Plant Layout contd. & Foundry

Dear Students,
Kindly make layouts i.e. Product and Process layouts. The objectives of a good plant layout are laid down.

1.Minimising & efficiently control of material handling and transportation.
2.Bottlenecks and congestion to be eliminated for smooth and continuous flow.
3.Movement of persons to be minimised for effective utilisation of equipment & space.
4.Working place to be safe,well ventilated, and free from dust,noise, fumes & odour.
5.Waiting time for semifinished product should be minimised.
6.Cubic space should be utilised in effective manner.
7.To increase productivity with reduced capital investment.
8.To provide flexibility of manufacturing and management.
9.To allow the movement of material with desired speed and lowest cost.
10.To promote job satisfaction and good relation between management & employees.

FOUNDRY.........FORGING..........FORMING

FOUNDARY: Foundary is a place, where casting is done.Casting is a process of pouring molten metal in a cavity called MOULD.When this mould is filled with molten metal, it solidifies and produces a casting.

PATTERN:Pattern is a model of desired product(casting)i.e. constructed in such a way that it can be used for forming an impression called mould.Pattern is replica of casting.

Pattern Materials:
* Wood
* Metal(Cast Iron, Brass, Aluminium alloys & White Metal etc)
* Plaster
* Plastic Compound
* Wax

The following factors are to be considered for selection of pattern material.
1. Design of casting
2. Quality and quantity of casting
3. Shape and size of casting
4. Types of moulding
5. Types of process of casting
6. Moulding material
7. Possibility of design changes
8. Chances of repeat orders
9. Pattern material should be light in weight, easily worked, shaped and joinable.
10.It should be durable,strong, hard, resistant to wear abrasion, corrosion and chemical reaction.
11. Dimensionally stable,unaffected by variation in temprature and humidity.
12. Low cost, easily repairable and re-usable.
13. Ability to take a good finish.

Refer Casting processes figure at my site 9262k and draw of your own and write basic steps taken in a casting process as explained in the class i.e. from pattern making to dispatch of the cast product.
Main shops in the FOUNDRY.
Pattern Shop, Moulding shop and melting shop( Furnace).
Name the types of patterns and draw the figures. Write why & where are these used.
Types: Solid and single piece, Split(two Pieces), Multi-piece,Match plate, Gated, Skeleton,Sweep, Pattern with loose pieces, Cope & drag pattern, Follow board pattern and Segmental pattern.

Plant layout contd.

a) PRODUCT LAYOUT
Machines are arranged according to sequence of operations. This type of layout is preferred for mass production with less variety-normally used in assembly shop of automobiles, mass production of plastic goods and still mills etc.

Advantages:
-Minimizing material handling due to straight flow.
-Product completes in lesser time.
-Continuous flow of work.
-Better coordination in planning & control of production.
-Less floor area for same volume of work.
-Less skilled worker.
b) PROCESS LAYOUT
Machines performing similar operations are arranged in groups at one location not according to sequence of operation. For examples all lathe m/cs are placed at one place and all milling m/cs are placed at another place. Generally used for low volume of production needed at regular interval.

Advantages:
-Lower initial investment
-General purpose m/cs may serve the purpose
-Greater flexibility in utilisation.
-Optimum use of m/cs.
-At the time of breakdown, transferring of work to other m/cs may easily be done.
-Variety of parts make the work interesting and challanging.
-Better productivity,as supervisor and worker attend one type of m/c.

OBJECTIVES OF GOOD PLANT LAYOUT
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Plant Layout

Plant is a place, where persons, money, material, machinery, equipment and tools etc are brought together for producing/ manufacturing products. Layout means a plan/ method for arranging all these facilities/ things in an effective & perfect manner so that all the functions are carried out effectively and economically.

Layout is not restricted to plant only it is equally necessary for houses, buildings,schools, colleges, hospitals, malls and other such constructions.

Again plant layout does not mean of planning new plants only. It may involve:
1. Re-layout of existing plant i.e. relocation
2. Expansion of existing plant
3. Modification/ improvement of existing plant.
Plant layout may be divided mainly into two types.
a) Product Layout
b) process Layout