Plant Layout Assignment Requirements January 10, 1995 - DOC

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Plant Layout Assignment Requirements January 10, 1995 - DOC Powered By Docstoc
					                          Plant Layout Report Requirements, 2010
Assignment of Projects

Automated Manufacturing students in 3rd Year Project
     Design a manufacturing plant to create the 24,000 assemblies they are making for their
      third year project.

Divisions of teams for Robotics and Automation students in 3rd Year Project
     Since the R&A third year project is divided into 3 teams of 18 people
            o The industrial engineering (IENG3020) project will consists of teams of 6 people.
                Therefore there will be three teams for each third year project.
     Each IENG3020 project team is responsible to design a plant that makes approximately 1/3
        of the entire automated manufacturing cell.
     An example of the division of work for the plastic cup food processing line is as follows:
            o Team 1: Design a manufacturing plant to build 100,000:
                     Station#1: Heating & Forming
                     Station#2: Plastic cup filling
            o Team 2: Design a manufacturing plant to build 100,000:
                     Station#3: Sealing and Blanking
                     Station#4: Cutting Station
            o Team 3: Design a manufacturing plant to build 100,000:
                     Station#5: Folding and Gluing
                     Station#6: Final Packaging

Individual projects for all students which are not in the R&A or AM third year project
Design a manufacturing plant to create the 100,000 utility trailers. The assembly drawing, bill of
material and routing sheets are on the course website.

Components of Report

Executive Summary

Contains the following information:
 Description of what is being manufactured at this plant along with the quantity
 Summarize total square feet to accommodate footprints of all machinery
 Size of Manufacturing Plant (square feet)
 Size of office (square feet)
 Size of Site (acres)
 Number of employees
 Number of machines

Table of Content
List each Appendix

Appendix 1: Multilevel Indented Bill of Material: for AM & R&A Students in 3rd Year Project
    Multilevel Indented Bill of material for entire assembly. See example on pg 653 of
      Operations Management 6th ed. by Russell and Taylor


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Appendix 2: Product Structure Diagram: for all students
    Product Structure Diagram for entire assembly. See example on pg 652 of Operations
      Management 6th ed. by Russell and Taylor

Appendix 3: Drawings: for AM & R&A Students in 3rd Year Project
    Solidworks drawings of assemblies containing a bill of material.
          o Bill of material has drawing number, description, and quantity for each part in the
             assembly
          o If purchased parts are used, they must be identified description part of the bill of
             material with the follow phrase: (buy out)
    Solidworks drawing of each manufactured part that goes into the assemblies.
          o Raw material or casting used to manufacture each part must be stated on the
             drawing
          o Sufficient details must be provided on the drawings to completely manufacture the
             parts. This includes:
                  drill & tap information
                  chamfer and fillet details
                  specifying all machined surfaces
                  the manufacturing details provided on the drawings should match the steps
                     on the routing sheets.
    Wiring diagrams.

Appendix 4: Routing Sheets: for AM & R&A Students in 3rd Year Project
    Routing sheets for each:
          o Assembly - consistent with the assembly drawings.
                  Times for each activity will be estimated
          o Part - consistent with steps in manufacturing part drawings
                  Times for machine processes for AM students will be based on machining
                     times calculated for their third year project.
                  Times for machining process for R&A students will be estimated.
                  Times for manual labour process will be estimated for both AM and R&A
                     students.
          o Wiring consistent with wiring diagrams
                  Times for each activity will be estimated
    Template for routing sheets (see course website: Plant Layout Introduction: Example of
      Stool with Bill of Material, Product Structure, Routings, Operation Process Chart)
    Set-up time must be explained.
          o Is the process being done on a machine which does different parts in which case the
             setup time includes time to change to tooling required for each different part?
          o Or is the process being done on a machine dedicated
    Lot size must be explained.
          o Is the lot size based on the number of part that can fit in a bin. If bins are filled,
             describe the method of transporting to the next station.
          o If lot sizes are not used and parts continually flow from one station to the next,
             describe the method of transport (ie, conveyor belt or overhead rail).

Appendix 5: for AM in 3rd Year Project where operator attends to more than one machine
    Worker and Machine Process Charts:
          o These are required in situations where operators are attending to more than one
              machine. See Niebel’s Methods, Standards, and Work Design, 12th ed, pg 40 for
              further details.
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Appendix 6: Operation Process Chart: for all students
 See example in Niebel’s Methods, Standards, and Work Design, 12th ed, pgs 29-32

Appendix 7: Calculations of Number of Machines required: for all students
 Calculate the total machine time per piece per operation = (Process time per piece) + (fraction
   of setup time allocated to that piece)
 Note that fraction of setup time =(set up time per operation)/(batch size)
 Assume machines operate for 2 shifts (4000 hours per year)
 Assume a machine utilization of 85%.

Appendix 8: Calculations of Number of Direct Labourers required: for all students
 Use information from the number of machines to determine the # of direct labourers required.
   Note that number of machine calculations is based on 2 shifts, while people are needed for each
   shift.
 Note that for the routing sheets on the trailer project, where it states: Inspect 1/20, this means
   that every 20th part is being inspected. So the effective inspection time per piece is 1/20th of that
   stated on the routing sheet.

