SAFETY

IN
INDUSTRIAL OPERATION & DESIGN

P. Mondal
Asst. Professor (Senior Scale)

4/27/17 2
CONTENTS
PLANT LAYOUT
MATERIAL HANDLING
MATERIAL STORAGE
WORK ENVIRONMENT
HOUSE KEEPING

4/27/17 3
 People become injured,
disabled and are killed at
their workplaces due to
industrial accidents.

4/27/17 4
Causes of industrial Accidents
1. Technical equipment

Lack of equipment or faulty

design leading to a

sequence of unexpected

events which finally result in

4/27/17 5
Causes of industrial Accidents
2. Working Conditions
This influence indirectly
thereby causing accidents.
Factors include in this are:

.Disorder at the workplace

.Noise
.Temperature
. Ventilation
4/27/17 6
Causes of industrial Accidents
3. People

Your own performance

can increase the risks of
having an accident.

The employer has the

primary responsibility for
the planning and layout of
4/27/17
the workplace.
7
 Plant Layout

Plant layout refers to the arrangement of physical facilities such

as machines, equipment, tools, furniture etc. in such a manner so
as to have quickest flow of material at the lowest cost and with
the least amount of handling in processing the product.

4/27/17 8
4/27/17 9
 Objectives of good Plant
Layout
A well designed plant layout is one that can be beneficial in achieving the
following objectives:

Properandefficientutilizationofavailablefloorspace

Transportationofworkfromonepointtoanotherpointwithoutanydelay

Properutilizationofproductioncapacity.

Reducematerialhandlingcosts

Utilizelabourefficiently

4/27/17 10
 Objectives of good Plant
Layout:

Reduceaccidents

Provideforvolumeandproductflexibility

Provideeaseofsupervisionandcontrol

Provideforemployeesafetyandhealth

Alloweasymaintenanceofmachinesandplant.

Improveproductivity

4/27/17 11
 TYPES OF LAYOUT
PRODUCT OR LINE LAYOUT
In this type of layout the machines and equipments are arranged in one line
depending upon the sequence of operations required for the product. It is also
called as line layout. The material moves to another machine sequentially
without any backtracking or deviation i.e the output of one machine becomes
input of the next machine. It requires a very little material handling.

It is used for mass production of standardized products.

4/27/17 12
4/27/17 13
4/27/17 14
 TYPES OF LAYOUT
Advantages of Product layout:

1. Lowcostofmaterialhandling,duetostraightandshortrouteandabsence
ofbacktracking

2. Smoothandcontinuousoperations

3. Continuousflowofwork

4. Lesserinventoryandworkinprogress

5. Optimumuseoffloorspace

6. Simpleandeffectiveinspectionofworkandsimplifiedproductioncontrol

7. Lowermanufacturingcostperunit
4/27/17 15
 TYPES OF LAYOUT
Disadvantages of Product layout:

1. Higherinitialcapitalinvestmentinspecialpurposemachine(SPM)

2. Highoverheadcharges

3. Breakdownofonemachinewilldisturbtheproductionprocess.

4. Lesserflexibilityofphysicalresources.

4/27/17 16
 TYPES OF LAYOUT
PROCESS LAYOUT

In this type of layout the machines of a similar type are arranged together at

one place. This type of layout is used for batch production. It is preferred

when the product is not standardized and the quantity produced is very small.

4/27/17 17
4/27/17 18
 TYPES OF LAYOUT
Advantages of Process layout

1. Lowerinitialcapitalinvestmentisrequired.

2. Thereishighdegreeofmachineutilization,asamachineisnotblockedfor
asingleproduct

3. Breakdownofonemachinedoesnotdisturbtheproductionprocess.

4. Supervisioncanbemoreeffectiveandspecialized.

5. Greaterflexibilityofresources.

4/27/17 19
 TYPES OF LAYOUT
Disadvantages of Process layout:

1. Materialhandlingcostsarehighduetobacktracking.

2. Moreskilledlabourisrequiredresultinginhighercost

3. Workinprogressinventoryishighneedinggreaterstoragespace

4. Morefrequentinspectionisneededwhichresultsincostlysupervision

4/27/17 20
 TYPES OF LAYOUT
FIXED POSITION OR LOCATION LAYOUT

Fixed position layout involves the movement of manpower and machines to

the product which remains stationary. The movement of men and machines is
advisable as the cost of moving them would be lesser.

This type of layout is preferred where the size of the job is bulky and heavy.
Example of such type of layout is ships, boilers, generators, building, aircraft
manufacturing, etc.

4/27/17 21
 TYPES OF LAYOUT
FIXED POSITION OR LOCATION LAYOUT

4/27/17 22
4/27/17 23
 TYPES OF LAYOUT
Advantages of Fixed position layout

1. Theinvestmentonlayoutisverysmall.

2. Thelayoutisflexibleaschangeinjobdesignandoperationsequencecan
beeasilyincorporated.

3. Adjustmentscanbemadetomeetshortageofmaterialsorabsenceof
workersbychangingthesequenceofoperations.

4/27/17 24
 TYPES OF LAYOUT
Disadvantages of Fixed position layout

1. Astheproductionperiodbeingverylongsothecapitalinvestmentisvery
high.

2. Verylargespaceisrequiredforstorageofmaterialandequipmentnearthe
product.

3. Asseveraloperationsareoftencarriedoutsimultaneouslysothereis
possibilityofconfusionandconflictsamongdifferentworkgroups.

4/27/17 25
PLANT OPERATION AND
LAYOUT
Safety is a prime consideration in plant
sitting.

Other important factors include:

Access to raw materials and markets,
Availability of land,
Availability of labour,
Availability of cooling water,
Means of sufficient disposal,
Interlinking with other plants; and government policies,
including planning permission and investment incentives.

4/27/17 26
Some of the important ways in which plant layout contributes to safety
and loss prevention (SLP) are:

1. Segregation of different risks;

2. Minimization of vulnerable pipework;
3. Containment of accidents;
4. Limitation of exposure;
5. Efficient and safe construction;
6. Efficient and safe operation;
7. Efficient and safe maintenance;
8. Safe control room design;
9. Emergency control facilities;
10. Fire fighting facilities;
11. Access for emergency services;
12. Security

4/27/17 27
 Layout Techniques and
Aids
There are a number of methods available for layout
design. These are generally more applicable to the
analysis rather than the synthesis of layouts, but
some have elements of both. They include:
(1) classification, rating and ranking;
(2) critical examination;
(3) hazard assessment;
(4) economic optimization.

There are also various aids, including:

(5) visualization aids;
(6) computer aids.
4/27/17 28