UnitsIII-IM

INDUSTRIAL MANAGEMENT: 

INDUSTRIAL MANAGEMENT UNIT III

UNIT III: 

UNIT III Plant Management: Plant location, plant layout, Types of maintenance such as break down, predictive& preventive maintenance, stores management, Industrial safety, causes & cost of accidents, safety Programs, Production planning & control, job, batch & process type of production.

Plant location: 

Plant location Need for selection Selection Region Raw material Market Power Transportation Climate Gov Policy

Plant location: 

Plant location Selection of Community Labor Civic Amenities for worker Complementary Competing Finance R&D

Plant location: 

Plant location Auxiliary factors Local taxes and restrictions Momentum of an early start Medical Facility Fire fighting Personal factors

Plant location: 

Plant location Selection of Site Area Soil, Water Supply Topography Disposal of Waste

Plant Layout: 

Plant Layout Arrangement of desired machine or equipment and facility in such way which will permit the easiest flow of material at lowest cost and minimum handling Factors affecting Plant Layout Types of Industry Extractive Conditioning Analytical Synthetic

Plant Layout: 

Product Workers Machine location Plant Layout

Principal of Plant Layout: 

Principal of Plant Layout Principal of minimum travel Principal of sequence Principal of usage Principal of compactness Principal of satisfaction Principal of flexibility Principal of minimum investment

MAINTENANCE: 

MAINTENANCE British Standard Glossary of terms (3811:1993) defined maintenance as: The combination of all technical and administrative actions, including supervision actions, intended to retain an item in, or restore it to, a state in which it can perform a required function.

Maintenance Activities: 

Maintenance Activities Activities of maintenance function could be either repair or replacement activities, which are necessary for an item to reach its acceptable productivity condition and these activities, should be carried out with a minimum possible cost.

Principle Objectives in Maintenance: 

Principle Objectives in Maintenance To achieve product quality and customer satisfaction through adjusted and serviced equipment Maximize useful life of equipment Keep equipment safe and prevent safety hazards Minimize frequency and severity of interruptions Maximize production capacity – through high utilization of facility

Problems in Maintenance: 

Problems in Maintenance Lack of management attention to maintenance Little participation by accounting in analyzing and reporting costs Difficulties in applying quantitative analysis Difficulties in obtaining time and cost estimates for maintenance works Difficulties in measuring performance

Problems Exist Due To: 

Problems Exist Due To Failure to develop written objectives and policy Inadequate budgetary control Inadequate control procedures for work order, service requests etc. Infrequent use of standards To control maintenance work Absence of cost reports to aid maintenance planning and control system

Maintenance Objectives: 

Maintenance Objectives Must be consistent with the goals of production (cost, quality, delivery, safety) Must be comprehensive and include specific responsibilities

Maintenance Costs: 

Maintenance Costs Cost to replace or repair Losses of output Delayed shipment Scrap and rework

Types of Maintenance: 

Types of Maintenance Maintenance may be classified into four categories: (some authors prefer three categories- scheduled and preventive maintenances are merged ) Corrective or Breakdown maintenance Scheduled maintenance Preventive maintenance Predictive (Condition-based) maintenanc e

Corrective or Breakdown Maintenance: 

Corrective or Breakdown Maintenance Corrective or Breakdown maintenance implies that repairs are made after the equipment is failed and can not perform its normal function anymore Quite justified in small factories where: Down times are non-critical and repair costs are less than other type of maintenance Financial justification for scheduling are not fe lt

Disadvantages of Corrective Maintenance: 

Disadvantages of Corrective Maintenance Breakdown generally occurs inappropriate times leading to poor and hurried maintenance Excessive delay in production & reduces output Faster plant deterioration Increases chances of accidents and less safety for both workers and machines More spoilt materials Direct loss of profit Can not be employed for equipments regulated by statutory provisions e.g. cranes, lift and hoists etc

Scheduled Maintenance: 

Scheduled Maintenance Scheduled maintenance is a stitch-in-time procedure and incorporates inspection lubrication repair and overhaul of equipments If neglected can result in breakdown Generally followed for: overhauling of machines changing of heavy equipment oils cleaning of water and other tanks etc.

Preventive Maintenance (PM): 

Preventive Maintenance (PM) Principle – “Prevention is better than cure” Procedure - Stitch-in-time It locates weak spots of machinery and equipments provides them periodic/scheduled inspections and minor repairs to reduce the danger of unanticipated breakdowns

Candidates for Preventive Maintenance: 

Candidates for Preventive Maintenance Mean Time Between Failure (MTBF) Frequency of Failure Good candidates have more normal distribution with low variability

Advantages of PM: 

Advantages of PM Reduces break down and thereby down time Lass odd-time repair and reduces over time of crews Greater safety of workers Lower maintenance and repair costs Less stand-by equipments and spare parts Better product quality and fewer reworks and scraps Increases plant life Increases chances to get production incentive bonus

Predictive (Condition-based) Maintenance : 

Predictive (Condition-based) Maintenance In predictive maintenance, machinery conditions are periodically monitored and this enables the maintenance crews to take timely actions, such as machine adjustment, repair or overhaul It makes use of human sense and other sensitive instruments, such as audio gauge, vibration analyzer, amplitude meter, pressure, temperature and resistance strain gauges etc.

Predictive Maintenance (Contd.): 

Predictive Maintenance (Contd.) Unusual sounds coming out of a rotating equipment predicts a trouble An excessively hot electric cable predicts a trouble Simple hand touch can point out many unusual equipment conditions and thus predicts a trouble

Maintenance Costs: 

Maintenance Costs Maintenance Commitment Cost Breakdown Cost

Maintenance Costs: 

Maintenance Costs Maintenance Commitment Cost PM Cost Breakdown Cost

Maintenance Costs: 

Maintenance Costs Maintenance Commitment Cost PM Cost Breakdown Cost Total Maintenance Cost

Maintenance Costs: 

Maintenance Costs Maintenance Commitment Cost PM Cost Total Maintenance Cost Breakdown Cost Optimal

MAINTENANCE: 

MAINTENANCE Why do we need maintenance? What are the costs of doing maintenance? What are the costs of not doing maintenance? What are the benefits of maintenance? How can maintenance increase profitability of company? What are the types of maintenance?

Industrial safety: 

Industrial safety Industrial safety, causes & cost of accidents safety Programs