MT Unit-6

Q1. Describe in details Features and application of Material Handling equipments used for Loading
and Unloading during machining operations.

Ans: Material handling equipment is used to move raw materials, finished products, and work-in-
progress within a manufacturing facility. There are many different types of material handling
equipment, each designed for specific tasks and environments.

For loading and unloading during machining operations, some common types of material handling
equipment include:

 Overhead cranes: These are used to lift and move heavy loads horizontally. They consist of a
bridge that runs on rails, and a trolley that runs on the bridge. The trolley is equipped with a
hoist for lifting the load. Overhead cranes are often used in machining operations to move
heavy raw materials or finished products.
 Forklifts: These are used to lift and move pallets of materials. They consist of a platform with
wheels, and a mast that can be raised or lowered to lift the load. Forklifts are often used in
machining operations to move pallets of raw materials or finished products.
 Conveyors: These are used to move materials horizontally or at an incline. They consist of a
belt or chain that runs on rollers or pulleys. Conveyors can be used to transport raw
materials, finished products, or work-in-progress between different stages of a machining
operation.
 Automatic guided vehicles (AGVs): These are used to move materials automatically. They
consist of a vehicle with wheels that is guided by a system of sensors and markers. AGVs can
be used to transport raw materials, finished products, or work-in-progress between different
stages of a machining operation.
 Hoists: These are used to lift and lower heavy loads vertically. They consist of a drum or a lift
wheel that is powered by an electric motor. Hoists are often used in machining operations to
move heavy raw materials or finished products.

Q2. What is the role of Loading and Unloading in flexible manufacturing system.

Ans: In a flexible manufacturing system (FMS), loading and unloading refers to the process of
bringing raw materials, work-in-progress, and finished products into and out of the system. This is an
essential aspect of the FMS, as it enables the system to handle a wide variety of products and to
quickly change between different production runs.

The loading and unloading process in an FMS is typically automated, and is usually done by
specialized material handling equipment such as robots or automated guided vehicles (AGVs). This
ensures that the materials and products are handled quickly and accurately, and that the system can
operate at maximum efficiency.

The role of loading and unloading in an FMS is to provide a seamless flow of materials and products
throughout the system. This includes:

 Bringing raw materials and work-in-progress into the system and ensuring that they are
delivered to the correct production line or machine.
  Removing finished products from the system and ensuring that they are delivered to the
correct location, such as a warehouse or shipping area.
 Managing the flow of materials and products within the system, such as moving work-in-
progress from one machine to another.

Q3. What are the causes of hazards inherent in the working environment in casting industry.

Ans: The casting industry involves the production of metal parts by pouring molten metal into molds.
This process can be hazardous due to the high temperatures and heavy equipment used, as well as
the potential for exposure to hazardous chemicals and materials. Some common causes of hazards
in the casting industry include:

 High temperatures: Molten metal can reach temperatures of up to 2,500 degrees

Fahrenheit, which can cause burns and other thermal injuries. Workers may also be exposed
to hot surfaces, steam, and radiant heat.
 Heavy equipment: The casting process involves the use of large, heavy equipment such as
cranes, hoists, and casting machines. These can pose a risk of injury if they are not properly
maintained or if operators do not follow proper safety procedures.
 Noise: Casting operations can generate high levels of noise, which can cause hearing loss and
other auditory problems.
 Airborne particles: Workers in the casting industry may be exposed to airborne particles
such as dust, fumes, and smoke, which can cause respiratory problems.
 Chemical hazards: Many casting operations involve the use of chemicals such as lubricants,
coolants, and mould release agents. Workers may be exposed to these chemicals if they are
not handled or stored properly, or if they are not used in accordance with safety guidelines.
 Fire and explosion: The casting process involves the use of flammable materials and high
temperatures, which can increase the risk of fire and explosion.
 Ergonomic hazards: Repetitive motion, awkward postures, and heavy lifting can cause
musculoskeletal disorders.

