facilities design project

Contents:

Title page

Chapter One : Introduction

1.1 Introduction ……………………………………………………………………………………………… 1

Chapter Two : Product Overview

2.1 Common Terms………………………………………………………………………………………….. 2

2.2 The Perfect Frame for you! ………………………………………………………………………. 3

2.3 Frame Parts ……………………………………………………………………………………………….. 4

2.4 Eyeglass Frame Styles ……………………………………………………………………………….. 5

Chapter Three : Project Requirements

3.1 Raw Materials …………………………………………………………………………………………. 6

3.2 Engineering Drawing Designs ………………………………………………………………….. 7

3.3 Plant layout ……………………………………………………………………………………………….. 9

Chapter Four : Manufacturing Requirements

4.1 Bill Of Materials ………………………………………………………………………………………… 10

4.2 Assembly Chart ………………………………………………………………………………………….. 11

4.3 Manufacturing Operations ………………………………………………………………………… 12

4.4 Required Machines and Equipment …………………………………………………………. 13

4.5 Required Machines ……………………………………………………………………………………. 14

Chapter Five: Time Study and Process Design

5.1 Required Data for the mathematical calculations …………………………………… 16

5.2 Raw Materials Required For The Project ………………………………… 17

5.3 Labor Required For The Project ………………………………………….. 17

5.4 The operation chart…………………………………………………………. 18

5.5 Route Sheets …………………………………………………………………. 19

5.6 Assembly Line Balancing …………………………………………………… 21

5.6.1 Calculation of efficiency of manufacturing line ………………………………………… 21

5.6.2 The efficiency of the production line after optimization………………………………. 22

5.6.3 The efficiency of the production line after optimization………………………. 23

Summary ……………………………………………………………………………………………………….. 24

References………………………………………………………………………………………………………. 25

Chapter one

Introduction

INTRODUCTION

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1. INTRODUCTION

Eyewear consists of items and accessories worn on or over the eyes, for fashion or adornment,

protection against the environment, and to improve or enhance visual acuity.

Modern eyeglass frames are available in a huge variety of styles, sizes, and materials. For those who

are fashion conscious, there are dozens of designer styles. Children's and safety frames are now

available in materials that are nearly indestructible. New materials and design technology have made

frames more lightweight and comfortable. Good quality frames are now available in all price ranges,

too. An experienced, knowledgeable optician can help when selecting a quality frame that looks

good and fits well.

Many people require glasses for the reasons listed above. There are many shapes, colors, and

materials that can be used when designing frames and lenses that can be utilized in various

combinations. Oftentimes, the selection of a frame is made based on how it will affect the

appearance of the wearer. Some people with good natural eyesight like to wear eyeglasses as a style

accessory.

In the 20th century, eyeglasses came to be considered a component of fashion; as such, various

different styles have come in and out of popularity. Most are still in regular use, albeit with varying

degrees of frequency.

http://en.wikipedia.org/wiki/Fashion

Chapter two

Product Overview

Product Overview

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2.1 Common Terms

Here are some of the frame terms you may hear when being fitted for a new pair of eyeglasses:

Frame front: Front part of the eyeglass frame that holds the lenses in place and bridges the top of

the nose.

Eye wires (rims): Part of the frame front into which the lenses are inserted.

Bridge: The area between the lenses that goes over the nose and supports 90 percent of the weight of

the eyeglasses.

A keyhole bridge is shaped like an old-fashioned keyhole and rests on the sides of the upper

part of the nose. This style is for those with small or flat nose bridges.

A saddle bridge is shaped like a saddle and spreads the weight of the frame across the sides

and the top of the nose. This style works well for heavy glasses or for those who are sensitive

to pressure.

An adjustable bridge includes nose pads that can be adjusted for fit and comfort.

A double bridge has a reinforcing bar over the top of the bridge.

End pieces: Extensions of the frame front to which the temples are attached.

