Unit One: Overview of Machine/Plant Installation

This unit is developed to provide you the necessary information regarding the following content
coverage and topics:

• Basic knowledge of workplace design principles

• Waste disposal and inspections
• Preparation of commissioning procedures.
• Operational flow chart
• Applicable codes and standards to machine installation sits
• Basic principle of ergonomics
• Basic skills of applicable Data software
• Types of machine/plant installation manuals
• Apply OHS and workplace procedures
This unit will also assist you to attain the learning outcomes stated in the cover page. Specifically,
upon completion of this unit, you will be able to:

• Grasp basic knowledge of workplace design principles

• Prepare commissioning procedures
• Be familiar with waste disposal and inspections
• Understand operational flow chart of machine/plant installation
• Identify applicable codes and standards to machine installation sits
• Demonstrate basic principle of ergonomics
• Manipulate applicable Data software
• Interpret machine/plant installation manuals
• Observe OHS and workplace procedures
1.1 Basic Knowledge of Workplace Design Principles
Plant Layout is about planning and arranging manufacturing machinery, equipment and services
for the first time in completely new plants. The improvements in layouts already in use in order to
introduce new methods and improvements in manufacturing procedure. Plant layout has broad
scope of operations as it not only deals with the primary decisions of machines and other facilities,
but also concerned with all the improvements that have to be made to the existing layout based on
the subsequent developments in the production methods. In simple terms, a plant layout is a floor
plan which is meant for determining and arranging the machinery and equipment of a plant at the
most suitable place such that both the materials flow and handling can be obtained at low cost.
1.1.1 Principles of Plant Layout

• The principle of Minimum Travel: Operations manager must design layout in such a way
that the distance between operations is minimum which intern helps in avoiding the labor
& time wastages there by reducing the cost of material handling.
• The Principle of Sequence: The machines & operations must be arranged sequentially. This
principle is effectively attained in product/ line layout.
• The Principle of Usage: The available space needs to be optimally utilized. This principle
has wide acceptance in towns and cities where a piece of land is very much expensive.
• The principle of compactness: All the significant factors need to be fully integrated and
related, producing a well-integrated and final layout.
• The Principle of Safety & Satisfaction: The layout must have provisions for safety of
workers. It must be planned, based on the comfort and convenience of the workers for
making them feel satisfied.
• Principle of Flexibility: The layout must allow improvements with less difficulty and at
minimum cos.
• The Principle of Minimum Investment: The ideal layout must provide savings in fixed
capital investment not by ignoring the installation of required facilities but by efficiently
and optimally using the available facilities (economies of scale).
1.1.2 Types/Classification of Plant Layouts

A plant layout mainly deals with the arrangement and grouping of machines which are used for
producing goods. Mostly grouping is employed on different product lines. The selection of a
particular layout relies on many factors.
A. Process layout/ Functional layout/ Job-shop layout.
B. Product Layout/ Line processing layout/ flow line layout
C. Fixed position Layout / Static Layout.
D. Cellular manufacturing Layout/ Group Technology Layout
E. Combination Layout/ Hybrid Layout.
Process/Functional/Job Shop Layout
Process Layout: - is a type of layout which is characterized by the presence of similar machines or
similar operations at specified location. It is known by different names. It is also called as
functional layout or Job shop layout or bath production layout. In Process layout the machines are
grouped on the basis of their operational characteristics. I.e. machines that are performing the same
operation are installed at a specific location.
• All drilling machine are installed in drilling department.
• All lathe machines are installed in Turning (Machine)department.
• All welding machines are installed in welding department.
Product /Line Process / Line/Flow Line Layout
Product Layout: refers to the sequential or orderly arrangement of machines in one line based on
sequencing rules. It is also called as straight-line layout or layout for serialized manufacture.
In this layout, there exist several machines such that the partly processed products or working in
process (WIP) of machine becomes an input for the other machine.

Fixed Position /Stationary / Static Layout

Fixed Position Layout: In this type of layout, material remains at a fixed place and the complete
job is done at a fixed station with materials. Men and machines are moved to the place of materials
for the necessary operations. This type of layout is suitable for hydraulic turbines, shipbuilding,
and locomotive industry.
 Cellular Manufacturing Layout/ Group Technology Layout
Similar shape operations are made as a group or cellular and respective are installed as a group.
Combination/ Hybrid Layout /
This layout contains a mix of process and Product layout that is considered for special production
line.
1.1.3 Layout Planning

