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
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. Thousands of pounds per week to departments 2 3 4 5 6 7 8 9 10 11 90 75 15 20 45 5 13 5 35 3 5 5 18 12 10 5 20 33 90 10 5 2 3 10

12

13

3000 10000 15000 4000 9000 15000 6000 1200 8000 6000 10000 2000 8000

1 3000

90

2 10,000

15 75

4 4000

13
8 1200

3 15,000

2
5
12 2000

16
20 3 5
5 9000

45
6

5 10 20 5 18

15,000

10
13 8000

12

35
9 8000

90

11 10,000

33
7 6000

10 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 3000 10,000 4 4000

1
3 15,000 8 1200

2
8 3 12 6 5 11 10

Fit Into Existing Building Space

13

5 12 2000 9000

6 15,000

13 8000

11 9 10,000 8000

7 6000

10 6000

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 Na 1 1 2 3 3 4 4 5 Element Description 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
7 2 1

0.2
12 8

0.4

0.3 0.2 0.8 0.3

0.1

0.2
3

0.7

0.8
10 6

14

0.6

0.6
11

13

0.3

0.5

Work Stations
1,3 0.9 2,4,7 0.9 5 0.8 6,10 0.9 9 11,13 0.8 8,12, 14 0.9

0.8

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