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Introduction To Process Industry By: Engr. Dr. Syed Amjad Ahmad

The document discusses different types of industries and classifies manufacturing industries as either process industries, which transform raw materials into intermediate or end products through chemical, physical, electrical, or biological transformations, or discrete product industries, which produce distinct parts or products. It also outlines various manufacturing operations including transformation, assembly, material handling, inspection, and coordination/control as well as factors that influence factory layouts such as production quantity and product variety.

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72 views

Introduction To Process Industry By: Engr. Dr. Syed Amjad Ahmad

The document discusses different types of industries and classifies manufacturing industries as either process industries, which transform raw materials into intermediate or end products through chemical, physical, electrical, or biological transformations, or discrete product industries, which produce distinct parts or products. It also outlines various manufacturing operations including transformation, assembly, material handling, inspection, and coordination/control as well as factors that influence factory layouts such as production quantity and product variety.

Uploaded by

Ali
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Introduction to process industry

By
Engr. Dr. Syed Amjad Ahmad
Classification of Industries

1. Primary industries – cultivate and exploit natural


resources
 Examples: agriculture, mining
2. Secondary industries – convert output of primary
industries into products
 Examples: manufacturing, power generation,
construction
3. Tertiary industries – service sector
 Examples: banking, education, government, legal
services, retail trade, transportation
Industry Classifications

 Process industries, e.g., chemicals, petroleum, basic


metals, foods and beverages, power generation

 Discrete product (and part) industries, e.g., cars, aircraft,


appliances, machinery, and their component parts
Manufacturing Industry
 Transformation Operations
 Machine Processing
 Assembly
 Adding value*
 Other Operations
Material handling Raw Part or
Inspection and testing Material Transformation Process Product
Coordination and control

Scrap or
Power Waste
Tools
Machines
Labour
Processing Operations

 Shaping operations
 Solidification processes
 Particulate processing
 Deformation processes
 Material removal processes
 Property-enhancing operations (heat treatments)
 Surface processing operations
 Cleaning and surface treatments
 Coating and thin-film deposition
Assembly Operations

 Joining processes
 Welding
 Brazing and soldering
 Adhesive bonding
 Mechanical assembly
 Threaded fasteners (e.g., bolts and nuts, screws)
 Rivets
 Interference fits (e.g., press fitting, shrink fits)
 Other
Material Handling

 Material transport
 Vehicles, e.g., forklift trucks, AGVs, monorails
 Conveyors
 Hoists and cranes
 Storage systems
 Unitizing equipment
 Automatic identification and data capture
 Bar codes
 RFID
 Other AIDC
Time Spent in Material Handling
Inspection and Testing

Inspection – conformance to design specifications


 Inspection for variables - measuring
 Inspection of attributes – gauging
Testing – observing the product (or part, material,
subassembly) during operation
Coordination and Control

 Regulation of the individual processing and assembly


operations
 Process control
 Quality control
 Management of plant level activities
 Production planning and control
 Quality control
Production Facilities and Layout

 Facilities organised in the most efficient way to serve the


particular mission of the plant and depends on:
 Types of products manufactured
 Production quantity
 Product variety
Production Quantity (Q)

 Number of units of a given part or product produced


annually by the plant
 Three quantity ranges:
1. Low production – 1 to 100 units
2. Medium production – 100 to 10,000 units
3. High production – 10,000 to millions of units
Product Variety (P)

 Number of different product or part designs or types


 ‘Hard’ product variety – products differ greatly
 Few common components in an assembly
 ‘Soft’ product variety – small differences between
products
 Many common components in an assembly
Low Production Quantity (Qlow)

Job shop – makes low quantities of specialized and


customized products
 Products are typically complex (e.g., specialized
machinery, prototypes, space capsules)
 Equipment is general purpose
 Plant layouts:
 Fixed position
 Process layout
Fixed-Position Layout
Process Layout
Medium Production Quantities (Qmed)

1. Batch production – A batch of a given product is


produced, and then the facility is changed over to
produce another product
 Changeover takes time – setup time
 Typical layout – process layout
 Hard product variety
2. Cellular manufacturing – A mixture of products is made
without significant changeover time between products
 Typical layout – cellular layout
 Soft product variety
Cellular Layout
High Production (Qhigh)

1. Quantity production – Equipment is dedicated to the


manufacture of one product
 Standard machines tooled for high production (e.g.,
stamping presses, molding machines)
 Typical layout – process layout
2. Flow line production – Multiple workstations arranged in
sequence
 Product requires multiple processing or assembly
steps
 Product layout is most common
Product Layout
PQ Relationships

Q
Product Quantity and Variety

 Let Qj = annual quantity of variety ‘j’


 P = variety of products from ‘1’ to ‘j’ P
 Total number of product units = Qf = Q j
j 1
Product and Part Complexity

 Product complexity np = number of components in


product
 Part complexity no = number of processing operations
per part
Factory Operations Model

Simplified :

 Total number of product units Qf = PQ


 Total number of parts produced npf = PQnp
 Total number of operations nof = PQnpno

where
P = Product variety
Q = Product quantity
np = Number of parts in product
no = Number of operations in product
Worked Problem
2.2: The ABC Company is planning a new product line and will build a
new plant to manufacture the parts for a new product line. The
product line will include 50 different models. Annual production of
each model is expected to be 1000 units. Each product will be
assembled of 400 components. All processing of parts will be
accomplished in one factory. There are an average of 6 processing
steps required to produce each component, and each processing
step takes 1.0 minute (includes an allowance for setup time and part
handling). All processing operations are performed at workstations,
each of which includes a production machine and a human worker. If
each workstation requires a floor space of 250 m2, and the factory
operates one shift (2000 hr/yr), determine (a) how many production
operations, (b) how much floorspace, and (c) how many workers will
be required in the plant.
Solution

This problem neglects the effect of assembly time:


(a) nof = PQnpno = 50(1000)(400)(6) = 120,000,000
operations in the factory per year.
(c) Total operation time = (120 x 106 ops)(1min./(60 min./hr))
= 2,000,000 hr/yr.
At 2000 hours/yr per worker, w = = 1000 workers.
(b) Number of workstations n = w = 1000.

Total floorspace = (1000 stations)(250 m2/station) = 250,000


m2
Manufacturing Capability

 Technological processing capability - the available set


of manufacturing processes
 Physical size and weight of product
 Production capacity (plant capacity) - production
quantity that can be made in a given time
Lean Production

Operating the factory with the minimum possible resources


and yet maximizing the amount of work accomplished

 Utilisation of Resources - workers, equipment, time,


space, materials
 Minimising time
 Maximising quality (accuracy)
 Minimising cost

 Doing more with less, and doing it better


Programs Associated with
Lean Production
 Just-in-time delivery of parts
 Worker involvement
 Continuous improvement
 Reduced setup times
 Stop the process when something is wrong
 Error prevention
 Total productive maintenance

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