The engineering or planning department is responsible for designing and installing a layout. In the
manufacturing and service organizations, the layout planning deals with the arrangement of
resources so that the performance of the operating system could be improved. A set of tools and
techniques can be provided by the layout planning which helps the operations manager to locate
resources and also for assessment of alternatives for locating the resources.
Layout Planning Tools and Techniques
The three different techniques that are available and useful for layout planning are: -
1 Templates
2 Operations Sequence Analysis.
3 Line balancing.
• Template:
It is a two-dimensional technique which is the most commonly used. Templates are the design
pattern which consists of a thin plate, made up of wood or metal and which serves as a gate for
performing mechanical activities.
➢ It constitutes the scaled representation of the physical object of the layout.
➢ Templates are fixed for preparing plans, for drawing several possible layouts. The best
possible option can be explored by eliminating the unnecessary handling and backtracking
of materials.
➢ It is usually employed for re-designing the existing department/building
➢ For verifying the layout design configuration decided by other layout technique.

• Operations Sequence Analysis:

Operations Sequence Analysis is an early approach to process type layout. It develops a good plan
for arranging the departments graphically so that the layout problems get an optimal solution.
Through the operations sequence analysis, the relative locations of operating department with
respect to one another can be predicted.
• Line Balancing:
Line Balancing is an important activity of an assembly line operation, which is mainly used for
the equitable distribution of work among the employees so that total number of employees can be
greatly reduced. Line balancing is not an easy task because there are different alternative methods
that can be far more easily applied than line balancing for the decision of work. Some of the
methods used by operation researchers to study line balancing problems include: -
➢ Linear programming,
➢ Dynamic programming and other optimal methods.
Classification of Layout Design Procedures/ Evaluating Methods.
The design procedures for layout are broadly classified into two types. They are,

1 Manual methods
2 Computerized methods
• The manual methods are conventional type and are sub-divided as follows.
➢ Travel chart method
➢ Systematic layout planning
➢ Local-distance analysis method
• Computerized methods are constructive type and improvement type algorithms and they are
classified as follows.
➢ Automated layout design program (ALDEP)
➢ Computerized Relationship Layout planning (CORELAP)
➢ Computerized Relative Allocation of Facilities Technique. (CRAFT)
➢ Computerized Plant Layout and Evaluation Technique. (PLANET).
➢ Computerized Facilities Design (COFAD)
Manual Layout Design Procedure
I. Travel chart method:
Travel chart method is a technique used for determining the overall flow of materials. The travel
chart is used to identify the most active departments when materials move from one department to
the other. In this method, the optimal solution can be reached by considering the trial-and-error
method wherein the active departments are located centrally so as to minimize the non-adjacent
flows. The travel chart is drawn by using circles for representing the workstations and lines for the
transportation of loads across the work centers and departments.
II. Systematic layout planning method
Some production systems like service systems make use of systematic layout planning wherein
the amount of material that flows between the departments may not be critical for the development
of an appropriate facility layout. In this method, a chart is prepared in which ratings are given for
representing the relative importance of locating one department close to another department and
is termed as “Relationship chart”. The important ratings are expressed with code letters a, e, I, o,
u and x which are called as “nearness codes”. Along with nearness code, a reason code is also used
which is indicated by a number that depends on a variety of reasons for locating any two
departments, adjacent to each other. When the problem is formulated in systematic layout planning
(SLP) method, based on the sequential steps in general design, the process starts as shown in below
flow chart. Layout decisions are one of the key facts determining the long-run efficiency of
operations.
Layouts have numerous strategic implications because they establish an organization´s
competitive priority in regard to: -
• Capacity,
• Processes,
• Flexibility and cost.
They are associated with the tactical decision horizon and are dedicated to the concretion of
strategic decisions like, e.g., facility location. Configured production systems are input for the
operational level, where the goal is to run the given system as efficiently a possible. An efficient
layout facilitates and reduces: -

• Costs of material flow,

• People, and
• Information between areas.
To achieve these objectives, a variety of configuration designs has been developed. The most
relevant ones, in the context of this module, are:

I. Fixed-position layout: addresses the layout requirements of large, bulky projects

 II. Job shop production (Process-oriented layout): deals with low-volume, high-variety
production
III. Cellular manufacturing systems (work cell layout): arranges machinery and equipment to
focus on production of a single product or group of related products
IV. Flow shop production (Product-oriented layout): seeks the best personnel and machine
utilization in repetitive or continuous production.
In fact, layouts II and I are often described as centralized, and layouts III and IV as decentralized
manufacturing systems. To illustrate the differences in fixed-position layout, job shop production,
cellular manufacturing systems, and flow shop production consider a situation in which four parts
(A, B, C, D) are to be produced and assembled into a single product.
The processing sequence: -
• For part A is saw, turn, mill, and drill;
• For part B it is saw, mill, drill, and paint;
• For part C the processing sequence is grind, mill, drill, and paint; and
• For part, D the sequence is weld, grind, turn, and drill.
All parts go to a central assembly department. The following table contains the proportional
capacity requirement of each part on each machine relative to the capacity availability of the
machine in one period.

