MECHANICS

Level-II

Learning Guide-23
Unit of Competence: Performe Equipment/
Machine Lay-out, Setting and Leveling

Module Title: Performing Equipment/

Machine Lay-out, Setting and Leveling

LG Code: IND MC S2 M07 LO1-LG-19

TTLM Code: IND MC S2 TTLM 1019v1

LO 1: Plan and prepare work

Page 1 of 41
 Instruction Sheet Learning Guide #23

This learning guide is developed to provide you the necessary information regarding the
following content coverage and topics:
• Planning and prepare work
• Following Occupational Health and Safety (OHS).
• Selecting Tools and equipment.
• Calculating material quantity with specification.
• Selecting and setting up leveling or alignment devices/ equipment
• Identifying electrical lightings, wirings/gadget.
• Identifying and applying environmental protection requirements.
This guide will also assist you to attain the learning outcome stated in the cover page.
Specifically, upon completion of this Learning Guide, you will be able to:
• Plan and prepare work
• Follow Occupational Health and Safety (OHS).
• Select Tools and equipment.
• Calculate material quantity with specification.
• Select and setting up leveling or alignment devices/ equipment
• Identify electrical lightings, wirings/gadget.
• Identifying and applying environmental protection requirements.
Learning Instructions:
1. Read the specific objectives of this Learning Guide.
2. Follow the instructions described below 3 to 6.
3. Read the information written in the information “Sheet 1, Sheet 2, Sheet 3 and
Sheet 4”.
4. Accomplish the “Self-check 1, Self-check t 2, Self-check 3 and Self-check 4” in
page -6, 9, 12 and 14 respectively.
5. If you earned a satisfactory evaluation from the “Self-check” proceed to “Operation
Sheet 1, Operation Sheet 2 and Operation Sheet 3 ” in page -15.
6. Do the “LAP test” in page – 16 (if you are ready).

Page 2 of 41
 Information Sheet-1 Identifying key information about local resources

1.1 Introduction

A Work Instruction is a document that provides specific instructions to carry out an

Activity. A Work Instruction is a step by step guide to perform a single instruction.
A Work Instruction contains more detail than a Procedure and is only created if detailed
step-by-step instructions are needed. Procedures and Work Instructions
Procedures describe a process, while a work instruction describes how to perform the
conversion itself. Process descriptions include details about the inputs, what conversion
takes place (of inputs into outputs), the outputs, and the feedback necessary to ensure
consistent results. The PDCA process approach (Plan, Do, Check, Act) is used to
capture the relevant information. Questions that need to be answered in a procedure
include:
• Where do the inputs come from (suppliers)?

• Where do the outputs go (customers)?

• Who performs what action when (responsibilities)?

• How do you know when you have done it right (effectiveness criteria)?

• What feedback should be captured (metrics)?

• How do we communicate results (charts, graphs and reports)?

1.1.2 Work Instructions

Work instructions should be very detailed on “how” to accomplish a specific job, task or
assignment.

For example, a work procedure could be developed for assembling the final housing of
a product with step-by-step instructions including such detail as the torque
requirements of the fastening screws.

Individual work instructions are very specific to an industry or company. Supplimental

documentation may be used including User’s Manuals, Engineering or Technical
Manuals, Technical Support notes, Manufacturing Notes, etc., in order to create
detailed work instructions.

Page 3 of 41
 1.1.3 Plans
• Layout planning is planning that involves decisions about the physical
arrangement of economic activity centers needed by a facility’s various processes.
• Layout plans translate the broader decisions about the competitive
priorities, process strategy, quality, and capacity of its processes into actual physical
arrangements.
• Economic activity center: Anything that consumes space -- a person or a
group of people, a customer reception area, a teller window, a machine, a workstation,
a department, an aisle, or a storage room.

