4-10 Industrial Planning and Production Methods (Mech-331) PDF

Industrial Planning
&
Production Methods
Part-I
LESSON PLANS
Note: There are no (Part II) Operation Sheets in Industrial Planning & Production Methods, because
of theoretical subject.
CONTENTS
Industrial Planning 01
Site Selection 05
Plant Layout 09
Types of Plant Layout 11
Criteria for a good Layout 13
Advantages of a good Layout 15
Production Methods 17
Types of production 19
Job Analysis 21
Micro Motion Study 23
Therbligs 25
Time study 29
Time Study Equipments 31
Time Study Procedure 33
Production Planning & Control 35
Quality Assurance 39
Maintenance Activities 41
Maintenance Schedule 43
Cost Determination 45
Factory Overheads 47
LESSON PLAN
TITLE OF TOPIC (Short, Description) Lesson No: 1

Industrial Planning Name: Khalid Mahmood
Subject (Course Title): MECH-331 Time: 50 Minute
Ind. Planning and production methods
GENERAL OBJECTIVES:-
To know about industry, it’s planning
of various fields
SPECIFIC OBJECTIVES:- Expected Entry behaviors
1. Definition of industrial Planning __________________________

2. To know the importance of Planning __________________________
3. Enlist various aspects (Phases). __________________________
4. To understand Financial Planning
Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch

With teacher student activities Teaching Aids/Evaluation
10 Industry The organization producing something to fulfill
Min the needs of human beings is called industry.
Somewhere Employees working in this
organization are limited, observing industrial
rules and regulation
15 Industrial Planning To set up a new industry, it requires very keen

Min consideration of each & every aspect which
could effect its working. Various aspects are
considered before deciding/finalizing the set-up
of a new industry. The proposed industry must
be beneficial for both, the industrialist and the
customer. Planning is looking ahead, pre-
determination of future achievements. The
industry produces quality products at the lowest
cost.
1
10 Various Aspects of Industrial A number of aspects are to be planned before
Min Planning deciding/finalizing the set-up of a new industry. For
example, the product, the site/Area, the cost, the
process etc.
15 Fiance Planning The finance is the universal tool for a dynamic

Min business. The total financial needs of the proposed
industry are worked out, their sources such as own
capital, shares, partners, loans etc. must be worked
out systematically.
Testing & Follow Up:- (to see if leaner accompanied information or skill)
Define industrial planning__________________________
Enlist various phases of Industrial Planning__________________
Special Assignment:- (Usually home work)

Write a brief note on financial planning in industrial Planning___
_______________________________________________
Tools Material & Aids:-

Information Sheets / Notes___________________________
__________________________________________________
Reference:- (Author, title, publisher, page or chapter number, date of

publication)
Industrial Engineering & Management System by Dr. S. Dalila and
Dr. Mansoor Ali (Standatrd Publishers/Distributors, New Delhi)__
2
LESSON PLAN
TITLE OF TOPIC (Short, Description) Lesson No: 2_______

Industrial Planning Name: Khalid Mahmood
The planning of new industry (Proposed)
is continued
1. Different phases of Industrial Planning __________________________

2. Financial Planning __________________________
3. To know about product (Design cost) __________________________
4. To learn the process of manufacture

05 Follow up of previous knowledge 1. What is Industrial Planning?
Min 2. Enlist various aspects of Industrial
Planning
3. Define Finance Planning
15 Product planning The product to be manufactured is finalized by

Min the management. Then the designer prepares its
design with the lowest cost with maximum
efficiency. The final design of the product is
approved by the management. The important
things which are to be decided are:
i) The product is considered in
parts/components. Standard parts
available from the market must be used
which reduce the production cost.
ii) The tolerance for each part is established
to reduce the wastage. The functional
utility of the part/component is strictly
observed.
iii) Some parts/components can be bought
from the local market through vendors.
It also reduce the production cost.
3
10 Selection of Material The material required to produce the product is
Min selected/finalized
20 Process Planning Usually a Component/Part can be manufactured by

Min different methods. The method/Process selected
must be easily available and efficient. It involves
complete production process to produce the
product. Sometime available delivery period also
plays important role in the selection of process.
When & how the design of the product is prepared_____
__________________________________________________
Write short notes on the followings ______________________

(1) Product Design (2) Process selection____________________

Information sheets / Notes___________________________
__________________________________________________

publication)
Industrial Planning / Engineering & Management System by Dr.S.
Dalila & Dr. Mansoor Ali (Ch# 13, Page # 329-342)_____________
4
Site Selection Name: Khalid Mahmood
To know about the site/ area, which is to
be selected for the proposed industry
1. The Site must be profitable __________________________

2. To learn about the various __________________________
elements/factors
3. To know the effect of these factors __________________________
4. To learn some important factors

10 SITE The Area/Place which is selected for the
Min proposed industry is called as SITE. The site
selected must be profitable easily approachable
and with least problems.
15 SITE SELECTION The selection of site must be determined on the

Min basis of optimum results i.e. better performance
& Higher Profits. The site selected must be easily
accessible, problem free. Many economical &
technical factors are considered while selecting a
new site. Some of these are:
i) Land
ii) Availability of labour
iii) Availability of Raw materials
iv) Power & Fuel supply
v) Transportation facilities
vi) Political situation of the Area
vii) Local Govt. Rules & Regulations
viii) Rebate in Taxes
5
15 Economical Factors involved in Site Many Economical factors are considered while
Min Selection selecting a new site. The Area/Piece of land must be
cheap in cost, easily approachable, must have
transport facilities. The sources of power must be
easily available. In some Areas, Government has
allowed Rebates in Taxes to invite industrials to
establish industries in that Area. For example
Gawadar in Pakistan.
10 Availability of Labour The site selected must be that Area where some type
Min of industry is already established. It will help to
share the technical knowledge, expertise, materials
etc. It will also help the availability of technical
labour required for new industry otherwise special
transport or housing arrangements are to be made if
site selected in far Areas.
How a site is decided for new industry___________________
Name various factors considered in Site Selection____________

