Factory line production

Presented By

Skand Kumar 2010BARC038

Shikha Negi 2010BARC049

Nabarun Dutta 2010BARC071

Anil Choudhary 2010BARC080

Content

1…Introduction

2…Areas of factory line production

3…Areas related with Architecture

4…Types

5…Advantage and Disadvantage

6…Case Study

- Literature

- Live

7…Conclusion

What is factory line production?

A factory line production is a set of sequential operations established ina factory whereby materials are put through a refining process to produce an end-product that is suitable for onward consumption; or components are assembled tomake a finished article.

History

It was popularized in the 1910s and 1920s by Henry Ford's Ford Motor Company,

which introduced electric motors to the then-well-known technique of chain or

sequential production.

Areas of factory line(a broad scenario)

Automobiles

Food products

Electronics

Construction

Aeronautics

Printing press…

Areas related with construction

Tiles

Panels

Purlin

False ceiling panels

Window frames

Paver Block

Electric poles

Railway sleepers

Fencing post

Safety Barriers

Metal Shuttering for concrete

Prefabricated concrete segments …

Classification of assembly line by Layout

Process layout(similar activities together)

Product Layout(Straight Line Assembly)

Fixed-position layout(Product Fixed Services Moving)

Cellular Layout( Multiple Small Assembly Line)

Types of assembly line by Layout

Batch model line

Mixed model line

Single model line

Classification by product

• Synchronous System

• Non Synchronous System

Types of Conveyor System

Pros and cons

May prove economical in mass production High initial cost

Faster production Reduces employment

Quality Demand is the main factor

Standardization May take time in setup

Chance of error reduced

Less manual labor

Literature case study

Autoclaved Aerated Concrete Block production

Manufacturer-Shandong Dongyue Building Machine Co Ltd., China

Conceptual Layout

Preparation and storage of raw material

Materials weighed and checked for quality

Preparation and storage of raw material

Materials put in conveyer belt for filtering

and quality assurance

Batching, Mixing and Pouring Area

Batching and mixing of raw material

Batching, Mixing and Pouring Area

Pouring of mixture

Curing area

Curing area

Curing chamber

Cutting area

Cutting area

1-Carriage box putting main block

over rail cart

2-Main block moving towards cutter

3-Chiselling of main block

Cutting area

5-Vertical cutting

4-Horizontal cutting

Area for autoclaving

Rapid curing with pressure and heat

Area for autoclaving

Packaging and dispatch area

Packaging and dispatch area

Live case study

Site area: 44750.070 m2

Supplier/ contractor: Larsen and turbo infrastructure

Client: Delhi metro rail corporation limited

Casting and stacking yard at Moti nagar, Delhi

Layout of casting and stacking yard

Office Parapet

casting

areaBatching

plant

Stacking

area

Casting

area

Bar binding

area

Fabrication

yard

Bar stacking

area

Cement godown

Water treatment plantQuality

analysis lab

ENTRY

Layout of casting and stacking yard

1. The site has• 3 Production lines• 4 Batching plants • 2 Cement godown• Water treatment plant

2. Design mix is used.3. Treated water is used.4. Concrete testing is done in QA/QC lab.

• Compression test• Impact test• Slump test• Consistency test• Density test

5. M-35 concrete is used.6. Fly ash is used which comes from Dharma

power plant nearby.

Water treatment plant

Batching plant

About Site

SEGMENTS PARAPET

Segments and parapets are fabricated

Some tests which are done before casting of members

Office Parapet

casting

areaBatching

plant

Stacking

area

Casting

area

Bar binding

area

Fabrication

yard

Bar stacking

area

Cement godown

Water treatment plantQuality

analysis lab

ENTRY

Layout of casting and stacking yard

Procedure for production of precast segments.

Bar binding

Arrangement for placing the shuttering

Office Parapet

casting

areaBatching

plant

Stacking

area

Casting

area

Bar binding

area

Fabrication

yard

Bar stacking

area

Cement godown

Water treatment plantQuality

analysis lab

ENTRY

Layout of casting and stacking yard

Shuttering

Deshuttering and coding

Normal water Curing of sections

Office Parapet

casting

areaBatching

plant

Stacking

area

Casting

area

Bar binding

area

Fabrication

yard

Bar stacking

area

Cement godown

Water treatment plantQuality

analysis lab

ENTRY

Layout of casting and stacking yard

Stacking the segments

Stack of segments

Office Parapet

casting

areaBatching

plant

Stacking

area

Casting

area

Bar binding

area

Fabrication

yard

Bar stacking

area

Cement godown

Water treatment plantQuality

analysis lab

ENTRY

Layout of casting and stacking yard

References

http://www.dongyuemachine.com SHANDONG DONGYUE BUILDING MACHINE

http://www.youtube.com/watch?v=C_JjLwPYdhk AAC Blocks production line

L&T Site Visit

Sumit Kumar (Engineer) L&T

Venkata Rao (Project Manager) L&T

A Review of Assembly Line Changes for Lean Manufacturing (IOSR Journal of Mechanical and Civil

Engineering (IOSR-JMCE))

Thank you