Planning to clearly communicate the central goal of an initiative, why it is important,

and what to select specific and measurable objectives expected to lead to the desired
result.
• To identify activities and resources needed to meet selected
objectives.
• Implementation
• To identify and collect data need to effectively monitor
initiative activities and improve programming.
• To create a common reference point for everyone involved in
the initiative.
• Evaluation
• To help determine if activities are being implemented as
planned.
• To help determine if the initiative is making progress.
• And, ultimately, to determine if the initiative has led to the
desired result.
Production Plant Layout

Page 4 of 41
 Reasons:
• new products
• changes in demand
• changes in product design
• new machines
• bottlenecks
• too large buffers
• too long transfer times

1.1.3 Specification
The standards against which conformity is measured can take various forms. The most
common source is usually the contract technical The most common source is usually
the contract technical. Other standards would often be referenced in this document,
and may include any of the following:
• Contract documents/specification generally
• Contract drawings - Approved workshop drawings and/or
calculations - Approved technical details/procedures
• Approved samples and/or prototypes
• Regulatory requirements
• Australian Standards

Page 5 of 41
 • International Standards
• Standard specifications
• Manufacturers’ recommendations
1.1.4 Quality requirements
• The Mechanical Code
The purpose of the mechanical code is to provide adequate requirements considered
essential for the safe installation of all mechanical equipment in order to protect the
public safety, health and welfare. The code sets forth comprehensive regulations for
the safe installation of mechanical equipment and systems.

• What is the mechanical code?

The Michigan Mechanical Code regulates the design, installation, maintenance,
alteration, and inspection of mechanical systems, including heating systems,
ventilating systems, steam and hot water heating systems, process piping, boilers and
pressure vessels, appliances utilizing gas, liquid or solid fuel, chimneys and vents,
mechanical refrigeration systems, fireplaces, barbecues, incinerators, crematories, fire
suppression systems and system utilizing solar or geothermal.

Page 6 of 41
 Self-Check -1 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in
the next page:
1. ________is a document that provides specific instructions to carry out an
Activity.(3 points)
A. Work Instruction C. Reasons
B. Layout planning D. Services
2. The most common source is usually the contract technical no specification 5
points)
A, true B, false

Note: Satisfactory rating - 3 and 5 points Unsatisfactory - below 3 and 5 points

You can ask you teacher for the copy of the correct answers.

Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: ______________

 Following Occupational Health and Safety (OHS).
Information Sheet-2

2.1 Introduction
The purpose of the Health and Safety policies and procedures is to guide and direct all
employees to work safely and prevent injury, to themselves and others. All employees
are encouraged to participate in developing, implementing, and Enforcing Health and
Safety policies and procedures.
All employees must take all reasonable steps to prevent accidents and never sacrifice
safety for expedience.
• Our goal is to eliminate or minimize hazards that can cause
accidents.
It is company policy that all employees be given a copy of the policies manual
2.1.2 Occupational Health and Safety and You
Under the occupational Health and Safety legislation and help you to make your
workplace safer and healthier
One of your most important responsibilities is to protect your Health and Safety
As well as that of your co-workers. Secondly each individual members of the company.
OHS Measures
• The safe work practices and safe work habits results when you also
must follow common recognized safety rules and safety practices in order to avoid
possible accidents or personal injury.
• The requirements are to be in accordance with federal legislations.

2.1.3 Health and Safety Policy

Your Company is committed to the goal of providing and maintaining a healthy and safe
working environment, with a view to continuous improvement. This goal is only
achievable by adherence to established objectives striving to exceed all obligations
under applicable legislation, and by fostering an enthusiastic commitment to health,
safety and the environment within Your Company personnel, contractors and visitors.
In particular:
Management, working in cooperation with the Joint Health and Safety
Committee, will strive to take all reasonable steps to reduce workplace hazards to as
low as reasonably achievable.

Page 8 of 41
 Supervisors and managers are held accountable for the health and safety of all
employees under their supervision. This includes responsibility for applicable training
and instruction, appropriate follow up on reported health and safety concerns, and
implementation of
Recommended corrective action. This accountability is integrated into the performance
appraisal system.
Supervisors, workers and visitors are expected to perform their duties and
responsibilities in a safe and healthful manner, and are accountable for the Health and
Safety of themselves and others. Your Company is committed to providing all
necessary training and instruction to ensure that appropriate work practices are
followed on the job, and to promote their use off the job. If necessary, Your Company
will take disciplinary action where individuals fail to work in a healthy and safe manner,
or do not comply with applicable legislation or corporate policies and procedures.
Health, safety, the environment and loss control in the workplace are everyone’s
responsibility.
Your Company expects that everyone will join in our efforts to provide a healthy
and safe working environment on a continuous day to day basis. Only through the
dedication and efforts of all individuals can Your Company succeeds in providing a
healthy safe working environment.
2.1.4 Workplace safety

