1. Enumerate various horizontal type layouts.
2. Write the advantages of CRAFT .
3. Define quadratic approach method.
4. Why Material characteristics are required for design of material handling equipment?
5. What type of material handling equipment required in Fixed position layout?
6. What are the advantages of process layout?
7. What are the elements of plant layout?
8. What are the factors are to be considered for product layout?
ans)
1. Here are some examples of horizontal type layouts:
- Line Layout
- U-shaped Layout
- L-shaped Layout
- Cell Layout
- Process Layout
2. CRAFT (Computerized Relative Allocation of Facilities Technique) has several
advantages:
- Optimal Space Utilization: CRAFT helps determine the most efficient allocation of
facilities, maximizing resource utilization.
- Improved Workflow: It considers factors like material flow and interdepartmental
relationships, promoting smooth and efficient workflow.
- Flexibility and Adaptability: CRAFT allows for easy modification of layouts to
accommodate changes in production requirements.
- Cost Reduction: By optimizing the layout, CRAFT reduces material handling, travel
distances, and improves productivity, leading to cost savings.
3. The quadratic approach method is a mathematical optimization technique used to solve
quadratic programming problems. It involves optimizing a quadratic objective function
subject to linear constraints.
4. The particle size distribution of a given material plays a major role in several aspects of
designing bulk material handling equipment. Not only does it factor into maximum
allowable capacity and unit sizing, but it can also influence conveying speed, particularly
when working with dusty materials.
Material characteristics are essential for designing material handling equipment because:
- Safety
- Equipment Selection
- Efficiency
- Equipment Durability
5. In a fixed position layout, the type of material handling equipment required can vary
based on the specific project needs. Common equipment includes cranes, hoists, lifts,
conveyors, and specialized tools or machinery for assembly or installation. The equipment
should be able to handle the weight, size, and requirements of the project.
6. Process layout advantages:
-flexibility
-specialization
-variety
-maintenance
-cost-effectiveness.
7. Elements of plant layout:
machines/equipment
-workstations
-material handling systems
-storage areas
-support facilities
-safety considerations.
8. Factors for product layout:
-product design
-production volume
-standardization-assembly
sequence
-equipment/machinery
-ergonomics.
*)Write about the Classification of Plant Layout. Explain any one type Plant Layout.
ans) Plant layouts can be classified into several types based on their arrangement and
design.
Types of Plant Layout:Product layout or line processing layout or flow-line layout. Process
layout or functional layout or job shop layout. Fixed position layout or static layout.
Cellular manufacturing (CM) layout or Group Technology layout.
In a Process Layout, similar machines and equipment are grouped together based on the
type of process they perform. For example, all milling machines are placed together, all
grinding machines are grouped together, and so on. This layout allows for a more efficient
flow of materials and resources within each department or process.
One advantage of the Process Layout is its flexibility. Since machines and workstations
are arranged based on process requirements, it becomes easier to rearrange them when
production needs change. This flexibility allows for quick adjustments and adaptability to
handle different product lines or production volumes.
Additionally, the Process Layout promotes specialization and expertise. Each department
or workstation can focus on a specific process, leading to increased efficiency and
productivity. It also simplifies maintenance and repair, as machines with similar functions
are grouped together, making it easier to access and service them.
Overall, the Process Layout is suitable for industries with diverse product lines or
low-volume production. It offers flexibility, specialization, and cost-effectiveness, making it
a popular choice in many manufacturing settings.
*)Explain the Layout design procedures in detail.
ans)The layout design procedures involve a series of steps to ensure an effective and
efficient arrangement of facilities within a plant. Here are the detailed steps:
1. Gather Information: Start by gathering all the necessary information about the production
process, product requirements, available space, equipment, and material flow.
2. Analyze Requirements: Analyze the production requirements, including the production
volume, product variety, and process flow.