Table 1: Proportional capacity requirement of each part on each machine

Based on the given capacity requirements we know that the minimum equipment needed is: 1
weld, 1 grind, 1 saw, 1 turning machine, 2 mills (0.3+0.5+0.3 > 1), 2 drills, and 1 painting machine.
According to the layout concepts listed above the following configurations for the example
problem could be realized (this is not a complete list of all possible configurations but an
illustrative selection of possible realizations).
1. Fixed-position layout: - in case of a fixed-position layout, it may be sufficient to have the
minimum machine equipment (see above). However, depending on how production is
scheduled it could also be necessary to install more machines in order to come up with the
needed production output.

Figure 1.1: Fixed-position layout

2. Job shop production (Process-oriented layout): -By applying a job shop production system
we are able to reach the minimum machine equipment. Clearly, depending on production
scheduling it may become necessary to install more machines than the minimum equipment.

Figure 1.2: Job shop production

3. Cellular manufacturing systems (work cell layout): -Figure 3 illustrates a cellular

manufacturing system for the example problem. For the chosen configuration (2 work cells) it
 is not possible to realize the minimum machine equipment. We need an additional turning
machine and an additional painter.

Figure 1.3: Cellular manufacturing system

4. Flow shop production (Product-oriented layout): -Figure 4 shows a flow shop production
system for the example problem. In this case we need 5 machines additional to the minimum
equipment (1 grind, 1 saw, 1 turning machine, 1 mill, and 1 paint):

Figure 1.4: Flow shop production

The decision to use a fixed-position layout is generally dictated by a particular characteristic of the
work-piece. It layout is used when the product is too large or cumbersome to be moved through
the various processing steps. Consequently, the processes are brought to the product rather than
taking the product to the processes (e.g. aircraft industry). This concept is realized by locating
workstations or production Centre around the product in the appropriate processing sequence.
Considerable logistics are involved in ensuring that the right processes are brought to the product
at the right times and are located in the right places.

Waste Disposal and Inspections

1.2.1Workshop Layout
The actual space any workers needs for their work must be based on an individual assessment,
which takes account of:
• The nature of the work,
• The ergonomics of equipment use,
• Any risks arising from the work,
• How well the allocated space will be managed, e.g. not overcrowded with other
(co)workers and equipment.
As a guide a value closer to 18m3 per person may be a reasonable compromise between excessive
workspace and a too constricted work area. Based on the above, the value of 18m3 per one person
should be applied. Safety Services recommended need to be practiced.
1 Flooring
Floor and traffic routes must be of sound construction and have adequate strength and stability
taking account of the loads placed on them by heavy machinery. A smooth surface is required to
allow easy movement of trolleys and equipment. Where leakage or spillage of oil or cutting fluid
is likely to occur around machines etc., a slip resistant surface must be used.
2 Layout
Machines must be installed with due regard to their interaction with other machines and the
requirement of the process. Space must be provided around each machine to allow clear separation
for passing traffic and for the storage of tools and work in progress. Consideration must be given
for access to the machine to allow sufficient space for work, maintenance, and cleaning, taking
into account the full projection of the machine. Recommended allowances are as follows: 500mm
working space around the equipment. Workshops require a suitable area for storage of materials
with easy access for loading, unloading and cutting.
3 Services
Service pipes and cables such as electrical power cables, compressed air lines or hydraulic systems
must be placed either below ground clear of the machinery foundations and provided with covers
of adequate strength, or at such a height as to have clear headroom; the traversing of gangways
must be avoided. Emergency power cut outs must be provided and positioned to ensure quick and
easy access to them.
4 Lighting
Poor lighting is often a factor in accidents and can increase visual fatigue. The employer must
provide:
• Good light - use natural light where possible, but try to avoid glare.
• A good level of local lighting at workstations where necessary.
• Suitable forms of lighting (fluorescent tubes operating at mains frequency may be
dangerous with rotating machinery when the rotating part can appear to have stopped).
• Special fittings for flammable and explosive atmospheres, e.g. in spray booths, to
reduce risk of ignition and explosion.
5 Ventilation
Where machinery gives rise to hazardous or objectionable levels of mist, fumes or dust; such as
welding, de-greasing, electro-plating etc., containment or suitable extraction equipment must be
provided. The levels of exposure to mist, fumes and dust must comply with the exposure limit
values for long- and short-term exposure. Fans and/or additional air inlets (at low level) and outlets
(at high level) may be needed in workshops where there are no means of ventilation other than air
leakage in and out and where:
• Work generates hazardous airborne pollutants
• Workshops have been sealed to conserve energy.
• Provide at least Five liters/second per occupant (eight is recommended for comfort)
and air movement of at least 0.1 to 0.15 meters/second.
• Measure velocities, using specialist help if needed, at input ducts (to calculate air flow
inwards) and inside workshops (to calculate air movements)
6 Compressors
Sitting of air compressors must allow for access to service and maintain them. They should be out
of the main working area to minimize noise problems, but not in a position where they are exposed
to a harsh environment where corrosion may occur. There must be a written scheme for
examination of certain pressure vessels, such as air receivers, steam boilers, fittings and pipework,
drawn up and examined by a competent person. Records must be kept.
 7 Sanitation
The employer must provide
• Suitable and Sufficient (and adequate ventilated and lit) sanitary conveniences and
(nearby)
• Washing facilities kept clean and orderly.
• Separate rooms for men and women, except where they are for the use of one person
and are capable of being secured from inside.
• Hot and cold, or warm water with means of cleaning and drying are required for
workshop staff.
• Room must be provided to change clothes, and lockers to keep work clothes separate
from own clothes.
8 Site visits
The major purpose of an on-site visit is to assess compliance with environmental requirements.
Inspections may include, but are not limited, to the following activities:

• Observation;
• Sampling;
• Measuring;
• Photographing;
• Coring;
• Drilling and excavating;
• Reviewing and copying records; and
• Seizing equipment, products, material or records.
• Within a modern inspection system, scheduled on-site visits should cover not only
compliance checking, but also elements of compliance assistance to promote operators’
knowledge and understanding of their environmental obligations.
 Figure 1.5, Systematic Layout planning (SLP) procedures.

Machine foundations
All machine foundations, respective to the size and type of machine, should be regarded as
engineering problems and their designs should be based on sound engineering practices. Dynamic
loads from the machines causing vibrations must be duly accounted for to provide a solution, which
is technically sound and economical. Though advanced computational tools are available for
precise evaluation of dynamic characteristics of machine-foundation systems, their use in design
offices, which was limited in the past, has now been found to be quite common.
A machine-foundation system can be modeled either as a two-dimensional structure or as a three-
dimensional structure. For mathematical modeling and analysis, valid assumptions are made
keeping in view the following:

• The mathematical model should be compatible with the prototype structure within a
reasonable degree of accuracy.
• The mathematical model has to be such that it can be analyzed with the available
mathematical tools.
• The influence of each assumption should be quantitatively known with regard to the
response of the foundation.
Vibration isolation techniques
Vibration isolation techniques need to be considered to reduce vibrations in the machines.
• Isolation leads to reduction in the transmissibility of the exciting forces from the machine
to the foundation and vice-versa.
• Use of vibration isolation devices is one of the methods by which one can achieve
satisfactory performance, which in turn can result in minimizing failures and reduce
downtime on account of high vibrations.
• However, for equipment on elevated foundations, it is desirable to have support structure
stiffness sufficiently higher than the overall stiffness of isolation system in order to get the
desired isolation efficiency.
• The vibration isolation system, comprising the machine, inertia block and the isolation
devices, also has six modes of vibration having specific stiffness values corresponding to
each mode of vibration.
• It is of interest to note that the lateral stiffness of an elevated structure is very much lower
than its vertical stiffness. If this lower (lateral) stiffness is comparable to the stiffness of
isolators, it certainly affects the overall stiffness and thereby the response of the machine-
foundation system.
 • Hence, the lateral stiffness of the support structure must also be computed and considered
while selecting the isolators. Finally, it may be desirable to carry out detailed dynamic
analysis of the complete system including the substructure.
Machine-Foundation System
The main constituents of a typical machine-foundation system are:
1 Machine: rotary machines, reciprocating machines, impact machines;
2 Foundation: block foundations, or frame foundations; and
3 Support medium: soil continuum, or a soil-pile system, or a substructure that, in turn, is
supported over the soil continuum or soil-pile system.

Figure 1.6, Schematic diagram of a machine-foundation system subjected to dynamic loads

Dynamic forces are internally generated forces by the machine itself, or externally applied forces
(applied directly to the machine or transmitted through the support medium/foundation) need to
be analyzed. Every foundation designer should remember that he/she is dealing with machines
weighing several tones and is required to design the foundations having dimensions of several
meters but with amplitudes restricted to only a few microns.
The designer, therefore, must clearly understand the assumptions, approximations, and
simplifications made during the modeling and must recognize their influence on the response. This
aspect makes modeling and analysis a very important part of design. For the purpose of analysis,
an appropriate mathematical model with the basic objective represents the machine-foundation
system that the model should be compatible with the prototype.