• A dirt or concrete floor is recommended, however, a wood floor

covered with sand or wet down is permissible.
• Protect any nearby combustibles (walls, floors, etc.) from slag and
flying hot metal with approved fireboard such as 518” gypsum.
• Work in a well-ventilated area. DO NOT ventilate with oxygen from
tanks.
• Fireproof any surface used as a worktable. Fire brick is
recommended because it is inexpensive, easy to find, and long-lasting
2.1.5Personal Protection
• Clothing shall be appropriate to the duties being performed. Long
pants, a clean neat shirt and steel toed shoes are the minimum requirements.
Horseplay, fighting or tomfoolery is strictly prohibited

Page 9 of 41
 • Do not attempt to use unless all guards and safety devices are in place
and securely attached.
• Stop machine before making measurements or work adjustment.
• All spills will be immediately cleaned up and reported

Remove your watch, rings etc. before using machine.

• Aisles are to be kept clear at ALL times

2.1.6 Machine safety
• Hand tools are to be used for their intended purpose only Machinery
and tools must be cleaned up before the end of your workday
• Only licensed personnel may operate machine or other warehouse
Equipment and must wear a seatbelt while doing so.

• Riding on equipment is prohibited except where designated for operator

• Do not unload a truck alone under any circumstances, if someone can
not
Help you then wait or call someone else for help.

When identifying the hazards related with machines, we shall consider

• type of machines
• layout of machines
• driven method, e.g. electricity, air, etc
• operating parameters, e.g. speed, pressure, temperature, size of
cut, mobility, etc.
• materials to be processed or handled and method of feed
• operator position and controls
• access for setting adjustments and maintenance
• environmental factors, e.g. dust, fumes, noise, temperature,
humidity etc
• operating requirements including what the operator needs to do

Typical hazards related with operation of machines include:

• mechanical:

e.g. crushing, shearing, cutting or

severing, stabbing or puncture
• high pressure fluid
ejection
• electrical shock
noise and vibration
• contact with extremes
of temperature
• ergonomics
• others

Loose Clothing

Page 10 of 41
 Self-Check -2 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in
the next page:
1________which of the following about related with machine hazards

A, type of machines C, materials to be processed

B , operator position and controls D, all

Note: Satisfactory rating - 3 and 5 points Unsatisfactory - below 3 and 5 points

You can ask you teacher for the copy of the correct answers.

Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

Information Sheet-3 Selecting Tools and equipment

Spirit Level
• Surveyor's leveling instrument
• Carpenter's level
• Line level
• Engineer's precision levels
• Digital level
Theodolite
Autocollimator
Shim (spacer)
Leveling Mounts, Leveling Feet and Leveling Pads

• Hand tools,
• Hand held power tools,
• Measuring tapes,
• spirit levels, line levels, optical levels, electronic levels, laser levels,
• Dial indicators, special type dial indicator fixtures,
• magnetic bases,
• feeler gauges,
• Bench centers, vee blocks

Page 12 of 41
 Information Sheet-4 Calculating material quantity with specification

4.1. Definition

From the practical point of view, the following requirements should be fulfilled.

• The groundwater table should be as low as possible and groundwater level

deeper by at least one-fourth of the width of foundation below the base
plane. This limits the vibration propagation, groundwater being a good
conductor of vibration waves.
• Machine foundations should be separated from adjacent building
components by means of expansion joints.
• Any steam or hot air pipes, embedded in the foundation must be properly
isolated.
• The foundation must be protected from machine oil by means of acid-
resisting coating or suitable chemical treatment.
• Machine foundations should be taken to a level lower than the level of the
foundations of adjoining buildings.
Definition Machine relate to the Where
foundation

Lf (length of the foundation) Lb + 2C, where c= Lb = length of the

10% of Lb
base plate

a (upper width of the foundation) Wb + 2C, where c= C = clearance

10% of wb

Wb = width of the
Wf (weight of the foundation) 3-5 (Wm)
Base plate.

Vf (volume of the foundation) Wf/d Wm =weight of the

machine Kg
b (Lower width of the foundation) N(Wf +Wm)/Sb.Lf d= density of the

h (depth of the machine foundation) 2Vf/(a+b)Lf concrete Kg/m3

Sb=Soil bearing Capacity

2
in kg/m

N = Factor of Safety

Page 13 of 41
Weight of Steel bar Reinforcements ( W SB ) ,W SB = 0.5 % to 1% x Wf

Anchor Bolts Recommendation :The anchor Bolts should be imbedded in the

Concrete at least 30 times the bolt diameter.

