Plant Layout

Arc Welding Processes

Lesson Objectives
When you finish this lesson you will
understand:

Learning Activities
1. Read Handbook Pp
1-16,
2. Look up Keywords
3. View Slides;
4. Read Notes,
5. Listen to lecture
6. Do on-line
workbook
7. Do homework
Keywords:

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.
Group Machines in centers which perform similar functions
Example: Movable Crane Manufacture
Outside Storage:
Incoming Plate and Supplies
Finished Product Awaiting Delivery
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
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
All arms moved to GMAW station where stiffeners are welded on
Arms inspected for straightness and weld workmanship
Arms assembled inside each other
All parts assembled and painted
Strain gage attached for lift proof testing
Proof Testing performed on each unit before storage or delivery
Advantages Disadvantages
Advantages Disadvantages
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
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
Turn to the person sitting next to you and discuss (1 min.):

Thousands of pounds per week to departments Thousands
of pounds
from
department
Sq.
ft.
2 3 4 5 6 7 8 9 10 11 12 13
1 3000 90 10
2 10000 75 15
3 15000 20 45 5 5
4 4000 13 2
5 9000 5 12 3
6 15000 35 10
7 6000 5
8 1200 3 5 5
9 8000 18 20
10 6000 33
11 10000 90
12 2000 10
13 8000
Load Path Method to Determine Plant Layout
1
3000
2
10,000
4
4000
3
15,000
8
1200
12
2000
5
9000
6
15,000
13
8000
11
10,000
9
8000
7
6000
10
6000
Direct:
Indirect:
90
16
15
90+
16+
15+
75
75+
20
20+
45
45+
5
5+
5
5+
13
13+
2
2+
5
5+
12
12+
3
3+
35
35+
10
10+
5
5+
3
3+
5
5+
5
5=
18
18+
20
20+
33
33+
90
90+
10
10= 499
82
Minimum Load Path Arrangement
1
3000
2
10,000
4
4000
3
15,000
8
1200
12
2000
5
9000
6
15,000
13
8000
11
10,000
9
8000
7
6000
10
6000
1 2
3
4
5
6
7
8
9
10
11
12
13
Fit
Into
Existing
Building
Space
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
Group machines in a line to make a certain product - Assembly line
A C B F G
A D E
Pallet from Group Layout
Example: Wheel Rim Manufacture
Coil handling equipment slit coils are fed into blank cutter
Blank cutter cuts pieces to exact length
Flat strip blank is rolled into a cylinder
Cylinder is flash welded
Cylinder is flared on each end to expand to outside
wheel dimensions
Wheel is roll formed though 3 or 4 successive expansions
to final wheel contour
The spider which was stamped on another line is mated with
the wheel and GMAW together
Advantages Disadvantages
A C B F G
A D E
Pallet from Group 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
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
Task
Element
Element
Time
(min)
Preceding
Elements
Element
Description
1 0.2 Na Place axel on car
2 .4 1 Place studs on axel
3 .7 1 Lubricate axel
4 .3 2 Place tire on wheel
5 .8 3 Place wheel on axel
6 .6 3
7 .2 4
8 .2 4
9 .8 5

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.
car
min
92 . 0
hr
cars
65
hr
min
60

The slowest work station will

dictate the entire line speed,
thus the slowest station must
take less time than 0,92 minutes
1
2
3
4
5
6
7
8
9
10
11
12
13
14
0.2
0.7
1,3
0.9
0.4 0.3
0.2
2,4,7
0.9
0.8
5
0.8
0.6
0.3
6,10
0.9
0.5
0.3
11,13
0.8
0.8
9
0.8
0.2
0.1
0.6
8,12,
14
0.9
Precedence Diagram
Work Stations
Turn to the person sitting next to you and discuss (1 min.):