An Introduction: Industrial Plant Design System and Equipment- Manufacturing

Prepared by: June Raymond L. Mariano

Date: June 16, 2020
Presented to: Mechanical Engineering Students (TUP-T)

Introduction

Industrial plant layout design & detailing is a significant component of the overall
operations, costs, operating expenses, product integrity and stability of an industrial
plant. The design of a manufacturing plant is directly related to how…
well that plant can compete in its given market. Efficient plants that produce products
that are in high demand can offer lower prices on its end product to the consumer than
a facility whose manufacturing process is costly and inefficient. The process begins on
paper on the drafting table and it answers to the overall purpose and direction of the
business plan. The initial design also determines how easy it will be to modernize the
plant when the time comes.
Plant design involves an initial layout of the process flows, site plot plans, foundation
plans, utility plans and automated systems plans. The design process is very detailed
and is intended to design an industrial plant so that it can be competitive. “What will this
facility produce?” is a question that will need to be addressed first. The overall design
has to conform to the end product, the size of the company, the future plans of the
company and the mission of the manufacture. The design can start years before the
ground is broken on the physical manufacturing plant.

Components of the future physical plant

Design begins with addressing many components of the future physical facility. These
components include, piping, waste treatment, equipment layout, automated systems
and software, control systems and utility distribution to name a few. Industrial size
manufacturing plants have a lot to consider before the blueprints are finalized. The
product the plant produces may require additional engineering that must conform to
government standards. For example, a nuclear power plant will have to consider
intensive audits, standards and overall back up safeguards that a sawmill would not
have to consider. The initial plant layout design must take this in mind.
Industrial plant layout design can be used as a solution for a global firm looking to
expand its facilities or for a single manufacturing facility. Furthermore, the design may
not be for a new facility. There is a constant need for existing facilities to be redesigned
and upgraded to compete in their market. Automakers, energy plants, sawmills and
steel mills are examples of plants that need to be redesigned from time to time to utilize
new, upgraded equipment or process flows to maximize efficiencies. Layout design is a
service that is ongoing.
Plant layout design uses computer software such as AutoCAD (Computer Aided
Design) to help engineer’s layout the details of the facility. Construction of the plant
follows the blueprints. An effective design not only creates a solution for manufacturing
a product efficiently to maximize production and reduce expenses, but it also provides
an expectation of the cost of construction of the plant itself. Whether your firm is a
global competitor, producing products in several different markets, or you are a local
business owner looking to mass-produce a product, the initial design of your plant will
be key to your success.

30 examples of industries
1- Textile industry
Produces and processes different types of fibers, such as cotton and wool, to convert
them into usable products such as: clothes, sheets, towels, textile bags and many more.
Originally the activities were labor-intensive, but with technological advances they have
been transformed into modern procedures with sophisticated machinery.
2- Footwear industry
Manufacture different types of footwear: sports, casual, moccasins, platforms, high
heels and school, among others. A wide variety of materials are used to make shoes,
such as fabrics, leather, plastic, rubber, wood and metal.
3- Clothing Accessories Industry
Within this category, a large number of items such as: wallets, belts, lenses, fasteners,
umbrellas and hats, among others, are manufactured.
4- Pharmaceutical industry
It produces synthetic preparations derived from natural plants Such as antibiotics,
vitamins, blood substitutes, hormonal preparations derived from animal organs, and
drugs in tablet, capsule and injectable solutions in ampoules.
5- Plastic industry
It produces products such as: containers, pipes, toys, among others, which are used in
the food, beverage, construction, household and industrial industries.
The main raw material are polymers which, due to their thermal and mechanical
properties, allow the plastic to take the desired shape through injection molding.
6- Electronic Equipment Industry
It produces electronic equipment for mass consumer industries, such as computers,
televisions and circuit boards.
The most profitable sector within electronics is the semiconductor industry which has an
overall value of about $ 248 billion. Asia produces 56% of electronic products, the
United States 37% and Europe 22%.
7- Cosmetic Industry
It includes the preparation, composition, processing and obtaining of articles to be
applied on the human body with the aim of cleaning it, beautifying it or altering its
appearance.
8- Primary metallurgical industry
In charge of the smelting and refining of ferrous and non-ferrous metals for the
manufacture of metallic alloys and foundries. It also includes coke refining. They are
intermediate industrial products.
9- Metal industry
From metal alloys and foundries, manufactures products such as metal cans, tinplate,
cutting blades, general fittings, power tools, non-electric heating appliances, forgings
and wires.
10- Preserved Food Industry
Dedicated to store and preserve food in glass and metal containers, using the process
devised by Nicolás Appert At the beginning of the 19th century.
By this invention, once the food is packaged, it must be subjected to pressure and
temperature controlled conditions, which will ensure the good condition of the product
after a considerable period of time.
11- Industry of processed foods
It manufactures and processes foods for human consumption and certain related,
includes most of the edible items available on supermarket shelves.
Pastas, oils, French fries, frozen dinners, among others. It does not include companies
that sell meat or fresh products.
12- Beverage industry