Manual Computational Method

• Block Foundations
For the machines on block foundations, it is good enough to use simple formulations (which are
equations of motion considering block as a rigid body supported on an elastic medium, i.e., soil).
Whereas majority of the machine and foundation aspects are well taken care of by these
procedures, some aspects, as given below cannot be fully managed by these manual computational
methods.

• Foundation Eccentricity
If foundation eccentricity is higher than the permissible value, the vertical mode of vibration will
no longer remain uncoupled from the lateral and rotational modes.

• Frame Foundations
The formulations used for manual computations cover only standard/ideal frames, i.e. frame beam
is rectangular in cross-section having machine mass at its center. Machine is relatively rigid
compared to the foundation and soil. It is considered contributing to the mass, only with its center
of gravity (CG) lying above the foundation level. While modeling the machine, the broad objective
is to represent the machine in such a way that its mass is truly reflected, and CG of the overall
mass of the model matches with that of the prototype.

1.3 Preparation of Commissioning Procedures

Installation processes the stage, at which machinery is unpacked, reassembled, realigned,
connected to essential services and then tested exhaustively to ensure it work at peak operating
efficiency when it finally goes into production is commissioning. In machinery installation, it is
one of the most critical parts of the whole process.
Commissioning systematic procedure are-
Step 1. Preparation
 Step 2. Design
Step 3. Pre-construction
Step 4. Construction
Step 5. Commissioning of services
1.3.1 Operational performance and process flow chart

The operational Performance of process flow can divide as Ideal and actual cycle time. Ideal cycle
time to calculate a performance score for the equipment. The ideal cycle time is how long it should
take a machine to produce one unit, while the actual cycle time it is operating time dividing by the
number of units it produces.

Figure 5, The regulatory cycle

As a whole, the regulatory activity is an iterative (cyclical) process that links legislation, as an
outcome of the policy process, to licensing/permitting (and other environmental approvals of
economic activity), compliance assistance, compliance monitoring, enforcement, and assessment
and feedback, closing the cycle with possible input for adjustments of the laws. Effective
regulation needs continuous, pervasive feedback and self-correction; not all its phases can function
solitarily. Due to these particularities, regulation is often considered as a dynamic regulatory cycle.
 Compliance assurance programming
Compliance assurance programming refers to the whole range of defining policies and establishing
procedures, targeting and action planning, budgeting, implementation, results measurement,
feedback, and operation improvement.
Principles of environmental compliance assurance
Worldwide, environmental compliance assurance is supported by several principles, most
importantly:
• Proportionality in the application of the law and in securing compliance;
• Consistency and credibility of approach;
• Transparency about how to operate as an inspectorate and what the regulated community
may expect from the inspectorate;
• Targeting of enforcement action.
Proportionality
The concept of proportionality is addressed through the balance of action to protect the
environment against risks and costs. Some incidents or breaches of regulatory requirements cause
or have the potential to cause serious environmental damage. Others may interfere with people’s
enjoyment or rights, or the inspectorate’s ability to carry out its activities. The inspectorate’s first
response is to prevent harm to the environment from occurring or continuing. The non-compliance
response taken by the inspectorate should be proportionate to the risks posed to the environment
and to the seriousness of any breach of the law.
Consistency
Consistency means taking a similar approach in similar circumstances to achieve similar ends. The
inspectorate aims to achieve consistency in the response to pollution and other incidents and the
use of powers and decisions on whether to prosecute. The inspectorate should recognize that
consistency does not mean simple uniformity.

Transparency
Transparency is important in maintaining public confidence in the inspectorate’s activities. It
means helping the regulated community and others, to understand what is expected of them and
what they should expect from the inspectorate. It is also means of making clear why an inspector
intends to, or has taken enforcement action.
 Targeting
Targeting means making sure that regulatory effort is directed primarily towards those whose
activities give rise to or risk of serious environmental damage, where the risks are least well
controlled, or against deliberate or organized crime. Action will be primarily focused on
lawbreakers or those directly responsible for the risk and who are best placed to control it.
Social factors motivating compliance:
• Moral and social values for environmental quality;
• Societal respect for the law;
• Clear government will to enforce environmental laws.
Social factors de-motivating compliance:
• Lack of social respect for the law;
• Lack of public support for environmental concerns;
• Lack of government willingness to enforce.
Personal factors motivating compliance:
• Positive personal relationships between programmer personnel and facility managers, free
of conflict of interests;
• Desire, on the part of the facility manager, to avoid the legal process;
• Desire to avoid jail, the stigma of enforcement, and adverse publicity.
Personal factors de-motivating compliance:
• Fear of change and inertia;
• Ignorance about requirements;
• Ignorance about how to meet requirements.
Factors increasing ability to comply:
• Availability of affordable technologies;
• Jobs and training dedicated to compliance;
• Bonuses or salary increase based on environmental compliance.
Factors generating inability to meet requirements:
• Lack of appropriate technology;
• Technologies that are unreliable or difficult to operate;
• Lack of internal accountability for compliance;
 • Lack of management systems for compliance;
• Lack of compliance training for personnel.