Hinges: Part of the frame that connects the frame front to the temples and allows the temples to

swing.

Temples: Parts of the frame that extend over and/or behind the ears to help hold the frame in place.

Top bar: A reinforcing bar that crosses the top of the glasses on some metal frames, popular in

aviator glasses.

Temple tips: Plastic coatings that often cover the ends of the temples behind and/or over the ears.

Rimless frames (or mountings): The temples and bridge attach by mountings directly to the lenses

without the use of eyewires or rims.

Product Overview

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2.2 The Perfect Frame for you!

The shape of your face is the most important factor when choosing frames. The following

descriptions should help you decide which frame design is right for you.

Round Faces

Rectangular frames would be most suitable.

Oval Faces

Most frames will suit this face shape. Size is the most important point when deciding on frames.

Triangular Faces

Rectangular frames would be most suitable

Square Faces

Oval Shaped or Round Frames would be most suitable.

Rectangular Faces

Oval and Round frames would be most suitable with medium or larger size models.

Product Overview

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2.3 Frame Parts

The eyeglass frame has the following parts shown in the figure (1.1) :

A- Frame Body

B- Left Arm

C- Right Arm

D- Jointing

E- Supporter

F- Join Screw

The parts shown in the figure above are the most common parts that exists in almos every frame

design.

Other parts can be included according to the design itself.

Product Overview

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2.4 Eyeglass Frame Styles

Eyeglasses have also become quite stylish as fashion accessories, especially among fans of high end

designers. Many people change their frames in the same way as shoes or handbags, with different

colors and styles to match their wardrobes.

Multi-colored inlays, composite materials, designer emblems, and enhancements such as insets of

precious stones may also be found in popular frame styles.

Rimless styles have become more popular in recent

years as an understated way to wear eyeglasses

without obvious frames. Rimless styles mainly

involve attaching plastic or metal temples directly

onto the lenses rather than onto a frame.

New eyeglass frame styles continually are being

announced. Innovations in both construction and

design include introduction of wood or bamboo in

frame materials.

Women's eyeglasses now are available in playful cat-

eye shapes, as well as cutouts with elaborate design

elements including swirls and angular patterns.

Men's eyeglasses have extra flair this season, with

new styles that include classy designer logos and

patterns embedded in translucent backgrounds.

Unisex eyeglasses for both men and women include

plenty of rimless styles, which are popular as a

good, generic fit for both sexes.

Kids' eyeglasses may look similar in style to those

worn by adults, but are often more colorful with

emphasis on durability to save parents the expense

of constant replacements.

Chapter Three

The Project

Requirement

Project Requirement

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Our view is to establish the basic requirements needed for building a small factory to manufacture

eyeglass frames.

In order to get those requirements we have studied the field of frame manufacturing and summarized

the basic requirements needed for that propose.

Those requirements are :

Raw Materials

Engineering Drawing Designs

Plant layout

3.1 Raw Materials

The materials used in the production of modern eyeglass frames are plastic, metal, or a combination

of the two (composites). Manufacturers select materials that are cost effective, adjust easily, offer

safety and workability, hold the lenses properly, and resist breakage, corrosion, and heat. Here are

brief descriptions of popular frame materials.

The frame is made of the different raw materials listed table (1.1) :

Table 1.1 ( Frame Raw Materials )

Part Name Raw Material

1- Frame Body Plastic ABS

2- Right Arm

Arm

Support

Plastic ABS

Steel

3- Left Arm

Arm

Support

Plastic ABS

Steel

4- Jointing (Two Parts) Steel

5- Join Screw Steel

Project Requirement

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3.2 Engineering Drawing Designs

If you're a glasses wearer you may notice some numbers on the arms or the bridge. These numbers

usually include the frame model, colour code and measurements. This may look something like the

following image:

The diagram below illustrates the fundamental elements and component parts which make up the

spectacle frame. In terms of the fitting of the spectacle frame, the bridge is perhaps the most

important part to consider when choosing your frames, because it is here that the major bearing

surface and area of contact between the front and the face is situated. The bridge design should

facilitate a comfortable and supportive fit which will maintain the position of the lenses over your

eyes with a natural gaze.