Coffee Bags
Two categories of beverages are distinguished within this industry:
With alcohol: beer , Wine and distilled spirits.
Non-alcoholic: water, soda, fruit juice, tea, coffee, energy drinks .
13- Cleaning products industry
Manufacture laundry detergents, dishwashers, disinfectants, chlorine and other general
purpose cleaners.
Each household cleaner requires optimal combinations of components such as
surfactants, stain removers, polishers and disinfectants to ensure maximum
performance, but also needs to be gentle and not harmful to users.
14- Leather industry
Responsible for the tanning, curing and finishing of hides and skins so that they can be
used in the manufacture of a wide range of clothing products, accessories and others. It
is an intermediate industrial product.
fifteen- Furniture and accessories industry:
Produces furniture for the home, offices, restaurants, shops and public places.
16- Industry of machinery and industrial equipment
It manufactures hand tools, machinery of various scales and industrial components.
It includes electric saws, drills, nuts, bolts, screws, springs, valves, pneumatic hoses,
polishing machines and metal working, as well as basic and complex industrial
equipment.
17- Wood industry
Companies dedicated to the cutting, treatment, transport, manipulation and other
activities of forest management. The products mainly include wood, chips, sawdust and
veneers against veneers.
18- Industry of measurement, analysis and control instruments:
Develop tools and sensors used to measure, examine, analyze and control. Here are
some examples:
Optical instruments and lenses.
Instruments for surveying.
Hydrological, hydrographic, meteorological and geophysical instruments.
Systems and equipment for search, detection, navigation and guidance.
Surgical, medical and dental instruments, equipment and supplies.
Ophthalmic products.
Photographic equipment and supplies.
19- Jewelry industry
It produces articles from precious metals, gems and other materials subjected to artistic
treatment. These objects are used as personal attire. According to the raw material
used, this industry is subdivided into:
Articles of gold with precious and semi-precious stones.
Articles of silver and non-precious metals with inserts of several stones and glass.
Articles with non-ferrous precious metals and their alloys, combined with plastics, ivory,
enamel, precious and semi-precious natural and synthetic stones.
20- Paper and related industries
It uses wood pulp and other cellulose fibers to manufacture products such as paper,
cardboard and derivatives: sheets, bags, boxes, among others.
21- Refining industry of Petroleum
Dedicated to the purification of crude oil for the production of fuel, pavement, lubricating
oils, greases, waterproofing mantles, among others.
22- Graphic arts industry
Provides services in the small and large-scale printing sector. Its range goes from the
elaboration of leaflets, cards, newspapers and books, to the production of billboards.
23- Rubber Industry
Manufacture of tires, guts and protectors for vehicles from natural and synthetic gums.
24- Stone, clay and concrete industry
It produces cement, clay, ceramics, concrete, gypsum, cut stone, asbestos and earth
products in the form of stone and sand.
25- Glass Industry
It uses the sand of silica, lime, dolomite and soda for the elaboration of:
Flat glass. It includes plate, architectural glass, automotive windshields and mirrors.
Pressed and blown glass. Includes containers, lamps, sculptures blown by machine and
by hand.
26- Tobacco industry
It manufactures cigarettes, cigars, cigars, using as an input the nicotine plant (tabacum).
27- Auto parts industry
Manufacturing parts and accessories of the motor vehicle according to the
specifications supplied by the assembler. This industry serves two markets: original
equipment and replacement.
28- Assembly industries
It is characterized by not manufacturing components. It acquires components, which it
then uses to couple them and constitute finished products. Example: Vehicle
assembling companies.
29- Aerospace Industry
Dedicated to the research, development and manufacture of flying vehicles inside and
outside the Earth's atmosphere. Includes: gliders without motor, commercial aircraft,
military aircraft, manned and unmanned space rockets.
30- Defense industry
Responsible for the manufacture of armaments, ammunition and devices related to
military technology, to be used by the armed forces and also civilians.