Prepare an Assignment on Site Selection from home__________
_______________________________________________

Information Sheets/Notes__________________________
__________________________________________________

publication)
Dalila & Dr. Mansoor Ali (Ch # 9, Page # 184-189)______________
6
LESSON PLAN
TITLE OF TOPIC (Short, Description) Lesson No: 4______

Site selection (Continued) Name: Khalid Mahmood
To know about the procedure followed in
Site selection
To know various factors considered

1. Economical Factors in Site __________________________
2. To know about Taxes & Rebate __________________________
3. To know about Technical factors, such __________________________
as Raw Materials, Power sources ,
Technical manpower etc

10 Technical Factors considered in Site Many technical factors are considered while
Min Selection procedure deciding upon a site such as availability of Power
sources, Transportation facilities, Technical
labour, product consumption, local Govt. Rules &
Regulations etc.
10 Availability of Raw Materials Generally a unit is established in that Area where

Min its raw material is available. It is to reduce the
production cost. The industries which require
huge amount of raw material must be located
near their source of raw material. For example
Sugar Mills, Cement Factories etc.
10 Transportation & Communication The site selected must have easy approach by
Min Road. Almost all industries use transport facilities
Means
to transport raw material, manpower, finished
product to the market. The site must have
modern communication facilities such as
Telephone, Micro wave, Internet etc. However
this factor has least weightage.
7
10 Consumption of the product The consumption of the product is calculated in
Min following grounds:
i) Actual Population of that Area
ii) The wealth factor of the people.
iii) The living standard of the people. Generally
an industry must be located in that Area
where it has its consumption otherwise
transportation cost will increase its cost.
10 Rebate ( Incentives ) offered by the Sometimes Govt. offers special incentives/rebates to

Min Government in Taxes invite the industrialists to establish new industry.
This policy is adopted for balance economic growth
in the country. It is also offered to promote the
economic status of the people of that Area. In
Pakistan, particularly Government has announced
“GAWADAR” in Baluchistan, to establish a new port
& industrial city as well.
Name different factors which are considered in site selection

__________________________________________________

Write down in detail any five factors considered in site selection
Procedure _________________________________________

__________________________________________________
__________________________________________________

publication)
Dalila & Dr. Mansoor Ali (Ch # 9, Page # 184-189)______________
8
LESSON PLAN

Plant Layout Name: Khalid Mahmood
Subject (Course Title): MECH-331 Time: 50 Min
Industrial Planning & Production Method
Definition of Layout (Plant)
Know the objectives of Plant Layout
1. To know about Plant Layout __________________________

2. Explain importance of plant layout __________________________
3. Describe the objectives of plant layout __________________________

15 Plant Layout The arrangement of industrial facilities such as
Min plant, machines, equipments and different
departments. Plant layout is a plan to get an
optimum arrangement of industrial facilities. It
is the floor plan for physical facilities. It is
designed to enable the plant to function most
effectively
10 Importance of plant layout Even employer of an industrial concern is

Min connected with plant layout. The worker is
interested to know the arrangement of his
work place. The supervisor is interested in the
layout of his section/department. The
executive is interested to know, how the layout
affects the output and production cost
9
10 Objectives of plant layout An optimum layout is one which provides
Min maximum satisfaction to all parties i.e. Employees
management production. The objectives of plant
layout
i. Effective utilization of place
ii. Worker convenience
iii. Less material handling
iv. Maximum labour utilization
v. High turnover production rate
vi. Overall satisfaction
15 Detail of objectives of Plant Layout

Min
i. Effective utilization of space: the
available space must be utilized most
effectively. Unorganized axes means poor
space utilization
ii. Worker convenience: Every worker
wants to work in a convenient
environment. It enhances the efficiency of
the worker
iii. Less material handling: Material
handling adds cost to the product. It must
be minimized as far as possible. The use of
transfer machines, automatic transfer
reduce material handling
iv. Maximum labour utilization: The labour
hired must be utilized maximum with the
help of good lay-out
v. High turnover: A good lay-out enhances
production or the unit
Define plant Layout____________________________________
Enlist objective of plant layout_______________________

Write a short note on plant layout including importance &_____
objectives_______________________________________

Information sheet and paper from book (Photocopy)__________
__________________________________________________
Reference:- (Author, title, publisher, page or chapter number, date of publication)

Ind. Management & Manag. System by Dr. S. Dalila (Page 208-212)
Factory Production Management by Lockyer Published ELBS –Page
96_____________________________________________________
10
LESSON PLAN

Types of plant lay-out Name: Khalid Mahmood
To know the different types of Lay-out
To know the advantages and limitations of various
types
1. Describe various types of plant lay-out __________________________

2. Explain product lay-out with __________________________
advantages
3. Explain process lay-out __________________________
4. Explain fixed position lay-out __________________________

O5 Types of plant lay-out These are the classical types of lay-out. Most of
Min the plants are laid out using a combination. It is
rare to find only one type, they exist side by
side. These types are
1. Product layout (Line lay-out)
2. Process layout (Functional Lay-out)
3. Lay-out by fixed position
15 The product lay-out In this type one type of product is produced in

Min an operating area. The product must be
standardized and manufactured in large
quantities, as the machines equipments are
arranged according to the sequence of
operations. The raw material arrives at one end
of the line and moves from one operation to the
next. Assembly lines in an automobile industry is
a good example of product lay-out, It is most
suitable to continues type of manufacturing
such as chemical industries, recommended for
mass production units
11
15 The process lay-out This lay-out is particularly useful where low volume
Min of production is required. It has greater process
flexibility. This lay-out is commonly suitable for job,
lot or non-repetitive jobs. Same type of operation
facilities one grouped according to function such all
easting work in foundry, mechanic works in machine
shop. Lot of flexibility in equipment and manpower
is obtained.
15 The-layout by fixed position It is the least important for today’s manufacturing.