Notes :The vertical distance from the floor or soil level to the top edge of the

Foundation must be around 6 inches (120 mm) as a minimum distance.

Concrete Materials Requirement:

CEMENT: (7.8 sacks/ m3) x 24.506 m3 = 191.15 Sacks

Say 192 sacks

SAND: 0.44 x 24.506 m3 = 10.783 m3 x 1 cu. Yard/ 0.765 m3

= 14.09 cu. Yard

STONE: 0.88 x 24.506 m3 = 21.57m3 x 1 cu. Yard / 0.765 m3

= 28.196 cu. Yard.

Page 14 of 41
 Self-Check -1 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in
the next page:
1 calculate 7.8 sacks/ m3) x 24.506 m3
2 A, Say 192 sacks C, materials to be processed
B , operator position and controls D, all

Note: Satisfactory rating - 3 and 5 points Unsatisfactory - below 3 and 5 points

You can ask you teacher for the copy of the correct answers.

Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: ______________

Information Sheet-5 Selecting and setting up leveling or alignment devices/
equipment.

5.1.2 Types of level

Surveyor's leveling instrument: Tilting level, dumpy level or automatic level are
terms used to refer to types of leveling instruments as used in surveying to
measure height differences over larger distances.

Fig 5.2

5.1.3 Carpenter's level

A traditional carpenter's spirit level looks like a short plank of wood and often has
a wide body to ensure stability and that the surface is being measured correctly.
In the middle of the spirit level is a small window where the bubble and the tube
is mounted. Two notches (or rings) designate where the bubble should be if the
surface is level. Often an indicator for a 45 degree inclination is included.
 Fig 5.3

5.1.4 Line level

A line level is a level designed to hang on a builders string line. The body of the level
incorporates small hooks to allow it to attach and hang from the string line.

Fig 5.4

5.1.5 Engineer's precision levels

An engineer's precision level permits leveling items to greater accuracy than a
plain spirit level. They are used to level the foundations, or beds of machines .

Page 17 of 41
 Fig 5.5

5.1.6 Theodolite:
Theodolite: is a precision instrument for measuring angles in the horizontal and
vertical planes. Theodolites are used mainly for surveying applications, and have
been adapted for specialized purposes in fields like meteorology and rocket
launch technology.

Fig 5.6

5.1.7 Digital levels

Digital levels are increasingly common in replacing conventional spirit levels particularly
in civil engineering applications, such as building construction and steel structure
erection, for on-site angle alignment and leveling tasks. The industry practitioners often
refer those leveling tool as: “construction level”, “heavy duty level”, "inclinometer" or
“protractor”.

Page 18 of 41
 Fig 5.7

5.2 What Is Alignment?

Machine set-up most often starts with the foundation. If the foundation is level and
flat you will have less problems with the rest of the installation and alignment of the
machine. The alignment of the machine, but also possibilities to perform the
following:

• Measure the flatness of the foundation

• Check plane parallelism for several surfaces on large machines

• Measure flatness for a single machine foot support surface

• Align the foundation level and plumb

• Align pipes straight and square. This is one of the reasons it can be used in so many
more places in your operations than just to align the shafts of rotating machinery

MAJOR BENEFITS OF ALIGNMENT You have much to gain in both time and money
through having your machines aligned to the correct tolerances. An investment in a
laser based alignment system such as Easy-Laser® rapidly pays for itself through lower
costs for replacement parts, less downtime and smaller electricity bills. Correctly

Page 19 of 41
aligned machines reduce the risk of expensive breakdowns and downtime. The benefits
of alignment are many:

• Increased availability and productivity of the machine = assured

production

• Increased life of bearings and seals = less use of replacement parts

• Complete seals = less leakage and better working environment

• Optimally utilized lubricant = less risk of overheating and secondary

damage

• Less lubricant leakage = less lubricant consumption

• Reduced friction = lower energy consumption

• Less vibration = reduced noise level

• Less risk of serious breakdowns = safer working environment

HORIZONTAL MACHINES Horizontally coupled machines often consist of
a pump and motor, but there can also be other types of machine such as a
gearboxes and compressors. Regardless of what the machine is it is easy
to measure and align with Easy-Laser®. The measuring units (M and S)
are mounted on each side of the coupling with cable or wireless
communication to the display unit. In the Horizontal and Machine train
programs, you can chose which machines are to be shown, which side
they are on, and specify the number of pairs of feet to correspond with
your reality. You can even name the machines individually.

