Plant Layout

Arc Welding Processes

Lesson Objectives
When you finish this lesson you will
understand:

Keywords:

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

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
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

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

Turn to the person sitting next to you and discuss (1 min.):

Load Path Method to Determine Plant Layout

Thousands
of pounds
from
department
1
2
3
4
5
6
7
8
9
10
11
12
13

Sq.
ft.
3000
10000
15000
4000
9000
15000
6000
1200
8000
6000
10000
2000
8000

Thousands of pounds per week to departments

2
3
4
5
6
7
8
9
10 11
90

12

13

10
75

15
20

45

5
13
5
35
3

5
5
18

12
10

5
2
3

5
20
33
90
10

90

15

10,000

3000

4
4000

75

13

15,000

16

45
20

5
3

12
2000

8
1200

9000

10
13

12

5
90

10

35
20

10,000

33
6000

10

11

8000

15,000

8000

5
18

6000

Direct: 90+15+75+20+45+5+13+12+3+35+10+5+18+20+33+90+10= 499

Indirect: 16+5+2+5+3+5+5= 82
Minimum Load Path
Arrangement

2
1

10,000

3000

4000

3
15,000

12
2000

13
8000

8
1200

Fit
Into

9000

15,000

11
10,000

10

6000

6000

9
8000

2
8
3

13

12

Existing
Building
Space

5
11
10

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

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

Pallet from Group Layout

Advantages
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

Disadvantages
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
1
2
3
4
5
6
7
8
9

Element
Time
(min)
0.2
.4
.7
.3
.8
.6
.2
.2
.8

Preceding
Elements

Element
Description

Na
1
1
2
3
3
4
4
5

Place axel on car

Place studs on axel
Lubricate axel
Place tire on wheel
Place wheel on axel

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.

min
60
hr 0.92 min
cars
car
65
hr

The slowest work station will

dictate the entire line speed,
thus the slowest station must
take less time than 0,92 minutes

Precedence Diagram
0.2

7
2
1

0.4

0.3

12
8

0.2
3

0.7

0.8

10
6

0.2
14

0.8

0.6

0.3

0.6

13
11

0.1

0.3

0.5

Work Stations
1,3

2,4,7

6,10

0.9

0.9

0.8

0.9

0.8

11,13
0.8

8,12,
14
0.9

Turn to the person sitting next to you and discuss (1 min.):