3. Develop Initial Layout Concepts: Generate multiple layout concepts based on the
gathered information and requirements. These concepts should consider the flow of
materials, equipment placement, workstations, and support facilities.
4. Evaluate Layout Options: Evaluate each layout concept based on criteria such as cost,
efficiency, flexibility, safety, and future expansion. Consider feedback from stakeholders,
including employees, supervisors, and management.
5. Refine the Chosen Layout: Refine the chosen layout by making adjustments and
modifications based on the feedback and evaluation results. Consider factors like
minimizing material movement, optimizing space utilization, and improving workflow.
6. Implement the Final Layout: Once the final layout is determined, start implementing it by
physically arranging the equipment, workstations, and support facilities according to the
design.
7. Monitor and Evaluate: After the layout is implemented, monitor its performance and
evaluate its effectiveness regularly.
*)Explain ALDEP procedure by considering a suitable example.
ans)The ALDEP (Activity Relationship Chart and Layout Evaluation Procedure) is a
method used for plant layout design. It involves analyzing the relationships between
activities and evaluating different layout options. Let me explain it further with an
example.
-Let's consider a manufacturing company that produces automobiles. The company has
various departments, including the assembly line, paint shop, welding shop, and engine
testing area. The goal is to design an efficient layout that minimizes material movement
and optimizes workflow.
1. Activity Relationship Chart: Start by creating an Activity Relationship Chart (ARC). This
chart illustrates the relationships between different activities or departments.
2. Layout Evaluation: Once the ARC is created, evaluate different layout options based on
factors such as material flow, equipment placement, and department interdependencies.
Consider the distance between departments, the number of material handlings, and
potential bottlenecks.
3. Determine the Best Layout: Analyze each layout option and determine the most
suitable one based on criteria like efficiency, cost, safety, and future expansion. Take into
account factors such as minimizing material movement, optimizing space utilization, and
improving workflow.
4. Implement the Chosen Layout: Once the best layout is determined, implement it by
physically arranging the departments, workstations, and equipment according to the
design.
5. Monitor and Adjust: After implementing the layout, monitor its performance and make
adjustments if necessary.
*)What is CORELAP? Write the procedural steps of CORELAP for Layout design.
ans)CORELAP (Computerized Relationship Layout Planning) is another method used for
plant layout design. It is a computer-based approach that helps optimize the placement
of departments or activities within a facility. Here are the procedural steps of CORELAP
for layout design:
1. Define the Problem: Clearly identify the objectives and constraints of the layout
design project.
2. Gather Data: Collect relevant data about the facility, including department sizes,
shapes, and interrelationships.
3. Input Data into the Software: Use specialized layout design software that supports
the CORELAP method.
4. Run the CORELAP Algorithm: The software will utilize the CORELAP algorithm to
analyze the input data and generate potential layout options.
5. Evaluate Layout Options: Review the layout options generated by the software.
Evaluate each option based on criteria such as efficiency, cost, safety, and future
expansion.
6. Refine and Adjust: If necessary, refine and adjust the chosen layout option based on
feedback from stakeholders, including employees and management.
7. Finalize the Layout: Once the layout design is refined, finalize it by documenting the
placement of departments, workstations, and equipment.
8. Implement the Layout: Implement the finalized layout by physically arranging the
departments, workstations, and equipment according to the design.
9. Monitor and Adjust: After implementing the layout, monitor its performance and make
adjustments if necessary.
*)How do you classify Material handling equipment? Explain each category with Suitable
applications.
ans)Material handling equipment can be classified into several categories based on
their functions and applications. Here are some common categories and their suitable
applications:
1. Conveyors: Conveyors are used to transport materials from one location to another.
They are suitable for applications such as assembly lines, warehouses, and distribution
centers.
2. Forklifts: Forklifts are versatile equipment used for lifting and moving heavy loads.
They are commonly used in warehouses, manufacturing facilities, and construction
sites.