Page 20 of 41
 b

A Information field. States what you must do at each stage of the measurement.
Also displays Bluetooth® connection, warning symbols etc. B. You can start from
a previous measurement and so avoid re-entering the dimensions, the barcode
reader is the fastest method. C. The detector surface is shown on the screen and
functions as an electronic target for the laser beams. D. 20° marking. The S unit
position on the shaft is shown. You can also choose to show the M unit when you
align uncoupled machines. E. Shims values for front and rear pairs of feet. Offset
and angular values are colour coded in order to determine the result more quickly:
red=outside tolerance, green=inside tolerance. F. Horizontal adjustment values.
Offset and angular values are color coded.
VERTICAL/FLANGE-MOUNTED MACHINES REFERENCE FOOT LOCKING
This function allows you to lock any pair of feet on the machine. This gives great
freedom when aligning base bound or bolt-bound machines.
MACHINE FEET CONFIGURATIONS The software can handle machine design of
all types: two pairs of feet, three pairs of feet, pair of feet before the coupling etc.
LIVE-ANY-ANGLE 360° This function allows adjustment of the machines live with
the measuring units positioned anywhere around the shaft. Good for when
machine parts prevent normal adjuster positioning.
Alignment of vertical and flangemounted machines. Shows centre offset, angular
error and shim value at each bolt.
STRAIGHTNESS MEASUREMENT
With our program for measuring straightness, you can easily measure long shafts,
rolls, bearings, bases, machine structures etc. All you have to do is define a
number of measuring points, in advance or while measuring. You will be able to
get the result for both the horizontal and vertical alignment, graphically as well as
Page 21 of 41
 digitally. The D22 Laser transmitter included with system E720 will provide even
more alignment possibilities for you.

5.3 Leveling procedures

A level is an optical instrument used to establish or verify points in the same horizontal
plane in a process known as leveling, and is used in conjunction with a levelling staff to
establish the relative heights levels of objects or marks

• The instrument must be check before use! (see lecture)

• The instrument and level must be stable settled-up
• The bubble tube must be leveled before the reading
Beware of sun exposure (will wander)
Ensure the instruments pendulum is in-limit
• The instrument must be set up in the middle between two staffs
Prevents curvature effects
If impossible, use the same distances, but opposite for the
next readings
• You must not use the parallax screw between the backsight and
foresight readings
• Readings must be taken 30-50 cm above the ground
• Surface refractions
• Beware also of temperature gradients (inside/outside buildings) !!!!
• Staff should be set up vertically
• A change plate should be used
• Leveling must be done in two opposite directions but the same line
(beware of gravity gradients)
• Staff should be calibrated, especially if INVAR
• Be careful when crossing rivers (large water surfaces)
• Use “same-time” (mutual) observations
• Repeat it during different times of the day

Page 22 of 41
The hand level and rod are used to establish and verify elevations. If you only want to
determine the difference between two points, then you can make two direct readings as shown
in Figure 10. The difference in rod readings (one subtracted from the other) is the difference in
elevation between the points.

Page 23 of 41
 Identifying electrical lightings, wirings/gadget.
Information Sheet-6

The Ethiopian Building Code Standard (EBCS-10) must be followed at all times
concerning every electrical design, installation and repair; whether in commercial,
industrial or residential buildings. Lighting Requirements (EBCS under Sec 3.
Illumination) 3.5 and Table 3.6 shall be taken as the recommended minimum values
on which the design and assessment of lighting installations are to be based.
1. Lux: can be used as a measure of the brightness of a light source. Lamp
illumination and design in any indoor and outdoor workplaces are expressed in lux. One
lux is equal to one lumen per square meter: 1 lux = 1 lumen/m2
2. Lumen: is a measure of the total amount of visible light emitted by a source. It is the
SI derived unit of luminous flux. A flux of 1,000 lumens, concentrated into an area of
one square meter, lights up that square meter with an illuminance of 1,000 lux.
However, the same 1,000 lumens, spread out over ten square meters, produce a
dimmer illuminance of only 100 lux.Therefore, the difference between unit’s lumen and
lux is that the lux takes into account the area over which the luminous flux is spread.
Common Fluorescent lamp and their average Lumen output
Type of Fluorescent Lumen Output Average Lumen per watt
lamp
4 feet Linear 25 Watt T8 2209 lumens 88 lumens per watt
4 feet Linear 28 Watt T5 2900 lumens 104 lumens per watt
4 feet Linear 32 Watt T8 2850-3100 93 lumens per watt
lumens
4 feet Linear 34 Watt 1930-2800 70 lumens per watt
T12 lumens
4 feet Linear 40 Watt 1980-3300 66 lumens per watt
T12 lumens
4 feet Linear 54 Watt T5 5000 lumens 93 lumens per watt