Min The material and major components remain in a
fixed location and the operating equipments are
brought to this location. The product material is too
heavy or too big and it is convenient to bring
necessary equipments to the workplace along with
the workers. This type of lay-out is used in huge
Aircrafts, Ships, Vessels, Pressure Vessels etc.
continuity of the operation is ensured and material
handling is minimum
Enlist the type of lay-out___________________________
Which one Lay-out is the most recommended task___________

Prepare an assignment showing diagrammatically different types
Of lay-out_______________________________________

Information sheets from the book (Pages 212 to 216)_________
__________________________________________________

Ind. Management & Manag. System by Dr. S. Dalila (Page 208-212)
Factory Production Management by Lockyer Published ELBS –Page
96 to 98________________________________________________
12
LESSON PLAN

Criteria for a good Lay-out Name: Khalid Mahmood
To know the different standards on which a
Lay-out falls
1. To learn difficult criteria for a good Lay-out __________________________

2. To learn about each standard in detail __________________________
3. _________________ __________________________

10 LIST OF DIFFERENT CRITERIA FOR A There is certain criteria which will be satisfied by
Min GOOD LAY-OUT a good lay-out
These are:
i. Maximum flexibility
ii. Maximum Co-ordination
iii. Maximum use of volume
iv. Maximum visibility
v. Maximum Accessibility
vi. Minimum distance
vii. Minimum handling
viii. Minimum discomfort
ix. Inherent safety
x. Maximum security
xi. Uni-directional flow
Explanation of each point
05 1. Maximum Flexibility
Min A good Lay-out can be modified rapidly to meet
changing circumstances particularly attention
must be paid to supply points.
05 2. Maximum Co-ordination
Min Departments/ sections should be so arranged
that it is possible to transport materials and
information in the least duration. It will save a lot
of time and energy
05
3. Maximum visibility All parts/areas in a Lay-out should be observable
Min
at all times. There should be no hiding places. It
will help to attain maximum level of efficiency in
both men and machines
13
05 4. Maximum accessibility All points of machines and equipments (operating /
Min serving) must be readily accessible. It will help the
operator to operate the machine or equipment In an
easy way and also for the maintenance of the
department
05 5. Minimum Handling The handling work adds cost to the product which
Min does not increases its value. It should be reduced to
a minimum level by the use of conveyers, lifts,
knuckles, industrial vehicles etc.
05 6. Minimum discomfort Proper light, Temperature help the worker to work
Min more diligently. The suitable environment should be
ensure In the lay-out. The worker must be provided
comfort during his work
05 7. Maximum safety All lay-outs must be safe. No person should be
Min exposed to danger. Moving parts of machines must
be covered properly. Dangerous areas must be
restricted
05 Fire, theft moisture deteriorates the Plant.
8. Maximum security
Min Safeguards against these must be provided in the
original lay-out. Barriers and the cages are the good
examples
Enlist different criteria for a good lay-out___________________
__________________________________________________

Prepare an assignment on “Criteria for a good Lay-outs from the
Photocopy provided_______________________________

Photocopy of Pages 99-101 of the book_________________
Factory & Production Management by Lockyer______________

Production & Factory Management by Lockyer Pages (99-101)__
_____________________________________________________
14
LESSON PLAN

Advantages of a good lay-out Name: Khalid Mahmood
To learn advantages of a good lay-out
To know the procedure of developing a lay-out
1. Describe the advantages of a good lay- __________________________

out
2. Explain the procedure of developing a __________________________
lay-out
3. _________________ __________________________

20 Advantages of a good lay-out A good lay-out has following advantages.
Min 1) The overall process time & cost will be
minimized by reducing un-necessary handling
and increasingly efficiency level
2) Labour supervision & production control will
be simplified by the elimination of hidden
areas
3) Changes in production will be accommodated
4) Total output from a given plant will be as high
as possible by effective use of space
5) A feeling of unity among workers will be
encouraged by avoiding un-necessary
segregation
6) Quality of the products will be sustained by
safer and harder methods of production
10 Preparing A Layout
Min (Information required for preparing The following information should be available
before a layout can be planned
a Lay-ouy)
i. Type and quantity of Man power
ii. Dimensional plan of the available space
iii. The volume of work to be produced
iv. The process to the followed is production
v. The equipment machines needed to carry out
operations
vi. The volume of materials, sub-stores and main
stores
15
20 Procedure of preparing a Lay-out Following are the key-points for preparing a Lay-out:
Min 1) Prepare model
2) Study the operation sequence
3) Choose “Key” operations
4) Locate ”Key” operations on plan
5) Locate main gauge ways
6) Locate remaking work areas
7) Locate major gauge ways
8) Plan individual areas in detail (Different section/
Departments)
9) Locate subsidiary equipment
10) The conyrleted Lay-out against the principles of
a good Lay-out
11) Verify the Lay-out on floor
12) Check against company’s policy
What are the advantages of a good lay-out_________________
Write down the procedure in sheet for preparing a Layout_____

Visit an industrial unit in your area and prepare a sketch of its__
Lay-out________________________________________

Notes and photocopies of the topic______________________
__________________________________________________

Factory and production management by Lockyer (Pages 101-104)
_____________________________________________________
16
LESSON PLAN

Production Methods Name: Khalid Mahmood
To learn production process in industry
(Organizational structure)
1. Define production Students must be familiar with various industries

2. Explain different types of production __________________________
i. Job order production __________________________
ii. Batch production
iii. Flow production

10 Production To manufacture production after processing raw
Min material in any organization to take for the needs
of human beings is called production. All
production starts with natural materials available
from earth, Sea or air. It is the gradual change in
the size and shape of these into required shape.
10 Types of production There are three main types of production which

Min are job, batch and flow production. It is very rare
to find in any industry that only one type of
production is carried out. These run side by side
as in the example of the Automobile parts are
manufactured under batch production while fluid
assembly is made under flow production.
15 1. Job order production