Appendix 9: Organizational Chart: for all students
 This will likely be a multi-page Organizational chart
 Identify all direct labourers along with people required to service the direct labourers, ie:
          o Maintenance
          o Material handing
          o Shipping/receiving
          o Janitorial
          o Supervisors
          o Sales
          o Accounting

Appendix 10: Machinery Details: for all students
 Identify source for machinery including name & address of selling company
 Obtain pricing for machinery.
 Explain any tooling that will need to be build or purchased to enable this machine to
   accomplish the required operations as identified in routing sheets.
 Summarized square feet to accommodate footprint for each machine detailed in Appendix 10
 Summarize total square feet for each type of machinery
 Summarize total square feet to accommodate footprints of all machinery

Appendix 11: Footprint Drawings for each type of piece of machinery: for all students
 Written description for each footprint drawing describing:
          o parts that will be built on this machine,
          o which operations will be performed on this machine
          o how raw material is delivered to this machine
          o is there temporary storage of finished parts before they are moved onto the next
             operation?
          o how are finished goods are move away from this machine
          o what are the tasks that the operator must perform.
 Footprint drawing will identify space for:
          o Operator
          o Raw material
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              o Finished goods
              o Machinery
              o Special access requirements for material handling

Appendix 12: Plant Layout SLP Analysis: for all students
 Describe the methods used for material handling for each different type of raw material, and for
   each manufactured component (ie: fork lift, conveyor belt, overhead crane, manually carrying)
 Include pathways for material flow
 Identify space for servicing machinery
 Summarize total square feet to accommodate footprints of all machinery
 Summarize total square feet for material handling and flow of human traffic
 Summarize total square feet for shipping & receiving, maintenance, tool rooms, etc.
 Steps 1 to 5 of SLP:
          o Chart the relationships
          o Establish Space Requirements
          o Diagram Activity Relationships
          o Draw Space Relationship Layouts
          o Evaluate Alternative Arrangements

Appendix 13: Plant Layout Drawing: for all students
 Detail the arrangement of machinery showing material handing access to machine
 Isles are at least 3 feet wide. Wider isles may be required for material handling (ie, forklifts) or
   for replacing machinery. These requirements need to be explained.
 Draw to scale in AutoCAD or SolidWorks
 Provide overall dimensions
 Drawings must have a suitable border and the drawings must be trimmed and folded correctly

Appendix 14: Office Layout SPL Analysis: for all students
 Steps 1 to 5 of SLP:
          o Chart The relationships
          o Establish Space Requirements
          o Diagram Activity Relationships
          o Draw Space Relationship Layouts
          o Evaluate Alternative Arrangements

Appendix 15: Office Layout Drawing: for all students
 Drawings must have a suitable border and the drawings must be trimmed and folded correctly

Appendix 16: Site Plan Drawing: for all students
 Describe the parking provided and truck access. Is this plant located site located in an urban
   area services by busses, or do workers need to drive to the plant?
 Drawings must have a suitable border and the drawings must be trimmed and folded correctly

Appendix 17: Construction Schedule: for all students
 Assume starting with a blank field on which the plant will be built (also called a green field)
 Provide a project schedule using a Gantt Chart format from site selection to full production. It
   should contain at least 40 separate activities (although the actual list would be a lot longer).
 B size plot of the Gantt chart is required.



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Appendix 18: Financial Analysis: only for students doing the trailer project

Use the following financial information:
            Prod Operator Wages                                      $15.00/Hr.
            Annual Interest Rate                                         9%
            Steel Cost $/pound                                          0.95
            Mark-up (Profit Factor) %                                  30%
            Scrap rate for parts                                       10%
            Tooling costs to be spread over                                5Years
            Machine utilization                                        85%
            Land Cost                                              $250,000per acre
            Building Construction Cost                                   $10Square foot
            Shipping costs to bring machinery to plant              $0.0003Per km-kg

   Calculate total cost for land and building
   Calculate the total cost for purchasing machinery, shipping it to the site (assume the site is at
    Conestoga College, Doon Campus). Example of shipping costs: Shipping 5000 kg for 2000 km
    will cost: 5000 *2000 * 0.0003 = $3,000
   Calculate installation costs:
            o Electrician Costs:
                     $200/machine for 120 volt machine
                     $1000/machine for 575 volt machine
            o Machinery mover to move machinery to final location within the plant
                     1$/kg
   Summarize total present worth: cost of land, building, purchasing machinery, shipping,
    electrical, and machinery movers.
   Use annual worth method to determine the effective annual cost of total present worth:
                                                    i(1  i) N 
            o AnnualWorth  Pr esentWorth *        (1  i) N  1 
                                                                   
                                                                  
                     i=0.09
                     N=5
   Calculate total direct manufacturing costs per trailer – including direct labour and direct
    material.
            o Costs of purchased parts are provided.
            o Costs of manufactured parts must be calculated using cost of steel $/pound to
                 purchase raw material and the number of pieces that fit on each piece of raw
                 material.
   Calculate the annual cost of direct labour use hourly rate of $15.00/hour, 40 hours per week,
    paid for 52 weeks per year (assumes 2 weeks paid holiday)
   Calculate non-direct labour costs per year (supervisors and support staff). Assume supervisors
    make 1.25 times the salary of their subordinates.
   Calculate utility and property taxes costs: assume utilities and taxes are $1/square foot per year.
   Calculate total annual cost = (Annual Worth) + (total direct manufacturing costs)+(annual
    direct labour and non-direct labour costs)+(utility and property tax costs).
   Calculate total cost per trailer = (total annual cost)/(number of trailers produced per year)
   Calculate selling price = (total cost per trailer)*(1+markup)




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