INSTITUTE OF AERONAUTICAL ENGINEERING (Autonomous) Dundigal, Hyderabad

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1 INSTITUTE OF AERONAUTICAL ENGINEERING (Autonomous) Dundigal, Hyderabad MECHANICAL ENGINEERING TUTORIAL QUESTION BANK Course Name : PLANT LAYOUT AND MATERIAL HANDLING Course Code : A80365 Class : B.Tech IV Yr II Semester Branch : Mechanical Engineering Year : Course Faculty : Mr. G. S. Vivek, Assistant Professor, Mr. A. Venu Prasad, Assistant Professor. OBJECTIVES: This course is an introduction to the concepts and problems underlying the design and operation of contemporary production systems. Emphasis is placed on the design and operation of manufacturing facilities, but many of the presented results apply also to the design, planning and control of operations taking place in the service sector. More specifically, the course seeks to offer a balanced development of the following issues: A systematic exposition of the design, planning and control problems that arise in the context of the aforementioned facilities. A systematic introduction to inventory control theory and its application in the contemporary production and distribution networks. A formal analysis of the dynamics of production processes, based on queuing theoretic concepts and models. The integration of the results developed in Step 3 to the prevailing production planning and control framework(s). S. No Question UNIT I Blooms Taxonomy Level Course Outcome 1 Explain the definition of plant layout. 3 2 Discuss the main objectives of layout. 5 3 Describe the principle of plant layout. 4 4 Explain the principle of minimum handling. 3 5 Explain the principle of maximum feasibility. 3 6 Explain the principle of cubic space utilization. 3 7 Describe about a good layout. 3 8 Explain various types of manufacturing units. 3 9 Explain process layout Explain the advantages of process layout. 4,5 11 List out the limitations of process layout Explain combination layout List out the limitation of fixed position layout Explain line balancing. 4

2 15 Compare process layout and product layout Explain about service establishment List out the advantages of product layout 4 18 Describe group technology Give outline of fixed position layout Describe the applications of process and product layouts 3 1 Explain the steps in selecting the plant site 3 2 Explain the advantages and disadvantages while selecting a site in rural areas. 5 3 Explain objectives of good plant layout. 4 4 Explain the advantages and disadvantage while selecting the site in urban area. 3 5 Describe the different types of layout. 5 6 List advantages and limitations of Plant layout. 3 7 What factors you consider while selecting a location for a plant. 3 8 Explain the overview of the plant layout. 3 9 Explain the Advantages and disadvantages of process layout Compare the differences between process and product layout Write the Advantages and disadvantages of group layout How product layout differs from process layout. 4,5 13 Write short notes on product layout What are the factors we need to select a process Layout? 3 15 Write short note on process layout What are the steps we need to select a Plant Layout? 4 17 List advantages and disadvantages of product layout Compare the applications between process and group layout Explain the overview of the group layout List out the difficulties in selection of a layout. 3 1 Considering a suitable example explain the process layout. 3 2 Considering a suitable example explain the product layout. 3 3 Considering a suitable example explain the group layout. 3 4 Explain how line balancing can be done in layout. 4 5 Summarize the behavior factor in adoption of machining. 3 UNIT II 1 Explain the features of ALDEP. 3 2 Identify steps involved in ALDEP. 5 3 Draw the structure of ALDEP. 4 4 Describe CORELAP according to Muther s. 3 5 Describe sweep pattern. 3 6 Summarize REL-chart. 3