Min Production is carried on customers
demand/order is called Job Production. It is the
manufacture of single complete unit by an
operator. A no of identical units run parallel in
job production. The manufacturing of jigs,
fixtures and dies are the typical examples. In case
of single specialized product, Job production is
used but in case of quantity manufacture, it is
often not used.
17
15 2. Batch Production As quantity of the product increase work is carried
Min out under batch production. The work content on
any product is divided into parts or operations. Each
operation is completed throughout the whole batch
before the next operation is undertaken. The
production of Automobiles parts, electrical
instruments, transformers is the typical examples of
this type of production
Define production______________________________________
Enlist the different types of Production_____________________

__________________________________________________
_______________________________________________

Write a short note on industrial production and its important__
Types____________________________________________

_____________________________________________________
18
LESSON PLAN

Types of Production Name: Khalid Mahmood
To know about Flow Production
To know about mass production
To learn requirements of Flow Production
1. Explain flow production Students must be familiar with the various______

2. Explain Mass production Production methods in industry______________
3. Enlist requirements for flow production ________________________________________
and explain each

15 Flow production Batch production turns into “Flow production”
Min the rest period as in case of batch production
vanishes. It is a type of production during which
the work content on the product increases
continuously. The processing of material is
continues and progressive. It means that as the
work of each operation is completed the unit is
passed to the next stage. In order to work can
flow smoothly; the time for each operation must
be of equal length.
15 Mass production Mass production is the manufacture of products

Min on large scale. The manufacture can be under
either job order production or Flow production
methods. The greater volume of mass production
will usually result in a reduced colour cost. Since
at total greater expenditure on production
equipment it results increase in productivity. It is
sometimes assumed that during man production,
quality will suffer. This is not so but generally
uniform quality is produced.
19
20 Requirements for the Flow Followings are the requirements of Flow
Min Production production:
1. Continuity in demand
2. Standardized product
3. Material to specification
4. All production stages balanced
5. Operations must be defined
6. Work must be of quality
7. Specialized plant/equipment
8. Maintenance of equipment (Preventive)
9. Inspection “In Line” with production
Define Flow production______________________________
Give examples of Mass production_________________________
Prepare an assignment of requirements of Flow Production____
_______________________________________________

Information sheets/ notes______________________________
__________________________________________________

_____________________________________________________
20
LESSON PLAN

Job Analysis Name: Khalid Mahmood
To learn about motion study
To know the history of Gilbreth the inventor
Of motion study
1. Define motion study __________________________

2. Explain the history of “Gilbreth” __________________________
3. _________________ __________________________

5 Job analysis Job analysis is defined as the analysis of work
Min task with a man. The specific method to do this
task and the time taken in doing this work/task
are find out. The first part of the analysis of the
work is the development of the best way to
doing that work/job. It is called as “Motion
study”
15 Motion study
Min The analysis of the movements of an operator
during a work is called “Motion study”. It is the
study of motions used in the performance of a
given task/job. It is done with the purpose of
eliminating all un-necessary motions and building
a sequence of the most useful motions. Motion
study developed by “Mr. Gilbreth” who used
largely an industries to improve methods
21
30 History of Gilbreth In 1885 Gilbreth as a young man entered the employ
Min of a building contractor. In these days brick
construction was the most popular method, so
Gilbreth learnt bricklayer trade. From the very
beginning of the century, he noticed that each
worker used his own method in doing his work. He
also observed this that worker did not use the same
set of motions. These observations led Gilbreth to
begin investigations to fluid” The best way” of doing
the given task. He readily learnt improvements in
methods. He continued to make program in bringing
about increased output among his workers. Gilbreth
invented a scaffold which could quickly be raised at
any height to the convenient level at all times.
Define Motion Study_______________________________
What are the purposes of Motion Study____________________

Write a short note on the history of Gilbreth in connection with
Motion Study_________________________________________

Notes/information sheets__________________________
__________________________________________________

Motion & Time study by M. Barnes (Pages 10, 11 and 16-17) ___
_____________________________________________________
22
LESSON PLAN

Micro Motion Study Name: Khalid Mahmood
To learn different techniques developed by
The Gilbreth_________________________
1. Explain procer chart __________________________

2. Explain cycle graph __________________________
3. Explain chronocycle graph __________________________

20 Procer Chart It is the technique developed by “Mr. Gilbreth” in
Min connection with “Motion study”. It is the
symbolic representation of the events involved in
the performance of a given task. Standard
symbols are used to show the events/steps
involved in the manufacture of a part product. A
set of five symbols is used.
1. A large circle indicates “Operation”. It is
the main step in the process. Usually a
part is modified /changed during
operation.
2. An arrow indicates transportation. It is
another important event during process.
The part is moved from one place to
another.
3. A Square indicates “Inspection” for
either quality or quantity.
4. A triangle represents a storage or delay.
The storage can either be permanent or
temporary.
23
15 Cycle graph Gilbreth developed the technique of cycle graph for
Min the study of this motion path of an operator. It is
possible to record the path of motions of an operator
by attaching an electric bulb to the finger hand or
arm of the operator. The photographs are taken with
a moving camera; the path of the light as it moves
through space is recorded. Such a record is called
Cycle graph.
15 Chronocycle graph If an interrupter is placed in the circuit of the bulb,

Min the height is flashed on movement and is off during
stoppage. The path of the bulb will appear as a
clothed line. It indicates the direction and speed of
the movement. The spots will be spaced according to
the speed of the movement. From this graph, it is
possible to measure time, speed of the motion. Such
a record is called chrono cycle graph.
Define a Procer chart_____________________________
Enlist process chart symbol____________________________

Prepare a process chart of manufacturing a bolt______________
_______________________________________________

Notes / information sheets_______________________________
__________________________________________________

Motion & Time study by Ralph .S. Barnes (Pages 18, 19 & 40-44)
_____________________________________________________
24
LESSON PLAN

THERBLIGS Name: Khalid Mahmood
To learn different techniques developed
By Mr. Gilbreth in Motion Study
1. Explain Therbbligs __________________________