Achieving an luminance of 500 lux might be possible in a 24m2house area with four
fluorescent light fixture with a combined output of 12,000 lumens. To light a factory floor
with dozens of times the area of the house would require dozens of such fixtures.
Thus, lighting a larger area to the same level of lux requires a greater number of
lumens. The ordinary four feet Linear Fluorescent Bulbs, 40 -watt, 220V, T12 has an
output average of 2600 lumens.

Page 24 of 41
 Example: What would be the total number of 40 - watts, 220V, T12 fluorescent lamp
fixtures to be installed in a 50 m2 area of school library if it requires having a 300 lux
illumination?
Given: Lux = lumen / m2
Lux = 300
lamp = 2600 lumens per 40 - watt F.L.
Lumen =?
Solution: Lumen = (Lux) (Floor area in m2)
Lumens = (300 lux) (50 m2)
= 15, 000 lumens
Lamp = 15, 000 lumens/ (2600 lumens per 40 - watt F.L.)
= 5.8 or 6 set of 40 - watts fluorescent lamp

Page 25 of 41
 Information Sheet-7 Environmental protection requirements

7.1 definition
Your working institution Committed to the Protection of the Environment for
Present and Future Generations. All Employees Are Responsible for
incorporating into Their Planning and Work the Actions Necessary to Fulfill this
Commitment.
Your Company Will Meet These Responsibilities by Endeavouring to
Provide the Resources for Continuing To:
Design and manage our operations to meet or surpass applicable
environmental laws. Work in partnership with customers, suppliers, trade associations
and
government agencies to promote the environmentally safe handling and
disposition of materials and products. Acquire knowledge and technologies to improve
the environmentally save efficient use of our processes and products. Formulate and
implement effective environmental emergency response
systems.

Page 26 of 41
 MECHANICS
Level-II

Learning Guide-24
Unit of Competence: Performe Equipment/
Machine Lay-out, Setting and Leveling

Module Title: Performing Equipment/

Machine Lay-out, Setting and Leveling

LG Code: IND MC S2 M07 LO2-LG-19

TTLM Code: IND MC S2 TTLM 1019vZ

LO 2: Perform layout
Page 27 of 41
 Instruction Sheet Learning Guide #24

This learning guide is developed to provide you the necessary information regarding the
following content coverage and topics:
• Inspecting shop area.
• Taking flow of equipment, material or personnel.
• Doing layout of equipment.
• Marking locations for form works.
• Clearing and preparing work area and surface.
.
This guide will also assist you to attain the learning outcome stated in the cover page.
Specifically, upon completion of this Learning Guide, you will be able to:
• Inspect shop area.
• Take flow of equipment, material or personnel.
• Do layout of equipment.
• Mark locations for form works.
• Clear and preparing work area and surface.
.
Learning Instructions:
7. Read the specific objectives of this Learning Guide.
8. Follow the instructions described below 3 to 6.
9. Read the information written in the information “Sheet 1, Sheet 2, Sheet 3 and
Sheet 4”.
10. Accomplish the “Self-check 1, Self-check t 2, Self-check 3 and Self-check 4” in
page -6, 9, 12 and 14 respectively.
11. If you earned a satisfactory evaluation from the “Self-check” proceed to “Operation
Sheet 1, Operation Sheet 2 and Operation Sheet 3 ” in page -15.
12. Do the “LAP test” in page – 16 (if you are ready).

Page 28 of 41
 Information Sheet-1 Inspecting shop area

1.1 introductions

Plant layout refers to the arrangement of physical facilities such as machines,

equipment, tools, furniture etc. in such a manner so as to have quickest flow of
material at the lowest cost and with the least amount of handling in processing the
product from the receipt of raw material to the delivery of the final product

The principal factors are:

• Location, with respect to the marketing area
• Raw material supply
• Transport facilities
• Availability of labor
• Availability of suitable land
• Environmental impact and effluent disposal
• Local community consideration
• Climate
• Political and strategic consideration
Objectives of good Plant Layout:
A well designed plant layout is one that can be beneficial in achieving the
following
• Proper and efficient utilization of available floor space
• Transportation of work from one point to another point without any delay
• Proper utilization of production capacity.
• Reduce material handling costs
• Utilize labor efficiently
• Reduce accidents
• Provide for employee safety and health
• Allow easy maintenance of machines and plant.
• Improve productivity