Q4. Describe in details about preventing hazards with suitable example.

Ans: Preventing hazards in the workplace is an essential aspect of maintaining a safe and healthy
work environment. There are several ways to prevent hazards, including:

1. Risk assessment: Conducting regular risk assessments is an important first step in identifying
potential hazards in the workplace. This can be done by looking at the tasks, equipment, and
materials used in the workplace, as well as the environment and the workers themselves.
This information can then be used to identify potential hazards and prioritize the need for
controls.
2. Engineering controls: Engineering controls involve making changes to the equipment,
materials, or work environment to reduce or eliminate hazards. For example, in a casting
industry, installing ventilation systems to remove harmful dust, fumes and smoke from the
workplace, using a machine with a guard to prevent contact with moving parts, or installing
an automatic fire suppression system to reduce the risk of fire.
 3. Administrative controls: Administrative controls involve changes to work procedures or
schedules to reduce or eliminate hazards. For example, in a casting industry, implementing a
lockout/tagout procedure to prevent accidental machine startup, or scheduling regular
maintenance and inspection of equipment to prevent breakdowns and malfunctions.
4. Personal protective equipment (PPE): PPE is equipment worn by workers to protect them
from hazards. For example, in a casting industry, providing workers with protective clothing,
gloves, goggles, and face shields to protect them from heat and radiation, or providing
respirators to protect workers from exposure to harmful dust, fumes and smoke.
5. Training and education: Providing workers with training and education on hazards and safety
procedures is an important way to prevent accidents and injuries. For example, in a casting
industry, providing regular safety training on the proper use of equipment and handling of
materials, as well as on emergency procedures and evacuation plans.

Q5. What cautions a chemical Industry has to take to avoid human hazards.

Ans:

1. Conducting regular risk assessments: This is an important first step in identifying potential
hazards in the workplace. This can be done by looking at the tasks, equipment, and
chemicals used in the workplace, as well as the environment and the workers themselves.
2. Implementing appropriate controls: This includes engineering controls, such as installing
ventilation systems to remove harmful fumes, using equipment with guards to prevent
contact with moving parts, and installing automatic fire suppression systems. Administrative
controls, such as implementing lockout/tagout procedures to prevent accidental machine
startup, scheduling regular maintenance and inspection of equipment to prevent
breakdowns and malfunctions.
3. Providing personal protective equipment (PPE): This includes providing workers with
protective clothing, gloves, goggles, and face shields to protect them from chemical
exposure, as well as respirators to protect workers from exposure to harmful fumes and
dust.
4. Proper storage and handling of chemicals: This includes storing chemicals in appropriate
containers, properly labelling and identifying chemicals, and providing workers with training
on the proper handling and disposal of chemicals.
5. Implementing emergency procedures: This includes having emergency response plans in
place, providing workers with training on emergency procedures, and conducting regular
drills to ensure that workers are prepared to respond in the event of an emergency.
6. Conducting regular safety training: This includes providing workers with training on the
proper use of equipment and handling of chemicals, as well as on emergency procedures
and evacuation plans.
7. Monitoring and measuring chemical exposure: This includes using air monitoring equipment
to measure chemical exposure, as well as conducting regular medical surveillance to detect
any health effects from chemical exposure.

Q6. What are the general principles of the safety and health provisions to avoid hazards.
Ans:

1. Identification of hazards: This is the process of identifying and evaluating potential hazards
in the workplace. This includes identifying the source of the hazard, the people who may be
affected, and the extent of the risk.
2. Risk assessment: This is the process of evaluating the potential risks associated with
identified hazards. This includes determining the likelihood and severity of harm, as well as
assessing the effectiveness of existing controls.
3. Control of hazards: This is the process of implementing appropriate controls to eliminate or
reduce the potential risks associated with identified hazards. This includes engineering
controls, administrative controls, and personal protective equipment (PPE).
4. Monitoring and review: This is the process of monitoring the effectiveness of existing
controls, and reviewing and updating them as necessary. This includes conducting regular
inspections and audits, as well as reviewing incident reports and other data.
5. Communication and training: This is the process of providing workers with the information,
training, and resources they need to safely perform their tasks and protect themselves from
hazards.
6. Emergency planning and response: This is the process of planning and preparing for
emergencies, as well as responding appropriately in the event of an emergency. This
includes having emergency response plans in place, providing workers with training on
emergency procedures, and conducting regular drills to ensure that workers are prepared to
respond in the event of an emergency.
7. Compliance with laws and regulations: This is the process of ensuring that the workplace is
in compliance with all relevant laws and regulations related to safety and health.