2. Prepare a chart of Therbbligs __________________________
3. Define each Therbblig __________________________

10 Therbligs (Fundamental) Hand Gilbreth, in his early work of motion study,
Min Motions developed a certain events common to all kinds
of manual work. There were seventeen
subdivisions of a cycle of motion. All of these
seventeen Therbligs are not pure or fundamental
but they are the most suitable classification of
hand motions. The experience analysts use these
Therbligs in industries. The word “Therblig” is
familiar to all industrial engineers than the term
“Hand Motion”. It is prepared when discussing
the subject of micro motion study with factory
personnels. The seventeen fundamental hand
motions with their letters, symbols and colour
designations are shown in chart on back page.
25
TOPICS,NOTES (Brief) Key points/Reminders/Sketch
40 Therbligs Chart Explanation of Therbligs:
Min 1. Search: The part of the cycle
during which the eyes or hands are
hunting an object and hands when
the object has been found
2. SELECT: The choice of one object
from among several. (Locating a
particular pencil from among
pencil box)
3. Grasp: Taking hold of an object.
(closing fingers around the pen)
4. Transport Empty: Moving the
empty hand in searching for an
object. (Moving Empty hand to
pen on disk)
5. Transport Loaded: Moving an
object from one place to another.
The object may be carried in hands
or fingers by sliding, pushing it
along.
6. HOLD: Relation of an object after it
has been grasped and no
movement of the object taking
place.
7. Release Load: Letting go of the
object is completely separated
from the hands to fingers
Define Therblig____________________________________
Enlist Therblig developed by Mr. Gilbreth _____________

Prepare a chart of any ten Therblig with their symbols and short
explanation______________________________________

Notes / information sheet_____________________________
(Photocopy of the pages from book)_____________________

publication)
motion & Time study by Barnes (Pages 116-118)_____________
_____________________________________________________
26
LESSON PLAN

Therbligs (Continued) Name: Khalid Mahmood
To learn different techniques developed
By Mr. Gilbreth in Motion study
1. Explain Therbligs __________________________

2. Prepare a Therblig __________________________
3. Define Each Therblig __________________________

30 THERBLIG CHART 8. POSITION: Turning or locating in
Min object in such a way that it will be
properly oriented to fit into the
desired Location. (Linning up a door
key before inserting it in the key
hole)
9. Assemble: Putting one object into
or another object with which it
becomes an integral part.
10. Dis-assemble: Separating one object
from another object of which it was
an integral part.
11. USE: Using a tool, device or piece of
apparatus. Use may refer to an
almost infinite number of particular
case (Using a pen in signing a letter
or painting an object with spray
gun)
12. Un-avoidable delay: A delay in the
process beyond the control of the
operator. It may occur due to any of
the reason.
(i) A failure in the process
(ii) A delay caused by an
arrangement made for specific
operation
27
13. Avoidable Delay: Any delay of the
operator for which he is responsible
and he has control over it. It refers
to delays which the operator may
avoid if he wished
14. Plan: A mental reaction which
proceeds the physical movement.
Deciding upon how to proceed with
the job
15. REST: A fatigue factor or allowance
provided to permit the worker to
stop his work. The worker to stop
his work. It is to overcome from thr
fatigue incurred by his work.
Define Therblig___________________________________
Enlist Therbligs developed by Mr. Gilbreth______________

Define a chart of conflite Therbligs with their symbols and
explanation________________________________________

Notes / information sheets______________________________
Photocopies of Pages (118-120)__________________________
publication)
Motion & Time study by Mr. Barnes (Pages 119-121)_____
_____________________________________________________
28
LESSON PLAN

Time Study Name: Khalid Mahmood
To learn about Time Study, Its Application
In Industries
1. _________________ __________________________
2. _________________ __________________________
3. _________________ __________________________

10 Definition of Time Study Time study is to calculate the time required by a
Min qualified and trained worker to do a task / job.
Time study involves measurement of work. The
result of time study is the time in “Minutes” may
a person will be given to do the task / job. The
person must be trained in the specified method
and will work at Normal / standard tempo. This
time is called the standard time for that
Operation / job.
15 Application of Time Study Although time study has greatest use for
Min determining “Standard Time”. It is also being
used for a number of other purposes. It may be
used for
i. Standard for the payment of wages
ii. Determines schedule planning the work
iii. Determining standard cost of Labour
iv. Estimating the cost of the product prior to
manufacturing it
v. Determining the selling price on the basis
of total cost
vi. Determining machine effectiveness, the
Number of machines, Number of men
needed in a gang
29
25 Time Study Procedure The exact procedure in making Time Study may vary
Min depending upon the type of operation being studied.
The following steps are usually required:
1. Secure & record the information about the
operation and the person being studied
2. Divide the process into elements and record
description of method
3. Record the time taken by the operator
4. Determine the no. of cycles (Times) to be
repeated
5. Rate the operator’s performance
6. Make it secure that sufficient number of
Cycles (Turns) have been timed
7. Determine the time allowances
8. Finally determines the standard time for the
process
Define Time study_____________________________________
Give the uses of Time study______________________________

Write a note on the application of Time study techniques in____
Industries_______________________________________

Notes / Information sheets___________________________
__________________________________________________

publication)
Motion & Time study by Barnes (Pages 335 – 340)______
_____________________________________________________
30
LESSON PLAN

Time Study Equipments_________ Name: Khalid Mahmood
To learn various instruments used in
Motion and Time study
1. Enlist different instruments used in __________________________

motion and time study
2. Explain each instruments in detail __________________________
3. _________________ __________________________