Page 29 of 41
 Information Sheet-2 Taking flow of equipment, material or personnel

Introduction
Types of shop layout considering work flow –
2.1 Process layouts (Job shop):
- Process layout (also called a job-shop or functional layout) is a format in which
similar equipment or functions are grouped together, such as all lathes in one area
and all stamping machines in another

2.1.2 Product layouts (Flow shop):

A product layout (also called a flow-shop layout) is one in which equipment or
work processes are arranged according to the progressive steps by which the
Product is made.

Input output
b

2.1.3 Hybrid layouts (Cellular):

A Hybrid (cellular) layout groups dissimilar machines into work centers (or
cells) to work on products that have similar shapes and processing requirements.

c
Page 30 of 41
 2.1.4 Fixed-Position layouts:
In a fixed-position layout, the product (by virtue of its bulk or weight) remains at
one location.
Manufacturing equipment is moved to the product rather than vice versa.

Page 31 of 41
Information Sheet-4 Mark Locations
Design principles of location purpose
The following principles should be followed while locating surfaces.
1.At least one datum or reference surface should be established at the first
opportunity.
2. For ease of cleaning, locating surfaces should be as small as possible.
3. The locating surfaces should not hold swarf and thereby misalign the workpiece
4 .Sharp corners in the locating surfaces must be avoided
5 .Adjustable type of locaters should be used for the location on rough surfaces

Page 32 of 41
 Information Sheet-5 Clearing and preparing work area and surface.

5.1 introduction

Reports and documentation

A system of documents being applied to let you know whether something in your
workplace should either be operated with extra care or left alone.
Purposes of Tag-Out Bill
To provide a procedure to prevent the improper operation of a component, piece of
equipment, a system, or portion of a system that is isolated or in an abnormal
condition.
To provide a procedure in operating an instrument that is unreliable or not in normal
operation condition.
To provide separate procedures when accomplishing certain planned maintenance
system

DANGER

5.1.2 Clear Work area and Disposed of, Reused Or Recycled materials
Cleaning even if things are NOT DIRTY. A regular cleaning schedule prevents things
from having the chance to get dirty.Maintaining the workplace in high standard of
housekeeping.
reuse of second-hand products
repairing broken items instead of buying new
designing products to be refillable or reusable
Encouraging consumers to avoid using disposable products
Designing products that use less material to achieve the same purpose

5.1.3 Check Plant, tools and equipment

Prepare a standard checklist.
Checklist should be very detailed and stringent based on the set of standard values
for inspection implement a periodic clean-up schedule; and an award and sanction
scheme
Evaluate workstations according to the standard checklist.

Example
. Is flooring clear of obstacles and spilled substances
Are aisles, exits and traffic areas clear
. Are walls clear and clean?
. Are tools stored in proper storage areas when not in use?
Are defective hand and power tools/attachments removed from storage area for
repair?

Page 34 of 41
 MECHANICS
Level-II

Learning Guide-25
Unit of Competence: Performe Equipment/
Machine Lay-out, Setting and Leveling

Module Title: Performing Equipment/

Machine Lay-out, Setting and Leveling

LG Code: IND MC S2 M07 LO1-LG-19

TTLM Code: IND MC S2 TTLM 1019vZ

LO 2: Perform setting and leveling

and alignment

Page 35 of 41
 Instruction Sheet Learning Guide #25

This learning guide is developed to provide you the necessary information regarding the
following content coverage and topics:
• Setting machine.
• Setting up levelling/aligning equipment
• Sequences(series) of machine setting operations
• Using hand tools for machine setting
• Adjusting machine.
• Levelling equipment.
• Completing levelling and alignment task.
.
This guide will also assist you to attain the learning outcome stated in the cover page.
Specifically, upon completion of this Learning Guide, you will be able to:
• Set machine.
• Set up levelling/aligning equipment
• Sequences(series) of machine setting operations
• Use hand tools for machine setting
• Adjust machine.
• Level equipment.
• Complete levelling and alignment task.
.
Learning Instructions:
13. Read the specific objectives of this Learning Guide.
14. Follow the instructions described below 3 to 6.
15. Read the information written in the information “Sheet 1, Sheet 2, Sheet 3 and
Sheet 4”.
16. Accomplish the “Self-check 1, Self-check t 2, Self-check 3 and Self-check 4” in
page -6, 9, 12 and 14 respectively.
17. If you earned a satisfactory evaluation from the “Self-check” proceed to “Operation
Sheet 1, Operation Sheet 2 and Operation Sheet 3 ” in page -15.
18. Do the “LAP test” in page – 16 (if you are ready).