Project Requirement

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The engineering drawing designs are the source of all machines setup and other requirements to be

done to start the production.

A sample of farms engineering drawings is shown in the figure bellow :

Project Requirement

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3.3 Plant layout

The figue below shows a sugested layout for the plant:

Chapter Four

Manufacturing

requirement

Manufacturing Requirements

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In order to start the manufacturing process of eyeglass frames we must set tools which will be used

through this process, those tools are:

Bill Of Materials

Assembly Chart

Manufacturing Operations

Required Machines

4.1 Bill Of Materials

The table bellow shows the bill of materials for the manufacturing order of the eyeglass frame :

Operation

no. Part no. No. Part name

Quantity

per Unit Buy / Make

01

05

10

15

20

25

30

A1

A2

A3

2

12

13

0001

0010

0020

0030

0040

0012

0013

Eye glasses frame

Frame Body

Right Arm

Left Arm

Arm Support

Jointing

Join Screw

1

1

1

1

2

2

2

Make

Make

Make

Make

Make

Buy

Buy

We notice that both of the jointing and the join screw will be bought , this decision is up to the

management after doing the required cost calculations and decide wither it is more suitable to buy

the part or to manufacture it ,


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4.2 Assembly Chart

The operation chart is a graphical and symbolic representation of the manufacturing operations used

to produce a product.

The operation chart illustrates only the value-adding activities in the manufacturing process;

therefore, material handling and storage are not illustrated in this chart.

The figure below is the assembly chart for the production of eyeglass frame :


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4.3 Manufacturing Operations

The manufacturing operations for the eyeglasses frame varies according to the production line of the

frame and the machines and equipment it includes, this operations are:

1- Share Operation :

In this operation stainless steel arms are cut with desired lengths suitable to the length of the frame

arms of the desired product.

2- Bending and Smoothing Operation :

Steel arms are pent with the required angels according to the engineering drawing designs, edges are

smoothed with a grinding machine till it becomes very smooth.

3- Injection Operation :

Steel parts are put in designed positions in templates as primary sitting for injecting the plastic into

the templates to take the shape of the frame.

Those templates are imported from countries specialized in the manufacturing of those templates,

and they can be used continuously after some treatment operations.

4- Assembly Operation :

In this operation frame parts are assembled , he assembly process is explained by the assembly chart

shown above.

5- Package Operation :

After polishing frames they are packed in transparent plastic bags (polyethylene) and closed to keep

them clean and in a reliable condition.


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4.4 Required Machines and Equipment

The following table lists the required machines for the manufacturing process:

( Required Machines and Equipment )

No. Part Name Q.

per

unit Make or Buy Machine name

Q. of

production

1 Support 1 make Steel wire decoiler 440 pc/min

2 Arm Join 1 Buy - -

SA1 Right Arm

Assembly 1 make

Injection Molding

Machine 200 pc/min

3 Support 1 make Steel wire decoiler 440 pc/min

4 Arm Joint 1 Buy - -

SA2 Left Arm

Assembly 1 make

Injection Molding

Machine 200 pc/min

5 Right Joint 1 Buy - -

6 Left Joint 1 Buy - -

SA3 Frame Body

Assembly 1 make

Injection Molding

Machine 100 pc/min

7 Screw 2 Buy - -

SA4 Frame Assembly 1 make Frame Assembly

Machine 120 pc/min

A5 Page 1 Buy - -

A6 Backing 1 Buy - -

A7 Finish Product 1 make Manual 180 pc/min

Material And Machines To Manufacture The Frame


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4.5 Required Machines

The manufacturing of the eyeglasses frames involves the operations mentioned above, those

operations are performed in specific machines designed for similar purposes, table (3.3) lists the

different machines that the eyeglass frame requires to be manufactured:

Machine and Fixtures Quantity Image

Plastic injection machine equipped with the

following parts:

- Head for mixing (mixing room).