10 Enlist different instruments used in The equipment used for motion & time study
Min motion & time study consists of following:
1) Decimal stop watch
2) Motion picture camera
3) Time recording H/C
4) Observation Board
5) Tacho Meter
10 Decimal stop watch The decimal stop watch is the most widely used
Min timing device for time study. The watch has the
dial divided into 100 equal parts, each represents
0.01 minute. The hand making one complete
revolution by the slide. It is possible to stop the
watch at any interval and start it again from their
position. It is also possible to return the time
reading to Zero.
31
15 Motion picture camera The time for elements of an operation can also be
Min obtained from the motion pictures made by motion
picture camera. The camera speed is 1000 frames
per minute. A motion picture of an operation
becomes a permanent record of the method used as
well as the time taken for each element.
15 Time recording Machine: For some years, machines have been used for
Min recording time on paper tape moving through the
on/c at uniform velocity. The time recording machine
consists of a small box through which a paper tape is
down at a uniform velocity of 10mm/min. The tape
has a printed scale in tenths of a mm. One division
denotes 0.01 minute. It may be used instead of stop
watch, enables the analyst to record shorter
elements.
Enlist instruments used in Motion and Time Study___________
__________________________________________________

Draw a neat sketch of a Motion picture camera_________
_______________________________________________

Notes / information sheets____________________________
__________________________________________________

publication)
Motion & Time study by Barnes (Pages 335-338)________
_____________________________________________________
32
LESSON PLAN

Time Study Procedure__________ Name: Khalid Mahmood
To learn about observation sheet used in
Time Study
1. Draw observation sheet Must be familiar with Time Study

2. Record data in time study __________________________
3. Plot data on observation __________________________
4. Determine the standard time __________________________

15 Observation Sheet The observation sheet is a printed form with
Min spaces provided for recording information about
the process being studied. These information’s
are, the eleventh operation of a process, the
name of the operator, the name of the machine
or equipment, Date and place of time study. The
form provides spaces for recording stop watch
readings for each element of the process. Space
may also be provided for a sketch of the job,
drawing of the past, specification of the material
etc.
30 Steps in Making Time Study Following steps are followed:

Min Observations 1) Discuss the operation to be trained with the
supervisor of the department
2) Make certain that the operator has been
informed
3) Secure the co-operation of the operator.
Explain them, what you are going to do.
4) Make certain that the operation is ready for
time study
5) Obtain all necessary information’s and
record on the observation sheet
6) Make a sketch of the work piece
7) Divide all operation into its elements. List all
these elements on the sheet. It is necessary
to describe the method on a spread sheet
33
8) Estimate the numbers of cycle to
be timed
9) Record the time of the day when
the study is begun
10) State the stop watch at the
beginning of the first element.
Read & record the time for each
elements of the cycle
11) When the study is completed,
calculations are made
12) Rate the operator’s performance
and record on the observation
sheet
13) Sign with date the study sheet
14) Check that certain numbers of
cycles have been timed
15) Add time allowances to calculate
standard time for the process
What is an observation sheet____________________________
Write any five steps in observation_______________________

Prepare a neat observation sheet formed used in Time study___
_______________________________________________

Notes / Information sheets__________________________
__________________________________________________

publication)
Motion & Time Study by Barnes (Pages 346, 362, 363) ________
_____________________________________________________
34
LESSON PLAN

Production Planning & Control Name: Khalid Mahmood
To learn about production planning (Schedules
Time Table of Production)
1. Define Production, Planning & Control __________________________

2. Describe the subjective of PPC __________________________
3. Explain functions of Production control __________________________

15 Define PPC Production Planning & control is the function of
Min the management which plans directs and
controls the production work. The three
management functions of planning, directing and
controlling apply to all jobs/ works. Production
planning is the process of deciding what to do in
future. Directing includes issuing orders/
instructions to the production team and co-
ordinating the production work. The control
finally means the implementation of the plans /
schedules and to constrain the events to follow
these plans.
15 Objectives of PPC Production Planning & Control is a three phase
Min activity which includes.
1) Directing
2) Co-ordinating
3) Controlling
35
20 Objective of PPC Directing: All the efforts can be directed to those
Min production areas which will contribute towards the
accomplishment of a given task. All the plans /
programs can be closely graved according to the
need of organization
Co-ordination: All the productive systems should be
so co-ordinated that the management can quickly
provide information to the customer. All the
activities of the system should be so arranged so as
to result into optimum use of facilities.
Controlling: A controlling mechanism is to be
involved to provide information where corrective
action is necessary. Then the management can
measure both the progress and effectiveness.
What is PPC_______________________________________
Write the objective of PPC_____________________________

Write a short note on the three phases of PPC_________
_______________________________________________

Notes / Information sheets______________________________
__________________________________________________

publication)
Industrial Engineering & Management systems by S. Dalila
(Pages 248-254) _______________________________________
36
LESSON PLAN

Production Planning & Control Name: Khalid Mahmood
To learn different phases of P.P.C
1. Explain Routing with its Procedure __________________________

2. Explain Scheduling __________________________
3. Give types of Scheduling Sysytem __________________________

15 Routing A complete program of production control starts
Min with planning. Routing includes planning where
and by whom work will be done. Fundamentally
Routing determines what work will be done on a
product, where and how it will be done. It
establishes the operation, their path, sequence
and proper class of machines and personnel’s.
Routing is a major responsibility of a production
control department
10 Routing Procedure The Routing procedure for a new product

Min consists of the following:
1. An analysis of the product what material
are needed
2. An analysis of the product to decide
what to be made and what to be
purchased
3. A determination of the manufacturing
operation’s with sequence
4. A determination of the lot size
5. An analysis of the cost of the product
37
15 Scheduling When a customer orders for a certain quantity of
Min goods, he is anxious to know, when the goods will be
delivered to him. If the product is not belonging to a
particular customer, the company will deliver these
to the market at certain schedule. The very
important phase of production control is to make a
program so that estimated delivery date can be
given. The preparation of this program is called
scheduling.
10 Type of Scheduling System There are three types;

Min Master Scheduling: This technique offers reasonable
control and provides necessary co-ordination
between the various departments. It is necessary to
have the information of machines hours available for
each group of machines
Scheduling by Loading: A schedule gives time table
to a department, while Loading gives time table to a
machine operator
Order Scheduling: Each and every operation is timed
such as Set up time, Operation time, Rest period time
etc.
Define Scheduling___________________________________
Give types of Scheduling system_______________________

