word principle can be defined as a prescribed guide to accepted
procedures established through past practice and is accepted as authorities by
practitioners and without which a system would be less effective.

Planning Principle - All material handling activities should be planned. Minimize

movement of men & material, plan for scrap removal, utilize truss capacities
and ceiling heights.

System principle - Handling activities ie. Receiving, Storage, in process handling,

inspection, packaging, shipping, transportation be integrated and co-ordinated.

Simplification Principle - Reduce combine or eliminate un necessary movements

of transportation.

Material flow principle - Material flow pattern must be determined by operation

sequence and pattern of equipment arrangement.
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Gravity principle - Utilize gravity wherever is possible

Unit size principle - Increase size, quantity, weight of the load handled. Since
larger the load, lesser the cost per unit handled.

Space utilization principle - Optimum utilization of building space. Utilize height of

building and use rack to permit higher stocking.

Safety principle - safe handling methods and equipment for better working
conditions and to avoid unsafe conditions.
Mechanization principle - For increasing efficiency use mechanized handling
equipment but to the desired extent only.

Flexibility principle - Equipment capable of handling variety of tasks be used.

Equipment selection principle - Select equipment very carefully considering all

aspects of materials, movements and the method

Standardization principle - Standardize equipment as well as methods

Light weight principle - Reduce weight of equipment

Motion principle - The handling equipment should be kept in motion ie. minimum
period for loading, unloading or other idleness

Idle time principle - Reduce idle and unproductive time

Obsolescence principle - Obsolete methods and equipment be replaced by

efficient methods and equipment

Maintenance principle - Preventive maintenance practices be adopted for handling

equipment
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Control principle - Control production and inventory through materials handling

equipment

Capacity principle - Production capacity should be fully achieved

Performance principle - performance of handling be measured in terms of cost

per unit handled, safe working condition, increase in production rate or
reduced manpower for handling

Factors to be considered for Material Handling

Factors to be considered in every material handling installation can be
classified as

 Factors relating to plant operating methods

 Factors depending on materials or parts handled
 Factors relating to handling equipment
 Money factors

Factors relating to plant operating methods

1. Is the present manufacturing or operating method permanent or

temporary?
2. How long will the present building remain in service
3. Is the general plant layout the best for manufacturing and handling
requirements?
4. Is the sequence of operations that gives greatest efficiency
5. What process and departments must be tied together

Factors depending on materials or parts handled

1. Kinds Or Nature of materials or parts handled

2. Bulk or units
3. Large or small
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4. Shape

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5. Handled separately or in containers

6. Under processing while moving
7. Distance over which transported

Factors relating to the handling equipment

1. kind or kinds suitable for the job

2. capacity of equipment
3. Size of the equipment
4. Power requirements
5. Ease of operations
6. Speed of operation
7. Adoptability to other devices
8. Durability
9. Hours it will be in service daily

Money factors

1. Initial cost of equipment

2. cost of installation.re arrangement and alteration to present equipment,
building
3. cost of maintenance, repairs, supplies etc
4. cost of power
5. rate of depreciation
6. salvage value when finally described
7. cost of labour to operate
8. taxes and insurance
9. License fees
10. cost of supervision

Types of Material Handling Devices

Manual handling
Here a labourer act as a handling device in bringing the raw materials for
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the operator and carrying away finished goods. If the manufacturing process

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are of continuous type it may be arranged that there should be some

gradient say 1 in 100 downwards from the entrance of material toward the
processing plant and further where finished goods are to be atoced.in this
method gravity assists in manual transport.

Mechanical handling
There can be three major divisions of handling equipment
1. Lifting and lowering devices (Vertical motion)
a) Block and tackle b) Winches
c) Hoists d) Elevators
e) Pillar crane f) Overhead cranes
2. Transporting devices (Horizontal motion)
a) Hand truck b) Narrow gauge mineral road
c) Tractors and trailers d) Railway equipment
e) Aerial tramways f) Skids
g) Pipe lines
3. Combination devices (lifting and lowering plus transportation)
a) Spiral chute b) Lift truck
c) Crane truck d) Auto truck
e) Conveyors f) Positioning equipment
g) Marine vehicle h) Air transport

Lifting and lowering devices (Vertical motion)

A) Block and Tackle-block and tackle arrangement of the lifting loads through a
vertical distance. This is one of the oldest and simplest device. It is still
used today by moving men and in hoisting machinery into position
B) Winch-This is used to lift loads vertically by winding the rope or cable on
a drum. It is frequently used in loading heavy equipment into ships,
construction of building and in similar jobs
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Block and tackle Winch Chain hoist

Pillar crane Overhead Crane

c)Power Hoist-Power hoist which is often operated between fixed guide rails,
for lifting things vertically. There is an infinite variety of hoists suitable for
different purposes. The simplest is the chain hoist, which is operated by hand.
There are also hoists operated by compressed air or by electric power
d) Elevators- The difference from the hoists by the fact that the operator
rides with the load. Although there are many different types of drives for such
elevators, in general the only important type is the electric one.
e)Pillar Crane- This may be stationary or mobile type. It is used for light duty
and for lifting loads upto 20 tonnes. All the movements to the carne are
provided by gearing and the electric motor drive
f) Overhead crane- Today all the big workshops such as foundry, powerhouse,
chemical plants, big repairing shops etc have these cranes. These cranes
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have the advantage of providing large service area and freedom obstruction on
the floor. In these all the movements are controlled by the driver seated in
the cabin