- Electronic control unit or electric each

entrance.

- Re-fill device.

1

Outfitted bend the wire Outfitted bend the

wire 1

Abrasive machine and soften

8-inch, 200-watt (15 x100x100cm) 1

Assembly Machine (150x100x100 cm)

Metal chassis Pinch white wood thickness of

5 cm. 2


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Vary Molding 2

End Surfacing machine 1

Smoothing machine 1

Total 9

Chapter Five

Time Study

and

process design

Time Study and Process Design

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In this chapter we will summarize the required data for the time study and process design such as

plant working hours and shifts, raw materials and labor required, operation chart, route sheet and

assembly line balancing.

5.1 Required Data for the mathematical calculations

After the investigation in the field of eyeglass frames industry and studying some existing companies

we concluded the following data that we are going to use to make our calculations in obtaining the

different variables affected by those data , such as:

- Takt Time Calculations.

- Number of workers.

- Number Of Machines.

- Assembly balancing.

And so on.

These data are as follows:

- The daily production of the eyeglass frames = 1000 unit per day.

- Shifts per day = 1 shift

- Hours per shift = 8 hours

- Performance efficiency = 80 %

- Various designs in same dimensions per month = 25000 unit

The efficiency used here is concluded after some calculations made as a percent of the actual output

of the plant and the planned output :

Efficiency =

= 80 %


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5.2 Raw Materials Required For The Project

The following Table lists the quantity of raw materials required :

Raw Material Quantity Unit

Plastic: Acrylonitrile butadiene

styrene (ABS) 25 Kg

Stainless Steel (1.5 mm

Diameter ) 27 Meters

Jointing (Stainless Steel) two

parts 20 Kg

Join Screw (1.5mm dia,4.5mm

Length) 200 number

5.3 Labor Required For The Project

The exact number of workers required for the manufacturing of the demand of the eyeglass frames

will be calculated in a later subsection, here we will introduce general names for the required staff

we must have in our project.

The following Table lists the various staff required :

Name Job Requirements

Project Manager Experience in the field of the design of plastic products.

Machines Operators Experience in running plastic based machines.

Turning Operators Experience in running various turning machines (Grinding-

Smoothing- etc.)

Normal staff Experience in assembly and packaging.


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5.4 The operation chart

The figure bellow illustrates the sequence of manufacturing processes for the frame parts, and

assembly operations and times spent on each machine (Time standard)


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5.5 Route Sheets

A route sheet is a document accounting for the output of production and tracing the sequence of

operations of a batch of manufactured components. The route sheet is used in serial and especially

individual production to show the workers’ output, calculate the wages of the workers, and exercise

operative super-vision of the movement of parts in production.

In this format we have the data going through the processes of product parts as well as the names of

machinery used and the time spent for each process. Used to facilitate manufacturing and project

management procedures and designers.

Frame Body route sheet

Part name : Frame Body Part number : 0010

Raw material : Plastic ABS

Order quantity :

Pics

per hr operation Machine name

Operation

No.

7200 Fabrication of plastic parts Injection molding 04

3600 Smoothing the external

surface Surface Smoothing

machine 05

Arm Support route sheet

Part name : Arm Support Part number : 0040

Raw material : stainless Steel

Order quantity : twice the no. of left arm

Pics


Operation

No.

26400 Cutting the weir Steel wire decoiler 01

3600 Smoothing the external

surface Surfacing machine 02

6000 Bend the steel weir of arm

supports Bending machine 03


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Right Arm route sheet

Part name :Right Arm Part number :0020

Raw material :Plastic ABS

Order quantity :

Pics


Operation

No.


Left Arm route sheet

Part name : Left Arm Part number : 0030

Raw material : Plastic ABS

Order quantity :

Pics


Operation

No.