3 7 Outline CORELAP algorithm. 3 8 Define placement order of departments. 3 9 Explain about CRAFT Identify features of CRAFT Describe cost matrix Explain initial layout Describe flow matrix Describe MCP List use of bound method List applications of branch method List out features of fixed position layout List out features of CRAFT List out features of ALDEP List out features of CORELAP. 3 1 Compare the differences between ALDEP and CORELAP. 3 2 Explain the process of CRAFT? 3 3 What are the computerized Facilities in plant layout? Explain. 3 4 Explain the process of ALDEP. 3 5 Write short notes on CRAFT. 3 6 Explain the principle of CAFL. 3 7 Explain the Automated layout design program (ALDEP)? 4 8 Write short notes on CORELAP. 4 9 Explain quadratic assignment model Write some of the examples of fixed position layout Explain the fixed position layout with a neat Sketch Write short notes group layout Write short notes on Branch method layout Write short notes on Bound method layout Explain the term Group layout Explain the term Fixed position layout Explain the about the heuristic procedure for CRAFT List out the steps involve in the heuristic procedure of ALDEP Explain the about the heuristic procedure for CORELAP Summarize about CORELAP. 3 1 Illustrate quadratic assignment model with a suitable example. 4 2 Explain ALDEP procedure by considering a suitable example. 3 3 Explain CORELAP procedure by considering a suitable example. 5 4 Illustrate branch method with a suitable example. 4 5 Explain CRAFT procedure by considering a suitable example. 3

4 UNIT III 1 Describe material handling according to Haynes. 3 2 List out objectives of material handling. 5 3 Summarize minimum utilization material handling. 4 4 Describe delays in material handling. 3 5 Explain planning principle. 3 6 Explain unit load principle. 3 7 Explain mechanization principle. 3 8 Describe motion principle. 3 9 Compare fixed path and variable path Summarize variable path equipment Explain Systems principle Explain gravity principle Explain simplification principle Explain safety principle Describe the applications of fixed path equipments Describe the applications of variable path equipments Mention the types of conveyors used in industries Name some industries equipped with robot handling Describe the purpose of fork lifters in industry Explain the basic working principle of conveyor Describe types of conveyors equipped in different industries Describe types of hoists Describe the purpose of industrial trucks Describe types of cranes Summarize fixed path equipment Describe various types of industrial trucks Describe the applications of hoists Describe the advantages of using robot in material handling List out various mechanisms of conveyor Identify dead containers Describe jib crane Compare plant layout and material handling Describe efficiency of material handling Summarize space importance Explain the popular industrial robot names Explain the different types of jobs done by industrial robots Explain performance principle Explain control principle/ 5 39 Explain capacity principle. 3

5 40 Explain maintenance principle Describe the ranges of fork lifters Mention the type of cranes used in ship building Explain different types of containers used in industries Mention the industrial handling systems produced by ABB & 3 KUKA. 45 Mention important criteria for planning a plant layout Explain orienteer s in material handling What is Palletizing Explain few types of dead containers. 4 1 What are the factors you consider in selection of Material Handling Equipment? 5 2 Write a brief outline on belt conveyor. 5 3 What do you think about the advantages of Material Handling? 7 4 Illustrate the major principles of Material Handling System. 5 5 How do you explain about the importance of Material Handling System? 3 6 Illustrate the minor principles of Material Handling System. 4 7 Illustrate about the functions involved in Material Handling 3 System. 8 Briefly explain the principles related to the equipment design. 3 9 Explain the working principle of conveying equipment Explain the working of an apron conveyor with a neat diagram Discuss about the Driverless trains and wire-guided pallet trucks Explain about bridge crane in material handling List out any five principles of material handling Explain about the usage of containers in material handling Compare between wheel conveyor and screw conveyor Explain the usage of cranes and hoists in material handling Explain about roller conveyor in material handling Explain the usage of industrial tractor in material handling Compare the features of various types of hoists List out the usage of belt conveyor. 3 1 Summarize the relationship between plant layout and material handling. 2 Describe the principle of overhead conveyor and difficulty in carrying a material in overhead conveyor Describe the operation of a belt conveyor with a neat sketch. 4 4 Describe the principle of Automate Storage and Retrieval System with a neat sketch. 3 5 Describe the operation of a Roll conveyor with a neat sketch. 3