3. Cranes: Cranes are used for lifting and moving heavy objects vertically and
horizontally. They are commonly found in construction sites, shipping ports, and
manufacturing facilities.
4. Automated Guided Vehicles (AGVs): AGVs are self-guided vehicles used for material
transport within a facility. They are equipped with sensors and can navigate through
predefined routes.
5. Pallet Jacks: Pallet jacks, also known as pallet trucks, are used for moving palletized
loads. They are commonly found in warehouses, retail stores, and distribution centers.
6. Stackers: Stackers are used for lifting and stacking materials vertically. They are
commonly used in warehouses, distribution centers, and manufacturing facilities.
7. Conveyor Sortation Systems: Conveyor sortation systems are used to sort and route
items to their respective destinations. They are commonly found in distribution centers,
airports, and mail sorting facilities.
*)List out and discuss various important Material Handling principles.
ans) Here are some important principles of material handling:
1. Planning: Proper planning is essential for effective material handling.
2. Standardization: Standardizing material handling processes and equipment helps
to improve efficiency and reduce errors.
3. Ergonomics: Considering ergonomics in material handling helps to ensure the
safety and well-being of workers.
4. Accessibility: Easy access to materials and equipment is crucial for efficient
handling.
5. Automation: Automation technologies, such as robotics and conveyor systems,
can greatly enhance material handling efficiency.
6. Flexibility: Material handling systems should be designed to accommodate
changes in demand, product variety, and operational requirements.
7. Safety: Safety should always be a top priority in material handling. Proper
training, the use of appropriate personal protective equipment (PPE), and adherence
to safety protocols are crucial to prevent accidents and injuries.
8. Maintenance: Regular maintenance and inspection of material handling
equipment are essential to ensure optimal performance and longevity.
9. Sustainability: Considering environmental sustainability in material handling can
have benefits such as reduced energy consumption, waste reduction, and use of
eco-friendly materials.
*)Enumerate the differences between Process layout and Product layout.
ans)Process Layout:
1. In a process layout, similar machines or operations are grouped together based on
their functions or processes.
2. Material flows through different departments or workstations based on the specific
process requirements.
3. It is suitable for industries that produce a wide variety of products with different
process requirements, such as job shops or custom manufacturing.
4. Process layouts allow for flexibility and customization, as they can easily
accommodate changes in product design or process requirements.
5. Material handling can be more complex in process layouts, as materials may need to
be transported between different departments or workstations.
Product Layout:
1. In a product layout, machines and workstations are arranged in a sequence that
follows the production flow of a specific product.
2. Each workstation is dedicated to performing a specific task in the production process.
3. It is suitable for industries that produce standardized products in large quantities, such
as assembly lines in automotive manufacturing.
4. Product layouts are highly efficient and optimized for mass production, as they
minimize material handling and reduce production time.
5. Changes in product design or process requirements may require significant
reconfiguration of the layout, making product layouts less flexible than process layouts.
*)Explain the Branch and bound method.
ans)The Branch and Bound method is a technique used in optimization problems to
systematically explore the solution space and find the optimal solution. It involves dividing
the problem into smaller subproblems, called branches, and evaluating each branch to
determine if it can lead to a better solution.
Here's how it works:
1. Start with an initial solution and calculate its objective function value.
2. Divide the problem into smaller subproblems, creating branches that represent different
possible solutions.
3. Evaluate each branch by calculating its objective function value.
4. If a branch's objective function value is worse than the current best solution, prune it
(discard it) as it cannot lead to an optimal solution.
5. If a branch's objective function value is better than the current best solution, update the
current best solution.
6. Repeat steps 2-5 for each branch until all branches have been evaluated or pruned.
7. Select the best solution found as the optimal solution.
The Branch and Bound method helps reduce the search space by eliminating branches that
cannot lead to the optimal solution, thus improving the efficiency of the optimization
process. It is commonly used in problems like the Traveling Salesman Problem, Knapsack
Problem, and Job Scheduling Problem.