Page 36 of 41
Information Sheet-1 setting Machine

1.1 Leveling
• The term level is defined as "being perpendicular to a vertical line.”
• If an object is parallel to the horizon, it also said to be "level".
• This concept is not limited to surveying.
When a picture is hung on the wall, care is taken to insure that it hangs
straight-- level.
Kitchen appliances are “leveled” when they are installed.
As a carpenter builds forms for placing concrete, they are leveled, or
checked to see if the top of the forms is the same elevation at all points.
• The application of the term level is dependent on a tube of liquid with an air
bubble called a spirit level.
• When air bubble is centered it is level.
• If the air bubble is not centered--it is out of level
• Spirit levels are attached to or built into surveying instruments so the instrument
can be set level.

Page 37 of 41
 Information Sheet-1 Adjusting machine.

Horizontal CNC machine Leveling Procedure

1. Calibrate and check the precision level for accuracy before leveling the machine.
NB:Place the level on a somewhat known level surface maybe on another machine. After
placing the level and letting the level sit for 5 minutes to get to room and pallet temperature.
Then note the position of the bubble, and then rotate the level 180 degrees and make sure the
level repeats. If it does not calibrate the level.

Rough machine leveling

2. Next check that the machine is at a height where the coolant pans and conveyors fit
under the machine. When leveling a machine lower is always better for a couple reasons.
When the machines are sitting on leveling screws the higher up the less stable. Also
keeping the machine tool lower prevents excessive splashing of coolant on to the floor
through areas between coolant tanks and conveyors.
3. Next move the machine so that all axes are at the center of their stroke. This will balance
the weight among all the jack screws for better feel and even weight distribution when
leveling.
4. Place two levels if possible on the machine. One parallel with the ways or with the linear
guides and one perpendicular with the ways.
Adjust the jack bolts on the machine so that it is level using 3 screws on each side of the
machine. Every machine has its tricks to use certain screws to make things easier so this is a
general rule of thumb certain screws may bring in the levels much quicker
Rubber Inserts
The Rubber Inserts are suitable for use as non-slip devices and floor protectors. They can be
retrofitted to Knuckle Feet D40 and D80

Page 38 of 41
Base Plate/Transport Plate
Base Plate/Transport Plates are stable fastening plates for adjustable feet, castors, ring
bolts and other elements. They can be screwed into the core bores in the profile end faces
or onto the sides of the profiles.

Foot Clamps
Foot Clamps are used for floor or wall mounting of Knuckle Feet D60 and D80. The fastening
set can be used to mount a machine to concrete.

ure 10 If more than two points are involved, then a leveling procedure is used. The procedure
involves starting at the benchmark, establishing the height of the instrument, and then taking
rod readings on points where new elevations are to be est

1. Locate the bottom edge of the level. This rests against the surface you're trying
to level.

Page 39 of 41
 2. Some models feature magnetic edges, which "stick" to metal surfaces for ease
of use.
3. Inspect the body of the level and check for grabbing points where you won't
block the vials with your hand(s).
4. Most levels feature a punched hole on at least one end for hanging above your
workbench.
5. The tube vial in the center of the level helps you find the true horizontal.
6. Tube vials on the ends finds the true vertical.
7. On many torpedo levels and other specialized levels, there is an angled tube vial
to find level at 45°.
8. If your spirit level features an electronic display, consult our guide on how to use
a digital electronic level.

3.1 setting machine.

• Manufacturing Industries and Products

• Manufacturing Operations
• Production Facilities
• Product/Production Relationships
• Lean Production
• Manufacturing Metrics
• Manufacturing Lead Time
• Rate of Production
• Production Capacity
• Work in Progress
• Design Times
• Utilisation/Availability

n2
n1

Time
Operation Time
Non-operation Time
T = Operation Time per Machine
o
T = Non-operation Time per Machine
no
Nm = Number of Machines
MLT = n ( T + T )
m o no

Note not enough more advance

Page 41 of 41