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5.6 Assembly Line Balancing

The goal of the Assembly line balancing is to give each workstation the same amount of work as

much as possible.

The purpose of using the technique of assembly line balancing is:

1- Equal work pressure.

2- Find out which processes are bottlenecks.

3- Select the speed of the Assembly line.

4- Specify the number of workstations.

5- Specify the compression ratio for each player.

6- Help determine the optimal layout of the site.

7- Reduce production costs.

5.6.1 Calculation of efficiency of manufacturing line

Efficiency of production line =

=68%

Assembly line balancing Product name: Eye glasses frame

No. Operation

Name

Time

Standard

NO .of

Stations

Rounded

Up

Average

Time

Percent

Loaded

Hours per

Unit

1 SA1 0.00500 0.01445 1 0.00500 50 0.0001667

2 SA2 0.00500 0.01445 1 0.00500 50 0.0001667

3 SA3 0.01000 0.2890 1 0.01000 100 0.0001667

4 SA4 0.00833 0.02410 1 0.00833 83 0.0001667

5 A7 0.00556 0.01690 1 0.00556 56 0.0001667

Total 0.03389

5

0.000833


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5.6.2 The efficiency of the production line after optimization


=68%


No. Operation

Name

Time

Standard

NO .of

Stations

Rounded

Up

Average

Time

Percent

Loaded

Hours per

Unit

1 SA1 0.00500 0.01445 1 0.00500 60 0.0001667

2 SA2 0.00500 0.01445 1 0.00500 60 0.0001667

3 SA3 0.01000 0.2890 1+1 0.00500 60 0.0001667

4 SA4 0.00833 0.02410 1 0.00833 100 0.0001667

5 A7 0.00556 0.01690 1 0.00556 67 0.0001667

Total 0.03389

6

0.000833


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6.5.3 The efficiency of the production line after optimization


=87 %


No. Operation

Name

Time

Standard

NO .of

Stations

Rounded

Up

Average

Time

Percent

Loaded

Hours per

Unit

1 SA1 0.00500 0.01445 1 0.00500 89.9 0.0001667

2 SA2 0.00500 0.01445 1 0.00500 89.9 0.0001667

3 SA3 0.01000 0.2890 1+1 0.00500 89.9 0.0001667

4 SA4 0.00833 0.02410 1+1 0.00417 75 0.0001667

5 A7 0.00556 0.01690 1 0.00556 100 0.0001667

Total 0.03389

7

0.000833

Summary

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Summary

In this project we have only mentioned the basic requirements involving the manufacturing process,

more details are required in order to get a clearer idea about the whole project.

The information we have provided here are for a typical type of eyeglasses frame, here are many

styles and different designs according to many variables.

Modern eyeglass frames are available in a huge variety of styles, sizes, and materials. For those who

are fashion conscious, there are dozens of designer styles. Children's and safety frames are now

available in materials that are nearly indestructible. New materials and design technology have made

frames more lightweight and comfortable. Good quality frames are now available in all price ranges,

too. An experienced, knowledgeable optician can help when selecting a quality frame that looks

good and fits well.

Finally we hope that in this simple research we made it clear how to walk through the process of

establishing a production line for eyeglasses frame manufacturing.

Reference

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References

1- http://en.wikipedia.org/wiki/Glasses#Types_of_glasses

2- http://www.allaboutvision.com/eyeglasses/overview.htm

3- http://www.selectspecs.com/info/frame-measurements

4- http://www.ask.com/question/what-is-assembly-process-chart

http://en.wikipedia.org/wiki/Glasses#Types_of_glasses

http://www.allaboutvision.com/eyeglasses/overview.htm

http://www.selectspecs.com/info/frame-measurements

http://www.ask.com/question/what-is-assembly-process-chart

facilities design project

Documents

frame terms

eyeglass frame styles

frame parts

perfect frame

raw materials

new materials

bill of materials

manufacturing line