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Three Main components of robots 2. A robot must obey the orders given
1. Mechanical Components it by human being except where such
2. Electrical components
orders would conflict with first law.
3. A robot must protect its own
3. Computer programming code
existence as long as such protection
The latest technologies are used does not conflict with the first law
to develop machines that can substitute or second law.
for humans and replicate human actions
are called robot. Mr. Isaac Asimov
(1920 - 1992)
The robots are mainly used in
dangerous environments, manufacturing Isaac Asimov was an
process or where human cannot survive. American writer and
professor of biochemistry
at Boston University. He
9.8 Advantages and
was known for his works of
Disadvantages of Robot science fiction and popular science. He was
Advantages a prolific writer who wrote (or) edited more
1. Lifting and moving heavy objects
than 500 books and an estimated 90,000
letters and postcards.
2. Working in holistic environment
3. Providing repeatability and consistency
4. Working during unfavourable 9.10 Need of Robotics
hours „ To improve the quality of products
5. Performing dull or momotonous „ To reduce the preparation time
jobs
„ Skilled labour shortage
6. Increasing productivity and safety
„ To reduce rising cost
7. Achieving more accuracy than „ Pressure to increase production
human beings rates to compete market.

Disadvantages
9.11 Types of Robots
1. The robots lack capability to
respond in emergencies 1. Based on application
a. Assembly robot
2. The initial and installation cost of
equipment high b. Welding robot
c. Heavy duty robot
3. They replace human workers, thus
causing unemployment. d. Military robot
e. Hospital robot

9.9 Asimov Laws of robotics f. Cleaning robot

g. Agricultural robot
1. A robot must not injure a human
h. Medical industry robot
being or, through inaction, allow a
i. House hold robot
human being to come harm.
j. Nano robot

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2. Based on coordinate system, 9.12 Materials used for

a. Base on the reference point robots
i. Base coordinate system It is
Following are some of the plastics most
located at the base of the robot
frequently used as rigid structural materials.
ii. 
T he work piece coordinate
system 1. Polystyrene

 
It is related to the work piece 2. Plexiglass
and is often the best one for 3. Rigid PVC
programming the robot. 4. ABS plastic
b. Based on geometry 5. Polycarbonate
   i. Cartesian coordinate system
6. Polyethylene and polypropylene
ii. Cylindrical coordinate system
7. Nylon
iii. Spherical coordinate system or
polar coordinate system

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(a) Cartesian (b) Cylindrical (c) Spherical / Polar

Robot Coordinate System

ACTIVITIES
1. Buying the Robotoys and give practice for dismantling and assembling the parts.
(d) Jointed-arm
2. Students to know about the functioning of parts of robot.
3. How to operate the electric equipments in home and offices through the
(e) Scara
cellphone.

Questions

Part I.
Choose the correct option 1 Mark
3. The brain of the Robot is called
1. “Centralized control automation” is __________
the other name of ______
a. Sensor
a. Building automation system
b. Controller
b. Industrial automation system
c. Piston
c. Standard automation system
d. Gears
d. Partial automation system
4. The part which receives the
2. The basic principles of Robot is commands and send to the control
formed by system in Robot is
a. Asimov a. Controller
b. Hectare b. Gears
c. George devil c. Sensor
d. Joseph rengal Berger d. Piston

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Part II.
Answer the following questions in one or two sentences 3 Marks
5. What is meant by “Automation”?
6. What are the different types of automation?
7. What are various types of “Based on control”? of automation
8. Mention the types of “Based on Application” of automation
9. What is “Robot”?

Part III.
Answer the following questions in about a page 5 Marks
10. What are the needs for industrial automation?
11. What are the applications of automation?
12. What are the needs of robot?
13. What materials are required to make “Robot”?

Part IV.
Answer the following Questions in detail. 10 Marks
14. What are advantages and disadvantages of automation?
15. Explain about the important parts of robot.
16 What are the advantages and disadvantages of robot

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PTE
HA
C

10

R
INDUSTRIAL MANAGEMENT

Learning Objectives

„ To know about the industrial management, the types of management,

important factors of plant location in industries.
„ To know about the production and productivity and quality control.
„ To know about the F.W. Taylor and Henri Fayol management and their
principles.
„ To know about lean manufacturing, 7QC tools, SPC and 6σ
„ To know about the cost estimation

CONTENTS
10.1 Introduction 10.9 Function of PPC
10.2 Plant Location 10.10 Quality Control
10.3 Important Factors to be 10.11 Principles of Management
considered in Selecting a plant 10.12 Organisation
Location 10.13 Lean Manufacturing
10.4 Plant Layout 10.14 Seven Quality Control Tools
10.5 Work Study (7QC Tools)
10.6 Production and Productivity 10.15 Statistical Process Control (SPC)
10.7 Productivity based on different 10.16 Six Sigma
Sources 10.17 Kaizen
10.8 Production Planning and Control 10.18 Cost Estimation
(PPC)

10.1 Inroduction
Factory is a place of required resources collected in one place to manufacture materials in
correct size and correct shape. The resources are trained men, raw materials, machines etc.

