FACILITY PLANNING

Pen

TABLE OF CONTENTS

-Introduction -product design -process design -schedule design -facility area -material handling

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INTRODUCTION

Manufacturing and Service companies spend a significant amount of time andmoney to design or redesign their facilities. This is an extremely important issue andmust be addressed before products are produced or services are rendered.A poor facility design can be costly and may result in:

•poor quality products, •low employee morale,

•customer dissatisfaction.2

PRODUCT

. Name :Ballpoint pen

Function :Is a pen that dispenses ink over a metal ball at its point.

:it works on two principles

-frictional force between pen and paper .

-gravitational force due to which ink follow in downward direction .

3

PRODUCT DESIGN

Isometric view Exploded view

4

PROCESS DESIGNPART LIST

5

Bills of material Assembly chart

Upper body

Retract tube

button

clip

lower body

INK TUBE

INK SUPPLY

SPRING

BALL

Packaging material

I – 1

A-1 SA -1

006

008

007

005

A-2 SA -2

003

002

009

001

004

6

Operation process chart

body button

010010

010010010

Injection molding process

Injection molding process

Injection molding process

Injection molding process

Injection molding process

Ink tube Clip Retract tube

cooling020

labeling030

040 inspect

040

coolingcooling

Filling

inspect

cooling cooling

inspect

020

020020020

040

060

004-009 006 001 002003

SA-1

SA-2

spring ball007 005

A-4

I - 1Packaging material

030 labeling

040 inspect

050

020

040

Ink supply008

Extrusion

cooling

inspect

SA-3

040 inspect

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SCHEDULE DESIGN

Schedule design provide answers to questions involving how much to produce and when to produce. Production quantity decisions are referred to as lot size decisions; determining when to produce is referred to as production scheduling. In addition to how much and when, it is important to know how long production will continue; such a determination is obtained from market forecasts

Schedule design decisions impact machine selection, number of machines, number of shifts, number of employees, space requirements, storage equipment, material handling equipment, personnel requirements, storage policies, unit load design building size, and so on. 8

Equipment requirements are a function of the following factors:

•Number of shifts (the same machine can work in more than one shift).

•Setup times (if machines are not dedicated, the longer the setup, the more machines needed).

•Degree of flexibility (customers may require small lot sizes of differentproducts delivered frequently – extra machine capacity will be required tohandle these requests.)

•Layout type (dedicating manufacturing cells or focused factories to theproduction of product families may require more machines.)

•Total productive maintenance (will increase machine up time and improvequality, thus fewer machines will be needed.)

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Required machines

10

FACILITY AREAList of department in production area

11

Material flow

12

Production area layout

13

How to calculate Production area layout

Ex : Filing ink department

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According to 1-machine characteristics (1.9L x 0.9W) m2

2-standard of conveyor dimension from elcom company

(flat belt conveyor)(width from 20 to 1000 mm)

3-ingress & egress 0.762-1.0668 m for passage between operating machine from standard

4-distance between machines and the closer wall is three times distance between machines (from Reynolds company)

5-distance between machines and the farther wall 6 times

distance between machines (from Reynolds company)

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16

17

Parking area

18

Food service

19

Locker room

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Rest room

20

Health service

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MATERIAL HANDLING EQUIPMENTIn the departments

Transport equipment

Used for -transporting light and medium weight loads between

operations, departments and buildings-Provides considerable control over the orientation and

placement of the load

Four or more wheeled hand truck with handles for pushing or hitches for pulling.

Used in injection molding department there is component go to the filling ink department and other component to assembly department

Flat belt convoyer

Floor hand truck

deflector

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Positioning equipment

Lift/tilt/turn table

manual

Under ideal circumstances, maximum recommended weight for manual lifting to avoid back injuries is 51 lbs Recommendation based on NIOSH (National Institute for Occupational Safety and Health)

1991  

Used when positioning involves the lifting, tilting, or turning of a loadCan be used to reduce or limit a worker’s lifting and/or reaching motions .

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Unit Load Formation Equipment

cartons

pallets

Used to unitize and protect loose discrete items.Large quantities of finished carton blanks or knocked-down cartons can be stored on pallets until needed 

 

Platform with enough clearance beneath its top surface (or face) to enable the insertion of forks for subsequent lifting

purposes

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Storage Equipment

Sliding rack

Equipment used for holding or buffering materials over a period of time.

  

-High cube utilization and complete accessibility to all loads 

-Provide increase security for items compared to other racks

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identification and communication

equipment

Bar coding

-Reduction in error 

-Saving in time 

-Improving operation efficiency 

-Overall cost savings.

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Out of the departments

Fork lift

Forklifts are a type of machinery used primarily for moving heavy things. Since the invention of forklifts, workers are able to move materials easily to different locations. These machines help workers to increase their productivity and eliminate the strain on the body caused by lifting heavy objects

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Any questions ?

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