Industry 4.0

What is Industry 4.0 and what does it contribute to my company?

Technology plays an important role in many areas of our lives, it has made it possible
for information access to be faster and faster, producing a transformation in the way we
consume and relate with data. Business environment is getting more involved in this
constant technological evolution. The industrial sector has been incorporating gradually
greater uses of automation and connectivity.
The concept of Industry 4.0 refers to some aspects that you have surely heard: fourth
industrial revolution, smart industry, interconnected industry or cyber industry. All these
definitions refer to the use of technologies to make the manufacturing process more
agile, flexible and noticeable to customers.
But surely you are interested in knowing what a fourth industry revolution entails, what
its benefits are and how you can implement it in your business.
What is industry 4.0?
The concept of industry 4.0 refers to the so-called fourth industrial revolution. This
involves the digital transformation of the industry with the integration and digitalization of
all the industrial processes that make up the value chain, characterized by
its adaptability, flexibility and efficiency that allows to cover customer’s needs in the
current market.

Industry 4.0 uses digital technologies to react more quickly to market changes, offer
more personalized products and increase operational efficiency.

This paradigm shift in Industry 4.0 is based on the following principles:

Interoperability: the communication ability of all the elements of the factory, cyber-
physical systems, robots, corporate information systems, smart products and the
people, as well as third-part systems.

Decentralization: the capacity for the design of autonomous sub-processes within

the factory with cyber-physical elements with the capacity to make decisions
autonomously.

Real-time analytics: the ability to collect and analyse large amounts of data (Big
Data) that allow the monitoring, control and optimization of processes, facilitating any
result and decision derived from the process immediately and at every moment.
 Virtualization: the ability to generate a virtual copy of the fabric by collecting data
and the modelling industrial processes (physical), obtaining virtual plant models and
simulation models.

Service orientation: the ability to transfer the new value generated to the customer
in the form of new services or improved services with the exploitation of new disruptive
business models.

Modularity and Scalability: the flexibility and elasticity to adapt to the needs of
industry and business at all times, with the ability to scale the technical capacity of the
system in accordance with the technical requirements required by the evolution of
business demand in each case.
What are the benefits of industry 4.0?

Greater productivity and better management of resources.

More efficient decision-making based on real information.
Optimized and integrated productive processes
Increase the flexibility to achieve a mass production and personalized in real time.
Direct communication between clients and organizations, which means that we
can better understand what customers need.
Reduction of manufacturing time both in the design of new products and in the
merchandising of these.
Reduction of the percentage of defects or shrinkage in the factories since it will be
possible to test the prototypes in a virtual way and the assembly lines will be optimized.
Reference:

http://www.bepengineering.com/
Bryson, J. et al. (2005). Handbook of Manufacturing Industries in the World
Economy. Cheltenham, Edward Elgar Publishing Limited.
Manufacturing Industry. Retrieved from: economywatch.com.
Manufacturing Industry. Retrieved from: hq.nasa.gov.
Spiffy, D. (2012). Hub pages: Types of manufacturing Industry. Retrieved from:
hubpages.com.
Standard Industrial Classification Manual, NATL Technical Information. Retrieved from:
swrcb.ca.gov.
Szirmai, A et al (2013). Pathways to Industrialization in the Twenty-First Century .
Oxford, Oxford University Press.

Video links to watch:

https://www.youtube.com/watch?v=qvxqhWT-RzA&t=78s

https://www.youtube.com/watch?v=mWaQfjEJIMQ&t=65s

https://www.youtube.com/watch?v=JTl8w6yAjds

https://www.youtube.com/watch?v=ecJdrs7d2MU

https://www.youtube.com/watch?v=gXuPXqNdCLw