1s.4 Operational Performance and Process Flowchart

Operational performance and process flow charts are valuable tools for understanding and
optimizing the operations of a machine plant. Let us explore each of these concepts in more detail:
1.4.1 Operational Performance
Operational performance refers to how effectively and efficiently a machine plant operates. It
encompasses various aspects, including productivity, quality, reliability, and safety. Monitoring
and improving operational performance can help enhance overall plant efficiency and profitability.
Here are some key factors to consider:
Productivity
Measures the output or throughput of the plant over a specific time period. This could be the
number of units produced, tasks completed, or services delivered. Identify bottlenecks or
inefficiencies that may be hindering productivity and implement strategies to address them.
Quality
Assess the quality of the plant's output by monitoring defect rates, customer satisfaction, or
adherence to specific quality standards. Implement quality control measures such as inspections,
testing, and continuous improvement initiatives to ensure consistent and high-quality output.
Reliability
Evaluate the reliability of the machines and processes within the plant. This includes analyzing
equipment downtime, mean time between failures (MTBF), and mean time to repair (MTTR).
Implement preventive maintenance programs, conduct regular inspections, and address equipment
reliability issues promptly.
Safety
Prioritize and maintain a safe working environment for employees and equipment. Identify
potential safety hazards, conduct risk assessments, and implement safety protocols and training
programs to mitigate risks and prevent accidents.
Cost Efficiency
Assess the cost-effectiveness of the plant's operations. Monitor key cost drivers such as energy
consumption, raw material usage, waste generation, and labor costs. Identify opportunities for cost
reduction through process optimization, resource utilization improvements, or waste reduction
strategies.
1.4.2 Process Flow Chart
A process flow chart visually represents the sequence of steps or activities involved in a process
within the machine plant. It provides a clear and structured overview of how materials,
information, and resources flow through the plant, from the initial inputs to the final outputs. A
process flow chart typically includes the following elements:
Process steps: - Identify and list the individual steps or activities involved in the process. This can
include tasks such as material handling, machine operations, inspections, quality control,
packaging, and shipping.
Flow arrows: - Connect the process steps with arrows to indicate the flow of materials or
information between each step. This helps visualize the movement and progression of the process.
Decision points: - If there are decision points or branches in the process flow, use diamond-shaped
symbols to represent them. Decision points indicate where different paths or outcomes may occur
based on specific conditions or criteria.
Inputs and outputs: - Specify the inputs required for each process step and the resulting outputs
or products generated. This provides a clear understanding of the transformation that occurs at
each step
Timing and dependencies: - Optionally, include information about the time required for each
step and any dependencies between process steps. This can help identify potential bottlenecks or
areas where optimization is needed.

Process flow charts can be created using various software tools or even on paper using standard
symbols and shapes. They serve as a valuable visual aid for process analysis, improvement, and
communication within the machine plant.