Transporting Devices

a) Wheel barrows and hand rails-the simplest transporting devices are wheel
barrows and hand rails. All such equipment involves a large amount of man
power for a relatively small load. The main advantage of this equipment is its
very low cost, great flexibility, and easy portability from one job to another

Wheel barrow Hand Truck Aerial Tramways

Skids

b) Narrow Gauge Rail Road-in general, little use is made of such equipment
because it requires heavy investment in the roadbed and tracks has little
flexibility and is difficult to change at a later date.
c) Tractors and Trailers- these are one of the most common methods of
horizontal transportation. Trailers can be lift operated and can be picked up
by the different tractors. This is one of the most important methods of
handling materials inside the plant and from one building to another
d) Railway equipment-where plants are located at a considerable distance and
the items handled are extremely large, such as in some steel rolling
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operations, the use of actual railway equipment is advantageous

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e) Aerial tramways-the load carrying vehicle is supported from the top usually
by means of a cable or its equivalent
f) Skids-goods may be loaded into skids and then picked up with lift trucks.
The skid can be loaded as a unit and transferred from position to position
without subsequent loading and unloading.
g) Pipe line-pipe lines and pumps are used for horizontal transportation of
commodities. Most obvious among these is oil, which is pumped at great
distance through pipe line.

Combination Devices

a) Chute-one of the most simplest device that have vertical and horizontal
motion is a chute which may either be straight or spiral.in this gravity is
utilized to move the material. Chutes are common in railways and airline
terminal for handling package and baggage.

Platform Truck Fork Truck Crane Truck .Spiral chute

b) Lift Truck -the lifting feature in lift trucks provides clearance from the floor
for the skids and permits horizontal transportation
c) Crane Truck-these are used for materials that cannot be put on skids or
not available for skids at the present time or too much heavy to handle in
the lift trucks. This can be carried at will to any palce.in these cranes, the
solid rubber tyres are used. The cranes are revolving type so that the load
can be lifted from any position.
d) Fork truck-when the load is to be shifted from one shop to another fork
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trucks are used. These trucks do not require any extra man and driver

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operating the truck can also lift, carry and unload the material. self-loading
and unloading can be carried out by providing fork at the front end of the
truck.
e) Conveyors-if the path for the material is fixed then the provision of the
conveyors at suitable levels eliminates good deal of lifting and lowering of
materials.

Belt Conveyor
Conveyors require no stopping or starting but are continuous in operation.
There are several types of conveyors such as belt conveyors, roller conveyors,
Cain/cable conveyors, pipe line conveyors, screw conveyors..etc.

……………………………………………………………………………………….

IMPORTANT QUESTIONS

(April-2018)

1. Define plant layout

2. What is process planning
3. Compare production and productivity
4. Explain different types of production system
5. Explain briefly the various factors influencing the plant layouts
6. Explain break even analysis
7. What are the benefits of PPC

(Oct-2017)
1. Define industry
2. List the types of forecasting
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3. List and explain the functions of PPC

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4. Explain the concepts of Value engineering with its advantages

5. Explain the types of production
6. Draw and explain break even analysis curve
7. Explain various types of maintenance
8. State and explain the principles of material handling

(Oct-2016)
1. Define routing
2. Define plant layout
3. What are the advantages of good plant layout
4. Write six advantages of mass production
5. Briefly describe batch production
6. What are the advantages of value engineering
7. List out the factors to be considered in selecting material handling
equipment
8. Write down the procedure for process planning

(March-2015)
1. List any 4methods of forecasting
2. List different types of plant layout
3. Differentiate between preventive and breakdown maintenance
4. Explain characteristics of continuous type production
5. List advantages and applications of value analysis
6. Explain characteristics of process type plant type layout. List
advantages and applications
7. Explain a) JIT b) Break Even Analysis
8. Define Routing and explain its procedure
9. List the Principe of effective material handling

(March-2014)
1. Value engineering is a cost reduction technique. Justify
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2. Explain characteristics of batch production

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3. Draw and explain suitable plant layout for an industry which

produce same products in different sizes.
4. Planning phase of production planning has two phases. Explain
each and its elements
5. Illustrate and interpret a Gantt Load Chart for industry has 3
sections for 4 weeks(assume data)
6. Explain preventive maintenance procedure

(March-2013)
1. State any two applications of value engineering
2. Define productivity
3. What are the methods of increasing productivity? list any six
4. Explain process layout with a suitable line diagram
5. List the different steps in routing procedure
6. What are the factors to be considered in while locating industrial
plants
7. Sate the principle of material handling
8. Explain preventive maintenance and predictive maintenance
(Oct-2012)

1. Prepare an output-input model with block diagram for production

system
2. What is the use of breakeven analysis
3. What are the advantages of increasing productivity
4. What are the factors and objectives of forecasting and factors to
be considered while forecasting
5. Explain principle of plant layout
6. What are the various type of controls applied in production control
department? Explain
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