Q7. How are hazards controlled in a confined space?

Ans: Controlling hazards in a confined space involves a combination of different strategies and
controls. Confined spaces are defined as areas that are large enough for a person to enter and
perform work, but are not designed for continuous human occupancy. These spaces can present
unique hazards due to their limited access and ventilation, and the nature of the work that is
performed there.

Q8. What are common hazards at a construction site?

Ans: Common hazards at construction sites include falls, electrical hazards, struck-by hazards,
caught-in or -between hazards, and hazardous materials. Other hazards may include heavy
machinery, improper scaffolding, and lack of proper personal protective equipment.

Q9. What is the hierarchy of hazards?

Ans: The hierarchy of hazards is a framework used to prioritize and control hazards in the workplace.
It typically includes the following steps:

1. Elimination: The first step is to eliminate the hazard altogether, if possible. This may involve
redesigning a process or eliminating a certain type of equipment.
 2. Substitution: If elimination is not possible, the next step is to substitute the hazard with
something less dangerous. For example, using a less toxic chemical or a piece of equipment
with safety features.
3. Engineering controls: If substitution is not possible, engineering controls can be used to
reduce the risk of exposure to the hazard. This may involve enclosing a process or installing
ventilation systems.
4. Administrative controls: If engineering controls are not feasible, administrative controls can
be used to limit exposure to the hazard. This may include procedures, policies, and training
programs.
5. Personal protective equipment (PPE): PPE is the last line of defence and should only be used
when all other controls are not feasible or are not sufficient to control the hazard.

Q10. Will exposure to hazards in the workspace cause injury illness or other adverse health effects?
If yes then Justify.

Ans: Yes, exposure to hazards in the workplace can cause injury, illness, or other adverse health
effects. Different types of hazards can have different effects on the body. For example, exposure to
loud noise can cause hearing loss, exposure to certain chemicals can cause respiratory problems,
and exposure to vibration can cause hand-arm vibration syndrome.

Injuries can occur as a result of falls, being struck by an object, or being caught in or between
equipment. Some hazards can also cause long-term health effects, such as cancer or respiratory
illness, as a result of prolonged exposure.

It's also important to note that some individuals may be more susceptible to certain hazards due to
pre-existing health conditions or other factors. Employers have a legal responsibility to provide a
safe and healthy work environment and to protect employees from harm.

Q11. How automation helps to improve repetitive work cycle.

Ans: Automation can help improve repetitive work cycles in manufacturing processes by increasing
efficiency and reducing the risk of errors. Some specific ways automation can help include:

 Consistency: Automated systems can perform tasks with a high degree of consistency,
reducing the risk of errors and increasing the quality of the finished product.
 Speed: Automated systems can work faster than humans, which can increase production
rates and reduce lead times.
 Flexibility: Automated systems can be programmed to perform multiple tasks, making it
easier to adapt to changing production needs.
 Safety: Automated systems can reduce the risk of injuries by removing the need for humans
to perform dangerous tasks, such as working with heavy machinery or handling hazardous
materials.
 Cost-effective: Automated systems can help save on labour costs, as they don't need to take
breaks, get sick, or need vacation.
  24/7 Production: Automated systems can work around the clock, which can help increase
production capacity and reduce the need for overtime.

Q12. What is the contribution of Robots in automotive industry where work repetition is involved.