1.5 Applicable Codes and Standards to Machine Installing Site

When installing a machine at a site, various applicable codes and standards need to be considered
to ensure compliance with safety, performance, and regulatory requirements. The specific codes
and standards may vary depending on the location, industry, and type of machine being installed.
Here are some commonly referenced codes and standards:
1. National Electrical Code (NEC): The NEC, published by the National Fire Protection
Association (NFPA), provides guidelines for electrical installations, including wiring, grounding,
and electrical safety. It covers various aspects such as electrical supply, equipment, and protection.
2. International Electro technical Commission (IEC) Standards: The IEC develops international
standards for electrical and electronic equipment. These standards cover a wide range of topics,
including electrical safety, electromagnetic compatibility, and performance requirements for
specific types of machinery.
3. Occupational Safety and Health Administration (OSHA) Standards: OSHA sets workplace
safety standards in the United States. Relevant OSHA standards include those related to electrical
safety, machine guarding, lockout/tagout procedures, and general safety practices.
4. Machinery Safety Standards (ISO 12100 and ISO 13849): ISO 12100 provides general
principles for machine safety, including risk assessment and risk reduction measures. ISO 13849
specifically addresses the safety of machinery control systems, including the design and validation
of safety-related parts and control functions.
5. International Building Code (IBC): The IBC provides regulations for building design and
construction. It includes provisions for structural integrity, fire safety, accessibility, and other
building-related aspects that may impact the installation of machines within a building or structure.
6. Manufacturer's Specifications: The machine manufacturer's specifications and guidelines are
vital references during installation. They provide specific instructions for installation, operation,
maintenance, and safety considerations unique to the particular machine.
7. Local and Regional Building Codes: Depending on the jurisdiction, there may be local or
regional building codes that govern construction, electrical installations, fire safety, and other
aspects relevant to machine installation. Local building departments or authorities typically
enforce these codes.
It is important to consult with local authorities, regulatory bodies, and industry experts to
determine the specific codes and standards applicable to your machine installation site. They can
provide guidance on compliance requirements and help ensure that the installation meets the
necessary safety and regulatory standards. Always consult with relevant authorities and
professionals to ensure compliance with the appropriate codes and standards for your machine
installation site
 1.6 Basic Principle of Ergonomic

The basic principle of ergonomics is to design and arrange workspaces, equipment, tasks, and
systems in a way that optimizes human well-being, comfort, and performance. Ergonomics
focuses on adapting the work environment to fit the physical and cognitive capabilities and
limitations of the individuals performing the tasks. The goal is to minimize the risk of injury,
enhance productivity and efficiency, and improve overall user satisfaction.

Some key principles of ergonomics include

1. Fit the task to the person: Design tasks and work processes to match the abilities, skills, and
limitations of the individuals performing them. Consider factors such as physical strength,
cognitive abilities, sensory capabilities, and experience levels when assigning tasks.
2. Provide adequate adjustability: Ensure that workstations, tools, and equipment can be
adjusted to accommodate different body sizes, postures, and preferences. This allows individuals
to customize their work environment to achieve optimal comfort and performance.
3. Minimize physical stressors: Reduce physical stressors such as awkward postures, excessive
force requirements, repetitive motions, and excessive vibration or noise. These stressors can lead
to musculoskeletal disorders and other physical discomforts.
4. Optimize workstation design: Design workstations to promote proper posture, good visibility,
and easy access to tools and materials. Consider factors such as desk height, chair adjustability,
monitor placement, and organization of tools and supplies.
5. Support neutral body positions: Encourage neutral body positions that minimize strain on
muscles and joints. This includes maintaining a natural alignment of the spine, keeping wrists and
hands in a neutral position, and avoiding excessive reaching or bending.
6. Provide adequate breaks and recovery time: Allow for regular breaks and periods of rest to
prevent fatigue and promote recovery. Incorporate job rotation or task variety to reduce prolonged
exposure to specific physical or cognitive demands.
7. Enhance communication and feedback: Promote effective communication and feedback
channels between workers, supervisors, and management. This allows for the exchange of
information regarding ergonomic concerns, suggestions for improvement, and early identification
of issues.
8. Consider cognitive ergonomics: Take into account the cognitive demands of tasks, such as
mental workload, information processing, decision-making, and attention requirements. Design
systems and interfaces that support efficient and error-free performance.
1.7Basic Skills of Applicable Software

Applicable software available for processing data specifications. There are different types of data
processing. Among this data processing
• Manual data processing
• Mechanical and
• Electronic data processing we have to select the appropriate types of data processing for
the intended activities.
When working with data software, there are several basic skills that can be beneficial. Here are
some essential skills for working with data software:
1. Data Analysis: Understanding the principles of data analysis is crucial. This includes
knowledge of statistical concepts, data visualization techniques, and the ability to interpret and
draw insights from data.
2. Data Cleaning and Preprocessing: Data often requires cleaning and preprocessing before
analysis. This involves tasks such as handling missing values, addressing outliers, standardizing
data formats, and transforming variables as needed.
3. Data Manipulation: Being able to manipulate and transform data is important. This includes
skills like filtering and sorting data, merging and joining datasets, aggregating data, and creating
calculated variables.
4. Proficiency in Data Software: Familiarity with the specific data software you're using is
essential. This could include popular tools like Microsoft Excel, SQL databases, or more
specialized software like R, Python (with libraries such as Pandas), or statistical software like
SPSS or SAS.
5. Querying Databases: If you are working with databases, having skills in querying databases
using SQL (Structured Query Language) is valuable. This allows you to extract and manipulate
data directly from databases efficiently.
6. Data Visualization: Communicating data effectively through visualizations is a key skill.
Understanding how to create charts, graphs, and dashboards that present data in a clear and
meaningful way is important for conveying insights to others.
7. Data Security and Privacy: Awareness of data security and privacy considerations is critical.
Understanding how to handle sensitive data, comply with regulations, and ensure data
confidentiality and integrity is essential.
8. Problem-Solving: Data analysis often involves solving complex problems. Developing
problem-solving skills, critical thinking, and a logical approach to data-related challenges is
important for working with data software effectively.
9. Continuous Learning: The field of data analysis and data software is constantly evolving.
Being open to continuous learning, staying updated with the latest tools, techniques, and best
practices, and seeking out opportunities for professional development is crucial.