Write a note on P.P.C working_& Implementation____________
_______________________________________________

Notes / Information sheets____________________________
__________________________________________________

publication)
Factory & Production Management by Lockyer (Pages 256-261)
_____________________________________________________
38
LESSON PLAN

Quality Assurance Name: Khalid Mahmood
To learn quality control at various levels
of Production
1. Explain Inspection and its types __________________________

2. Explain quality Control __________________________
3. Describe quality standards __________________________

10 Definition of Inspection It is the comparison of product’s specification
Min with the drawing specification. It judges
production against the established standards. It
is with both, the instrument for quality
measurement and a part of activity of quality
control. It is an art of applying tests, measuring
instruments to observe whether the product is
within the specified limits of variability or not.
10 Objectives of Inspection It is done with following functions;

Min 1. To detect the errors in manufacturing
process leading to poor quality.
2. To protect the customers from such
quality product and permitting only the
quality goods to the customer.
3. To complete information regarding the
performance of the product in order to
improve quality and performance.
39
30 Quality Control Quality is the most important factor for capturing the
Min market because quality of the product influences the
purchaser. The quality of the product plays an
important role in customer’s decision. Once a
particular, then this quality level must be maintained
as a policy matter. Quality control is defined as a
mechanism by which the products are made to the
specifications determined from customer demand.
For carrying out quality control a complete control
procedure is to be designed. Following points are
important;
1. Setting the standards
2. Appraising (conformance)
3. Acting when necessary
4. Planning for improvement
What is inspection_______________________________
What are the types of inspection______________________

Write down the quality standards in vogue in industries__
_______________________________________________

Notes / Information Sheets________________________
__________________________________________________

publication)
Industrial Engineering & Management system (Pages 529-537)__
_____________________________________________________
40
LESSON PLAN

Maintenance Activities Name: Khalid Mahmood
To learn about maintenance activities in Industries
(Working of Maintenance department)
1. Explain function of maintenance __________________________

department
2. Explain types of maintenance __________________________
3. _________________ __________________________

20 Maintenance To Maintain (keep up) the machines and
Min 1. (Definition) equipment’s in running condition, so that the
production system may not fail. To keep up the
reliability of the entire production system is
called “Maintenance”. It can be maintained but
can be improved by following steps taken by the
maintenance department;
2. Duties of maintenance 1. Increasing the size of repair facilities
department (Men, Machines, Equipment’s) in
industry
2. Using the preventive system wherever
applicable. In such system critical parts
are replaced after a definite period
before they fail
3. Providing slackness in the production
schedules, so that machines can
overcome fatigue caused by working /
Load.
4. Regular inspection of parts (Machines)
from time to time to detect faults.
41
30 Types of Maintenance Basically there are two types;
Min 1. Preventive Maintenance Preventive: The maintenance of machines which is
carried / conducted periodically. Regular inspections
are made to locate faulty conditions and to take
corrective action. There are always certain weak
areas in the machines if they are neglected, can
cause serious breakdowns. These breakdowns can be
avoided by regular inspections. Critical parts of
machines, equipment’s are replaced after a definite
period before they fail.
2. Breakdown Maintenance
These steps / measures taken correct or repair the
faults after they have occurred. It is also called
corrective maintenance. In this type machines is
suspended and the repair work is carried out. The
production schedules are referred in this type. So
often industries adopt complete shut down for some
days to overhaul the work plant.
Define Maintenance________________________________
What are the responsibilities of Maintenance Department_

Write down the types of maintenance and explain each of them
_______________________________________________

Notes / information sheets_______________________________
__________________________________________________

publication)
industrial Engineering & Management System by Dr. S. Dalila___
Pages (869-872) _______________________________________
42
LESSON PLAN

Maintenance Schedule Name: Khalid Mahmood
To learn maintenance schedule of industry
1. Describe maintenance schedule __________________________

2. Explain replacement of parts __________________________
3. Explain replacement policy __________________________

20 Maintenance Schedule A preventive system of Maintenance with
Min periodic inspection (Hourly, Daily, Weekly, and
Monthly) brings out faulty conditions. This
minimizes breakdowns and maximizes
equipment availability. A preventive system of
planned maintenance requires scheduling of
time to perform inspections. Some equipment’s
require inspection while running some other
during shut down. This divides inspection into
lots:
1) Visual Inspection 2) Shut down Inspection
A schedule of inspection of different units

prepared depending upon the estimated life of
that units/ parts. The results of inspection are
recorded and a case history sheet of each unit is
prepared. This history sheet helps us to decide
the periodicity of inspection i.e. (Hourly, Daily,
Weekly and Monthly). It also helps whether the
transparency of inspection needs adjustment or
not.
43
15 Replacement of parts in machines Replacement of parts in machines & equipment’s are
Min & equipment’s necessary due to following reasons;
1) Physical impairment: The particular part / unit
have completed its working Hours / time.
2) Inadequacy: The part / unit have become
inadequate, so it may be replaced.
3) Obsolescence: The unit / part have become
obsolete, so it may be replaced
4) Rapid technological changes.
15 Replacement Policy There are general guidelines to carry out a actual

Min replacement policies which are;
i. The general outlook on operational
effectiveness of the existing asset
ii. The policy must include the aspect of furnace
conditions
iii. The policy should also cover the aspect of
regular checks on replacing each aspect
iv. The policy should identify the persons who
will carry out replacement studies
Explain maintenance schedule____________________________
What is replacement policy___________________________

Write a short note on maintenance schedule__________
_______________________________________________

Notes / Information sheets______________________________
__________________________________________________

publication)
Industrial Engineering & Management Systems by Dr. S. Dalila
Pages (873-875) _______________________________________
44
LESSON PLAN

Cost Determination Name: Khalid Mahmood
To learn procedure to calculate cost of
the product
1. Define total cost of the product __________________________

2. Explain procedure to explain __________________________
3. Describe elements of cost __________________________

15 Cost Determination Accurate cost determination is very important to
Min fix the selling price of the product. Few
industrialists want to know the unit cost of the
product exactly. In few enterprise system, the
prices of goods / service are determined by the
supply and demand. Actual costing makes it
possible, the analysis of various cost elements at
different stages of production. All the expenses
incurred to manufacture a product are
considered as “Cost”.
10 Objectives of Cost Determination Following are the objectives of costing.