6 6 Describe the operation of robot in assembly plant with neat sketch. 4 7 In which situation conveyors are preferred?why? 5 8 Explain the basic principles of material handling. 2 9 Discuss about container in material handling Explain briely with diagram about the working of gantry crane. 5 UNIT IV 1 List out different Belt conveyors. 5 2 List out diffferent Roller conveyors. 4 3 Describe the selection of material handling. 3 4 Identify difficulties in material handling. 3 5 Describe the path for overhead conveyors. 3 6 Describe about fork lifters. 3 7 Describe about material handling for continuous production. 3 8 Identify about material handling for batch production. 3 9 Identify about material handling for product process Compare roll conveyor to belt conveyor Compare heavy lifting to normal lifting conveyor Describe about functional material handling system List out equipment used for functional oriented system Compare normal material handling to functional material 3 handling. 15 Describe the role of material handling with robots Explain precision material handling system Compare conventional and unconventional material handling 3 systems. 18 Describe handling of miniature products List out best material handling for heavy machinery Compare path equipment and functional equipment. 5 1 Classify the material Handling Equipment? 5 2 List out disadvantages of material system. 3 3 Classify types of conveyor. 4 Illustrate the working principles of conveying equipment 5 5 Explain about fork lift truck used in industries. 5 6 Explain about two wheeled trucks 4 7 Illustrate about Roller Conveyors. 3 8 Explain about chain conveyors 4 9 Discuss the main features of four wheeled powered drives such as.fork lift, straddle trucks with aid of sketches Differentiate between roller conveyor and belt conveyor Differentiate platform truck and fork truck. 4 3

7 12 Explain relationship between plant layout and material handling Differentiate between fixed path equipment and variable 3 equipment. 14 List out principles involved in material handling Differentiate between chain hoist and electric hoist Explain how robots are used for material handling Differentiate between jib crane and bridge crane Differentiate between wheel conveyor and screw conveyor Explain the working of belt feeders with the help of a neat sketch List out objectives of material handling. 3 1 Explain the working of belt feeders with the help of a sketch. 3 2 Explain the various hoists and describe their features. 3 3 Discuss the main features of powered driven such as side loading trucks and straddle trucks with aid of sketches. 3 4 Derive a relation for path equipment. 5 5 Explain function oriented systems. 4 UNIT V 1 Describe cycle time in manufacturing. 3 2 Describe delays and damages in handling. 5 3 Explain promotive productivity. 4 4 Describe fixed cost. 3 5 List out two objectives of material handling. 3 6 Describe operating cost. 3 7 Describe how labour cost included in material handling. 3 8 Describe how to reduce cycle time. 3 9 List out limitation of automated material handling system List out methods of material handling systems Describe open conveyor systems Explain about multi-lines in assemblies Describe about uniformity principle Describe about ergonomics of material handling Describe lifting principle Describe lifting assistance Describe Pallet Jacket Describe how an organization should maintain work place List out elements of material handling systems Describe handling of miscellaneous equipment. 3 1 Illustrate the reasons or causes of accident in case of conveyors. 2 2 Which events could have involved during a crane Failure 3 3 How would you list out safety norms for conveyors and cranes 3

8 4 In how many possible ways that safety can be implemented in Material Handling Equipment 1 5 Can you write in your own words about conveyors 7 6 Write a brief outline on pallet trucks 3 7 What factors would you consider that needed for maintain of Material Handling System 8 How would you Explain the types of maintains in Material Handling System. 9 Illustrate the design of conveyors. 10 Write in your own words about dumpers and feeders 11 1 Judge the value of design methodology followed for different Material Handling Equipment 5 12 Write a brief outline on precautions considering for material handling 13 Illustrate briefly about the design of trucks 4 14 Illustrate briefly about the mobile lifting frame 5 15 Illustrate about the design Cranes 16 List out material handling ergonomics for human-beings Explain about material flow List out manual material handling tasks Explain about Air Cushion Handling Frame 9 20 Explain about ergonomics of material handling equipment. 1 1 Explain the maintenance of material handling equipment. 3 2 Describe the objectives of ergonomics in material handling. 3 3 List out elements of a material handling ergonomics program. 3 4 List out methods to minimize cost of material handling. 5 5 Describe how care should be taken while designing the feeding equipment to avoid spillage of materials Prepared By: Mr. G. S. Vivek, Assistant Professor, Mr. A.Venu Prasad, Assistant Professor HOD, MECHANICAL ENGINEERING