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10.2 Plant Location 9. Proper housing facilities for the

employees, presence of hospitals,
Plant location is an important exercise
educational institutions, banks,
of selecting a suitable site and area of
markets and recreational facilities
establishing a new plant or for expanding
should also be considered while
an existing plant. This is very essential as
selecting locations.
it decides the operational and capital cost
of the product. 10. Presence of related industries near
the location is preferable.
10.3 
Important Factors
to be Considered in 10.4 Plant Layout
Selecting A Plant The physical arrangements of buildings,
Location machinery, equipments, work-places and
other facilities for the manufacturing
1. The plant should be located as
process is known as plant layout.
near as possible to the place where
the raw materials are available.
This will reduce the cost involved in 10.4.1 Advantages of Plant Layout
transportation of the raw materials. 1. Handling of materials and
2. The location should be conveniently
transportation becomes minimum.
connected by highways and railways. 2. The rate of production increases

3. The availability of adequate labour

because of effective use of man and
is an important factor. machines.
3. Workers feel comfortable with less
4. The topography of geography, area
of available land, shape of the site movement inside the plant.
and drainage facilities should be 4. The available space is economically
suitable to the needs of the plant. and efficiently used.
The location should not be prone 5. Investments on equipments
to floods and earthquakes. becomes minimum.
5. Sufficient quantity of quality water 6. Simple, easy and effective
should be available near the plant supervision is possible.
location.
6. The atmosphere of the plant should 10.5 Work Study
provide adequate lighting and
ventilation facilities. Work study is a technique to increase the
productivity. It is used to find out the
7. Electrical power of adequate reasons for shortfall in the efficiency of
strength and necessary fuel should the human work and set guidelines for
be available at the plant location. improvement. By increasing production,
8. Location of the plant should be the cost is reduced and the product
selected to avail maximum tax reaches more people. Work study aims
concessions, loan facilities and low on the above objective.
power tariff.

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Work study is a combination of Production Output

two techniques namely Productivity =
Input of Resources
1. Method study
2. Work measurement. 10000
Productivity = X 100
Work study= Method study + Work 5000
measurement
Productivity = 200%
10.5.1 Method Study we consider another case where
Method study is a systematic recording the same agriculturist spend. ₹6000 for
and critical analysis of the method of better saplings and better methods of
doing a work. It also proposes a new cultivator in the same area and earns
method of doing the same work in a easy yields worth ₹15,000/-.
and effective manner to reduce costs.

10.5.2 Work Measurement Production Output

Productivity =
Work measurement is a technique to find Input of Resources
out the time taken for a qualified worker
to finish a specified work at a particular 15000
level of performance. Productivity = X 100
6000

10.6 
Production and Productivity = 250%
Productivity
Production can be defined as a process of In this case, the productivity is
manufacturing the required end product increased by 50%.
from the available raw materials.
Raw material ➞ production ➞ products 10.7.1 Productivity of Men
We consider a case of machinist who
Productivity can be defined as a works on a milling machine and makes
ratio between the output of products 40 gears a day. By improved methods
produced and the input resources for of work, the same machinist is able to
production. machine 50 gears in a day. The increase
Production Output in productivity can be calculated as,
Productivity =
Input of Resources
Change in Production
Increase in
= Original Production
Productivity
10.7 
Productivity Based On (Input)
Different Resources-
Productivity Of Land 50-40
Productivity = X 100
Let us assume an agriculturist spends 40
₹5000/- to plant casuarina saplings in Increase in Production = 25%
his land of 1 acre and earns yields worth
₹10,000/-.
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10.7.2 Productivity By Machine Production control is a process

Let us consider a case where an operator of making specific arrangements to
works on a drilling machine for 8 hours to carry out the procedures outlined by
make drills on 100 identical work pieces. production planning. It should also over
With the same machine, the operator is see corrective measures in case of failures
able to make drills on 140 work pieces in the production process.
by using jigs and drills with high cutting
speeds 10.9 Function Of PPC
1. Pre-planning: It involves the decisions
10.7.3 Factors increasing
of the preparatory functions in the
Productivity production process.
Some important factors of increasing the
productivity are given below, 2. Route plan: It is the plan arranging
various activities that take place
1. By improving the working conditions. from the stage of raw material to the
2. By improving the process involved finished product.
in production
3. Scheduling: Scheduling is the
3. By reducing the non-productive preparation of a time table to show
time by work measurement the time of starting and the time of
4. By providing suitable incentives to completing of operations involved in
the workers. production of each component.
5. By proposing better plant 4. Despatching: It is the process to
maintenance programmes. deliver the route plan and schedule
6. Old and worn out machines should be to the respective departments.
corrected to make them function as 5. Controlling: It is the process of
before. getting reports from all departments
7. Men, Machine and Materials should regarding production and taking
be maintained at the required correcting actions, if necessary.
quantum.
8. By providing the operators with new 10.9.1 Importance Of PPC
and proper training. PPC will provide the guideline to every
9. Layout of the plant and equipments industry. Guideline is very important to
should be improved. all departments. It must be clear and
correct. So PPC is the “Brain of the
10.8 
Production Planning and Industry”.
Control (PPC) The important task of arranging
specific instructions to the workers
Production planning is a process of
to carry out specific tasks, at specific
scheming the production procedures
time, frame with specific materials at
to get the finished products of required
specific quantity and quality on specific
quality from the raw materials with in a
machines.
prescribed time frame economically.

