Design a manufacturing plant layout to manufacture a ROOM DIVIDER. For this, design production processes, systems, engineering works etc. to make such products and/or components thereof. Create a hypothetical market of the product/component and design systems and processes that can meet those market quantities.

During the first part of the solution, concentrate on theseinitial steps (1 3) of the facilities planning process, namely:

1. Define or redefine the objective of the facility.

2. Specify the primary and support activities that must be performed to accomplish the objective.

3. Determine the interrelationship among all activities.

4. Determine the space requirements for all activities.

The following can be compiled from the information you generate:

Facilities planning hierarchy for a manufacturing plant (Figure 1.2, page 8 of text, or as shown in calculation learner guide).

Design (draw) your product and design a layout plan to manufacture this product. This layout plan must be presented in a report format (Chapter 12 of text, sections 12.1 to 12.2, and pages 807 - 831).

Your product of choice must consist of at least 5 parts and must undergo at least 5 manufacturing stages. Assume standard times where necessary as well as demand etc.

The final layout plan must include as many as possible of the points stated below.

Presenting the facilities plan

A reasonably complete written report should include the following:

A clearly stated goal with reference to:

1. minimizing unit cost;

2. optimizing quality;

3. promoting effective use of people, equipment, space and energy;

4. providing for the employee convenience, safety and comfort;

5. controlling project cost;

6. achieving production start date;

7. minimising work-in-progress inventory.

Set a volume and a plant rate:

1. For example 300 units per 8 hour shift;

2. personal fatigue and delay allowances;

3. historical information available;

4. the calculated plant rate.

Drawings of the product:

1. blueprints;

2. an assembly drawing;

3. an exploded assembly drawing;

4. a parts list.

Management policies:

1. inventory policy for example a 30 day supply, JIT etc;

2. investment policy for example ROI;

3.start-up schedule date;

4.make or buy decisions;

5.organisational chart/organogram.

Process design:

1. a route sheet for each make part;

2. number of machines required;

3. assembly chart;

4. assembly time standards;

5. conveyor speeds;

6. sub-assembly line layout;

7. assembly and packing layout;

8. process charts;

9. flow diagrams;

10. flow process charts.

Activity relationships:

1. activity relationship diagram;

2. work sheets;

3. dimensionless block diagram;

4. flow analysis.

Workstation design:

1. machine layouts;

2. area determination;

3. paint layout;

4. aisles.

Auxiliary services:

1. receiving;

2. shipping;

3. stores;

4.warehouse;

5.maintenance.

Employee services:

1. parking lots;

2. employee entrances;

3. locker rooms;

4. toilets;

5. cafeteria;

6. medical services.

Office planning:

1. office layout;

2. organisational chart.

Area allocation:

1. total space requirements worksheet;

2. building size;

3. dimensionless block diagram;

4. area allocation diagram

Layout:

1.plot plan;

2.master plan.

Sources:

1.name all sources used to do project

2.show the date the information was made available by the source

Management questions (to be included in presentation):

1.name the possible questions management will ask from you and what your answers will be.

2.how will you answer your managers if they do not agree with your proposed layout. (tip work study text book chpt 18)