10. Collaboration and Communication: Data analysis is often a collaborative effort. Being able
to work effectively in teams, communicate findings clearly, and present insights to stakeholders
is important for leveraging the value of data.

1.8 Types of Machine Plant Installation Manuals

All commissioning tests should be documented in the relevant test program and plans, test
procedure and test records and reports. Preparation and implementation of the commissioning test
program is a regulatory requirement in all countries having a nuclear power program. A
documented test program should contain sufficient information to allow review and approval by
the respective authority in addition to the commitment of the organization to implement
commissioning tests. Formally, the test program in the form of the program description is
submitted to the regulatory organization as a constituent part of the Final Safety Analysis Report
in support of the application for an operating license.

The description of the test programmers should discuss all commissioning test phases such as pre-
operational or non-nuclear tests, fuel loading and nuclear or startup tests. It should include a
description and schedule of all tests in relation to the completion of installation, the training
programmers for plant operators and the safety analysis report. The description should include:
• Assignment of responsibility for the preparation, review and approval of test procedures;
• Methodology and responsibility for performance of the test;
• Review, analysis and approval of test results;
 • Features of the plant that are not used during normal operation but must be in readiness to
perform a safety function during unusual circumstances (protection system);
• Tests to demonstrate satisfactory plant response to anticipated transients.
The test procedure should include the following elements:

1. Prerequisites: These include confirmation of prerequisites to be fulfilled before initiation

of tests such as: field inspection of completed construction and installation activities,
cleanness, checkout of wiring continuity and electric protection devices, setting of limit
switches, etc.
2. Test objectives: The objectives of the test should be stated.
3. System initial conditions: Instructions pertinent to system configuration, components that
should not be operating, etc.
4. Environmental conditions: Some tests will be performed in other than ambient conditions
to simulate both normal and accidental conditions
5. Acceptance criteria: The criteria against which the success or failure of the test will be
judged. These criteria may be both qualitative and quantitative. In the first case an event
does or does not occur; in the second qualitative values to be achieved in the test are the
acceptance criteria.
6. Data collection: The type of data to be collected and the form in which they are to be
recorded should be prescribed.
7. Special precautions: Those precautions to be taken to ensure safety of test personnel
should be indicated.
8. Detailed procedure: Detailed systematic procedure should be prescribed for each test.
When automatic systems and systems with automatic control are tested in an integrated test
the procedure should require demonstration of correct performance of these systems and
prescribe the proper system time constants under various input function forms.
9. Test results records: The procedure should identify the test records to be retained,
including test procedure, test results, the acceptability, possible corrective action taken as
well as test personnel responsible for data recording.
Test records and reports Test results should be documented in a number of records that are
prescribed by test procedures. It is customary to use standard recording forms for test results. They
may be named Test Data Record Form, Test Log or by some other title appropriate for the
recording of test results.
The test data record to be used with each test normally includes besides identification of the test
and equipment tested also:

• Test name and reference to test programmers (No. or paragraph);

• Specified value to be achieved in testing, or expected results of the test according to design
specification;
• Values observed during the test;
• Comments, in particular when specified values are not achieved;
• Identification of test recorder or observer.
Apply OHS and Workplace Procedures

• Machine safety checklist

Ensure all equipment has a rollover protective structure (roll bar). Confirm equipment brakes are
working well in both directions (forward and reverse). Confirm all equipment requiring seatbelts
have one in good working order. Check that the machine has guards where moving parts could
injure workers.

• Basic rules in machine safety

Inherently safe design here, the basic rule for machine design stipulates that, where the intended
use of the machine allows that, all accessible parts of the machine should have no sharp edges,
sharp corners, rough surfaces, protruding parts, etc.

• Safety checklist
Safety checklists are documents used during safety inspections for the identification of potential
hazards. OSHA has provided a wide range of checklists for the identification of potential hazards
in a variety of industries and applications.