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If the PPC does not work in right Scientific Management’ is one of the
way, the industry gets affected. So every important management books written by
industry needs skilled PPC. F.W. Taylor.
According to F.W.Taylor, Scientific
10.10 Quality Control Management involves the following
procedures.
Quality
1. Observation
Product quality refers to how well a
product satisfies customer needs, serves its 2. Measurement
purpose and meets industrial standards.
3. Experimented Comparison
It depands on the product, the machine,
cutting tools and work holding devices. 4. Formulation of Procedure.

Definition of Quality control 10.11.3 Henri Fayol

A system of maintaining standards in Henri Fayol was a French industrialist.
manufactured products by testing a sample He was a graduate in mining engineering.
of the output against the specification. He joined as an engineer in a coal mining
company in the year 1860. Later, he
became the managing director of the
10.11 Principles of
company. He retrieved the company from
Management near bankruptcy to set it as a leading coal
The Principle of management are the mining company in France.
activities that “plan, organize and control Based on his hand work and
the operation of the basic elements a successful managing experience,
(People), materials, machines, money he wrote a book titled “General and
and makets Industrial Management”. It contained
his general management principles. He
10.11.1 Management categorized all the activities of industrial
Management is a process of achieving the undertakings into six groups. They are,
objectives of an organisation by directing 1. Technical activities (production
and controlling the various activities of related)
the involved man power.
2. Financial activities (Capital related)

10.11.2 Frederick W. Taylor 3. Commercial activities (buying

Ferderick W. Taylor is called as the father material and selling products)
of scientific management. He started 4. Security activities (protection of
his carrier as a labour in Midvale steel properties)
company of USA in the year 1878. He
5. Accounting activities (Statistics and
held different positions in the company
Stock Taking)
and later become the chief engineer in
1884. He wrote many management books 6. Managerial activities (plan and
related to industries. ‘The principle of control)

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10.12 ORGANISATION 3. Line and staff organisation

4. Line and functional staff organisation
The process of organizing in a
industry involves the identification 5. Committee organisation.
and establishment of its objectives and
coordination of the capital, raw material, Organisation chart
machines and people to reach out the set It is a graphical representation of various
objectives. The institution which involves steps of organizational structure.
the process is known as an organisation.
1. Simple organization chart.
2. Functional organization chart.
10.12.1 Types of Organisation
1. Line organisation
2. Taylor’s functional organisation

Simple Organization Chart

Functional Organization Chart.

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10.13 Lean Manufacturing 7. Waste of Over Processing

Lean manufacturing is a systematic Processes that add more value to a

method for waste minimization/ product, but that is not a customer
elimination within a manufacturing requirement or product’s functional
system without sacrificing productivity. requirement is called as over
processing and is a waste.
Seven wastes - Lean
10.14 Seven Quality Control
manufacturing:
tools (7QC tools)
1. Waste of over Production
Producing more than customer 1. Check sheet
demand or producing too earlier is 2. Cause & Effect Diagram
called as over production and is a 3. Control Chart
waste. 4. Histogram
2. Waste of Rework 5. Pareto Chart
Producing defective products, 6. Scatter Chart
segregating and reworking defective 7. Stratification
products is a waste.
3. Waste of Waiting 10.15 Statistical Process
The parts should move from one Control (SPC)
process to the next and ultimately to Statistical process control (SPC) is a Quality
the customer without any waiting. Parts control method which uses statistical
waiting for want of anything is a waste. methods to monitor and control a process.
(Example: Machine breakdowns,
SPC helps to ensure that the
Tool/die changeover etc.,)
process operates efficiently, producing
4. Waste of inventory specification conforming products.
Inventory is the quantity / amount
of raw materials, Work in process 10.16 Six Sigma (6 ) σ
items (WIP) and finished goods
Six Sigma is a statistical based data driven
(Products) owned by a company
approach and continuous improvement
(available in hand). Holding more
methodology for eliminating defects/
inventory than needed is a waste.
reducing variation in a product, process or
5. Waste of transportation service.
Excessive (unproductive) movements
and handling of material due to Six Sigma (6σ ) Methodologies
incorrect plant layout is a waste. DMAIC
6. Waste of Motion
Any movement of people that does
not add value to the product is a
waste. Workplaces and processes
need to be designed considering
ergonomics.
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