DESIGN PROJECT
DESIGN OF A MANUFACTURING PLANT
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.
Presenting the facilities plan A reasonably complete written report should include the following: aA 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. blucprints; 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. oProcess 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)