Min 1. To determine the price of the product
2. Making production and sale policies
3. To make suitable steps at various stages
of production to control cost
4. To control the expenditures at every
level into the organization
45
25 Elements of Cost The industrial expenditures can be put under
Min following heads:
(1) Material Cost (2) Labour Cost (3) Other expenses
1. Material cost: The cost of materials while

become the part of the product. Material cost
constitutes the purchase price from the market
as raw materials. Materials are divided into two
groups
(a) Materials for fabricated parts
(b) Standard purchases parts
2. Labour cost: This constitutes the wages paid to
those workers who are engaged in production.
The wages paid to the workers directly involved
in the manufacturing of the product. The mode
of payment to those workers may be daily,
weekly monthly or price rate system.
3. Other expenses: All other expenses, other raw
materials and labour are part under this head
and are called factory “Over Heads”.
Define total cost of the product______________________
Describe elements of cost_____________________________

Write a short note on the objectives of costing__________
_______________________________________________

Notes / information sheets_____________________________
__________________________________________________

publication)
Industrial Management System by Dr. S. Dalila Pages (840-842)
_____________________________________________________
46
LESSON PLAN

Factory Overheads Name: Khalid Mahmood
To know about the factory overheads
Included in the cost determination
1. Define factory overheads __________________________

2. Enlist factory overheads __________________________
3. Explain each of them __________________________

10 Factory Overheads Factory overheads include all the expenses other
Min than material and labour. It does not include the
expenses of selling.
40 Enlist factory overheads The following list indicate Overheads:

Min i. Indirect materials: The cost of those
materials which are used or consumed
during the manufacturing process but do
not become the part of the product.
ii. Indirect labour: It is the labour employed in
service department such as tool room,
maintenance, material handling, inspection
etc.
iii. Power source: All expenses incurred on
Power (Electricity) such as WAPDA bills or
otherwise generated by the factory itself.
iv. Taxes: All the taxes (State) paid by the
factory. Different type of taxes which are
the rate of 50% of the total cost of the
production.
v. Depreciation: wear and tear of machines
and building may be charged as factory
overheads. The estimate life of the
equipment’s and building is established and
annual rate of Depreciation is calculated by
either method.
47
vi. Insurance: The services rendered by the
factory for its assets and employees from
some insurance companies are charged
under factory overheads. The monthly or
annual contribution made to insurance
company is included in factory overheads.
vii. Service department: all the expenses made
by service department are part under this
category.
What is Factory Overhead____________________________
Enlist different factory overhead_________________________

Write a short note on factory overheads with detail of each____
_______________________________________________

Notes / Information sheets_______________________________
__________________________________________________

publication)
Industrial Engineering & Management System by Dr. S. Dalila___
Pages (842-843) ________________________________________
48

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Industrial Planning

TITLE OF TOPIC (Short, Description) Lesson No: 1

1. Definition of industrial Planning __________________________

Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch

15 Industrial Planning To set up a new industry, it requires very keen

15 Fiance Planning The finance is the universal tool for a dynamic

Special Assignment:- (Usually home work)

Tools Material & Aids:-

Reference:- (Author, title, publisher, page or chapter number, date of

TITLE OF TOPIC (Short, Description) Lesson No: 2_______

1. Different phases of Industrial Planning __________________________

Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch

15 Product planning The product to be manufactured is finalized by

20 Process Planning Usually a Component/Part can be manufactured by

Special Assignment:- (Usually home work)

Write short notes on the followings ______________________

Tools Material & Aids:-

Reference:- (Author, title, publisher, page or chapter number, date of

1. The Site must be profitable __________________________

Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch

15 SITE SELECTION The selection of site must be determined on the

Special Assignment:- (Usually home work)

Tools Material & Aids:-

Reference:- (Author, title, publisher, page or chapter number, date of

TITLE OF TOPIC (Short, Description) Lesson No: 4______

SPECIFIC OBJECTIVES:- Expected Entry behaviors

Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch

10 Availability of Raw Materials Generally a unit is established in that Area where

10 Rebate ( Incentives ) offered by the Sometimes Govt. offers special incentives/rebates to

Name different factors which are considered in site selection

Special Assignment:- (Usually home work)

Tools Material & Aids:-

Reference:- (Author, title, publisher, page or chapter number, date of

TITLE OF TOPIC (Short, Description) Lesson No: 05

1. To know about Plant Layout __________________________

Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch

10 Importance of plant layout Even employer of an industrial concern is

15 Detail of objectives of Plant Layout

Special Assignment:- (Usually home work)

Tools Material & Aids:-

Reference:- (Author, title, publisher, page or chapter number, date of publication)

TITLE OF TOPIC (Short, Description) Lesson No: 06

1. Describe various types of plant lay-out __________________________

Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch

15 The product lay-out In this type one type of product is produced in

15 The-layout by fixed position It is the least important for today’s manufacturing.

Special Assignment:- (Usually home work)

Tools Material & Aids:-

Reference:- (Author, title, publisher, page or chapter number, date of publication)

TITLE OF TOPIC (Short, Description) Lesson No: 07

1. To learn difficult criteria for a good Lay-out __________________________

Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch

Special Assignment:- (Usually home work)

Tools Material & Aids:-

Reference:- (Author, title, publisher, page or chapter number, date of publication)

TITLE OF TOPIC (Short, Description) Lesson No: 08

1. Describe the advantages of a good lay- __________________________

Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch

Special Assignment:- (Usually home work)

Tools Material & Aids:-

Reference:- (Author, title, publisher, page or chapter number, date of publication)

TITLE OF TOPIC (Short, Description) Lesson No: 09

1. Define production Students must be familiar with various industries