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					Cameron Building Expansion Plant Layout




             Submitted to:
          IE431 Senior Design
           Mark Lehto (CEO)
            (Cluster Leader)


 Cameron, Flow Control - Muskegon Plant
        Todd DeBruyne (Client)

           Purdue University
     School of Industrial Engineering
      West Lafayette, Indiana 47907



          Submitted by Team 9:

            Kathryn Gorman
            (Communication)

              Dipta Imanto
         Fransisica Vina Zerlina
        (Technical Contributions)

             Daniel Hansen
        (Innovation & Creativity)

              Sheng Zhong
          (Project Management)


                3/30/2011
Table of Contents
Project Update............................................................................................................................................... 3
Next Steps ..................................................................................................................................................... 4
Appendix A: Racks Requirement ................................................................................................................. 6
Appendix B: Gantt Chart .............................................................................................................................. 8




                                                                                                                                                                2
Project Update

       Since the submission of the project status report 1, the team has continued to work on the

new plant layouts for Cameron. Activities that have been accomplished are listed on the Gantt

chart. The team has met every week to brainstorm the departmental layout, and each team

member was assigned to a specific individual work.


       The team met for brainstorming sessions on the week of March 5th. These brainstorming

sessions produced drafts of the new assembly lines and the overall new plant layout based on

different products’ material flow. The drafts were useful to develop AutoCAD drawings, which

were started after spring break on the March 21st.

       The team has made appropriate adjustments to the Gantt chart in order to have a primary

focus on assembly lines redesign. Secondary tasks that were scheduled for the second phase of

the project, such as ergonomics, have been delayed to give more time and critical focus on the

redesign of the assembly lines and overall plant layout. According to the chart, it indicates the

constraints of assembly line on the February 28th. From these constraints, the team has

developed two versions of assembly line layouts.

       When designing the WG assembly line, the team takes into account that WG will need an

overhead crane and the preferred flow to be directly into shipping. For the other assembly lines,

the team has separated materials that need to be painted and materials that do not need to be

painted. Materials that do not need to be painted need a way to flow directly to shipping area to

minimize congestion in the painting booth and along the conveyor belt. For individual assembly

line design, the team noticed that some products have common components and pre-assembly

procedure, so proximity would be valuable. Additional stations have been added to the assembly

due to the request made by the client. The shipping area has been placed in close proximity to the

                                                                                                3
dock doors to avoid backtracking within departments. When developing the layout of the

department the team took into account the key relationships between departments.

       The team has also compiled a racks requirement document for shipping, receiving,

staging, and storage areas on March 23rd. Client provided feedback on the document on the

March 29th, which can be seen in Appendix A. The team used this feedback to make significant

changes to the layout that will help with flow and efficiency.



Next Steps

       The Gantt chart has outlined the following targets to be accomplished by the final

presentation. The team will finalize the assembly line layouts on April 4th. Shipping, receiving,

inspection and R&D department layouts will also be completed. After feedback is received from

Cameron, the team will make the appropriate changes to these layouts while having further

brainstorming sessions to create and implement better solutions.

       Following addressing any concerns Cameron has with the proposed layouts, and revising

layouts the team will then begin to analyze the material flow to the machine shop. The team will

then integrate the analysis to the layouts. Appropriate adjustments will be made if necessary to

accommodate a better products flow. After the second phase is done, a comparison analysis

between the first and second layout will be made. This comparison will include layouts’ cost and

efficiency analysis.

       The team will submit the results from the comparison analysis to Cameron. Even though

feedback from Cameron has been an ongoing activity, this feedback will be reflected on the final

presentation on April 26th.

       The team has encountered some technical obstacles due to unavailability of AutoCAD in

Purdue ITAP software remote. Because of this problem, the team must meet on campus to work
                                                                                               4
on the layout. This obstacle does not allow for the team to work on the layout as much as

possible. The layout given by Cameron also is not standardized throughout. Some objects are

defined the same but are very different and other critical objects left out of the layout. Also some

objects throughout the plant do not remain a consistent dimension. The team has managed to

adjust to these obstacles in order to provide Cameron with two layouts that focus on efficiency

and flow.




                                                                                                   5
   Appendix A:
Racks Requirement




                    6
7
Appendix B:
Gantt Chart




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