Ans: Robots play a significant role in the automotive industry, particularly in areas where work
repetition is involved. Some of the ways robots contribute in the automotive industry include:

1. Assembly and welding: Robots are commonly used for tasks such as assembling car parts,
welding, and painting. They can work quickly and with a high degree of precision, reducing
the risk of errors and increasing productivity.
2. Material handling: Robots are used to move and transport materials around the factory,
which can help to increase efficiency and reduce the risk of injuries caused by manual
handling.
3. Quality control: Robots can be programmed to perform quality control tasks, such as
inspecting parts for defects, which can help to increase the quality of the finished product
and reduce the risk of errors.
4. Painting and coating: Robots are commonly used for tasks such as painting and coating,
which can be dangerous for human workers.
5. Inspection: Robots can be equipped with sensors and cameras to inspect and identify
defects in parts, which can help to improve quality control.
6. Testing: Robots can be used to test and perform various tasks, such as driving and collision
tests, which can help to improve the safety of the finished product.

Q13. Explain importance of robotics in Mobile Assembly line.

Ans: Robotics play an important role in mobile assembly lines as they provide a number of
advantages over traditional manual assembly methods. Some of the key benefits include:

1. Efficiency: Robotics can work faster and more accurately than humans, which can help to
increase production rates and reduce lead times.
2. Flexibility: Robotics can be programmed to perform a wide range of tasks, which allows for a
flexible approach to assembly. This is particularly useful in mobile assembly lines where
different products may need to be assembled in different ways.
3. Consistency: Robotics can perform tasks with a high degree of consistency, which helps to
improve the quality of the finished product and reduce the risk of errors.
4. Safety: Robotics can reduce the risk of injuries by removing the need for humans to perform
dangerous tasks, such as working with heavy machinery or handling hazardous materials.
5. Cost-effective: Robotics can help save on labour costs, as they don't need to take breaks, get
sick, or need vacation.
6. 24/7 Production: Robotics can work around the clock, which can help increase production
capacity and reduce the need for overtime.
7. Mobile assembly line is a concept where the assembly line is not fixed and it can move from
one location to another depending on the requirement. Robotics can help in this scenario as
well as it can be configured for mobile assembly lines as well.
Q14. How the robots are effectively used in Automobile Industry.

Ans: Robots are effectively used in the automobile industry in a variety of ways to increase
efficiency, improve quality, and reduce costs. Some specific ways in which robots are used in the
automobile industry include:

1. Assembly: Robots are commonly used to assemble car parts, such as engines, transmissions,
and body parts. They can work quickly and with a high degree of precision, which helps to
reduce errors and increase productivity.
2. Welding and painting: Robots are used for tasks such as welding and painting, which can be
dangerous for human workers. They can work quickly and with a high degree of precision,
which helps to improve the quality of the finished product.
3. Material handling: Robots are used to move and transport materials around the factory,
which can help to increase efficiency and reduce the risk of injuries caused by manual
handling.
4. Quality control: Robots can be programmed to perform quality control tasks, such as
inspecting parts for defects, which can help to increase the quality of the finished product
and reduce the risk of errors.
5. Testing: Robots can be used to perform various tests, such as driving and collision tests,
which can help to improve the safety of the finished product.
6. Machine Learning & AI: Robots are also being used in the automobile industry for tasks such
as predictive maintenance, and self-driving cars. They are equipped with sensors, cameras,
and machine learning algorithms which helps to improve the performance and safety of the
finished product.

Q15. What type of Robots is preferable on Assembly line?

Ans: Industrial robots, also known as factory robots, are commonly used in assembly line operations.
They are capable of performing repetitive tasks with high precision and speed, and are often used in
manufacturing and assembly operations. These robots can be programmed to perform tasks such as
welding, painting, packaging, and palletizing. They can also be equipped with sensors and cameras to
aid in their tasks. Collaborative robots, or cobots, are becoming increasingly popular in assembly line
operations as they are designed to work safely alongside human workers.