CHAPTER ONE

BACK GROUND

1.1 Introduction

In industry sectors, it is important to manufacture the products which have good quality products
and meet customers demand. This action could be conducted under existing resources such as
employees, machines and other facilities .In this project the industry under consideration is
intended to produce dashboards for LIFAN MOTOR. The management of this production plant
has decided to construct new layout for the raw materials, for the production house, for the service
giving areas, for the administrative offices, and for the finished products. Therefore we are required
to design effective layout for this dashboard producing industry that helps to attain high
productivity in use of plant, equipment, labor, and materials. Since production efficiency needs to
be achieved so we have aimed to carry out the design for the plant as follow.

1.2 Problem statement

There are so many problems that come along when designing a layout. This will affect the
production process. Some of the problems are:

1. Unnecessary material handling equipment: unnecessary equipment are just waste. There has to
be material handling equipment which is necessary for internal transport in the industry in a proper
amount.

2. Arrangement of the machines is not organized: in a layout, the arrangement of the machines
may not be well organized, which means the process will take more time than it actually takes.
This will be just a waste of time.

3. Inefficient of space utilization: too much space or disorganized space can be a waste. And also
if the aisle space is not in a right dimension then the workers will not do the job at the right time.

4 .Excessive man power: if the number of workers required at a given time to do the work is more
than it is needed, then it is just a waste of cost.

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5. Poor working environment: unsafe place of employees, light conditions, ventilation,
temperature, noise are some of the examples that make up for bad environment.

6. The cost of waiting time: there is no continuity of Material Flow through the facility which
reduces productivity.

1.3 General objective

The overall objective of this project is to design a layout for dashboard factory by optimizing the
layout of a plant so that to improve productivity, safety and also to avoid unnecessary efforts of
materials handling.

 To design cost effective and efficient layout.

 To design flexible to meet variations in output and varieties.
 Less amount of materials in process and
 Easy to supervise and control

1.4 Specific objective

 To produce produce dashboard for LIFAN MOTOR

 To must be standardized and manufactured in large quantities in order to justify the product
layout.

 To minimize cubic space utilization

 To easily produce products and to give customer service

 Easy of martial flow

 To reducing and/or if possible avoiding backtracking

 To reducing handling cost, ordering cost other overheads.

 To effective utilization of material handling equipment’s

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 1.5 Methodology

In order to work out this project, we have planned to do in the following methods.

 Gathering basic data ( primary technical data) and information from other sources.
 Analyze the basic data
 Design the production process
 Plan the material flow pattern
 Consider the general material handling plan
 Calculate equipment requirements
 Plan individual work station
 Select the specific material handling equipment
 Coordinate group of related operations
 Design activity relationships
 Determine storage requirements
 Plan service and auxiliary activities
 Determine space requirements
 Allocate activity to total space
 Production type
 Construct master layout
 Obtaining approvals
 Install the layout
 Follow up on implementation of the lay out

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 Chapter two

Literature review

2.1 plant location

Means deciding a suitable location, area, place, etc. where the plant factory will start
functioning. Location of an industrial plant is an important management decision. Location
decision is based on the organization’s long term strategy such as technological, marketing,
resource availability and financial strategies. The objective of plant location decision-
making is to minimize the sum total costs affected by location.
The importance of a plant location are the following:
 Location influence plant layout facilities needed.
 Location influences capital investment and operating costs.
 Affects the efficiency , effectiveness, productivity and profitability of the plant

2.1.1 Location analysis

Locational analysis is a dynamic process where entrepreneur analyses and compares the
appropriateness of the otherwise of alternative sites with the aim of selecting the best site for a
given enterprise. It consists the following:

a) Demographic analysis: it involves study of population in the area in terms of total

population (in no.), age composition, per capita income, educational level, occupational
structure etc.
b) Trade area analysis: it is an analysis of the geographic area that provides continued
clientele to the firm. He would also see the feasibility of accessing the trade area from
alternative sites.
c) Competitive analysis: it helps to judge the nature, location, size and quality of
competition in a given trade area.
d) Traffic analysis: to have a rough idea about the number of potential customers passing by
the proposed site during the working hours of the shop, the traffic analysis aims at
judging the alternative sites in terms of pedestrian and vehicular traffic passing a site.

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 e) Site economics: alternative sites are evaluated in terms of establishment costs and
operational costs under this. Costs of establishment is basically cost incurred for
permanent physical facilities but operational costs are incurred for running business on
day to day basis, they are also called as running costs.

2.1.2 Selection criteria

The problem of the selection of a factory or a plant can be solved in the following two stages:

a) The General Location of the Plant

b) The Selection of a Particular site

A. The general location of the plant

 Availability of Raw Materials  Availability of Water

 Proximity to Markets  Availability of Capital
 Transport Facility  Social and Recreational
 Availability of Efficient and Facilities
Cheap Labor  Business and Commercial
 Availability of Power and Fuel Facilities
 Climatic and Atmospheric  Existence of related Industries
Conditions  Other factors …

B. Selection of a particular site

 Community Attitude
 Community Facilities
 Topography
 Transportation Facilities
 Waste Disposal
 Ecology and Pollution
 Size of Land

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  Supporting Industries

2.2 Plant layout

Means the disposition of the various facilities (equipment’s, materials, manpower, etc.) and
services of the plant within the area of the site selected. Once the site of the plant has been
decided, the next important problem before the management of the enterprise is to plan
suitable layout for the plant.
It is the act of planning an optimum arrangement of industrial facilities including:
Personnel
 Plant layout is defined
 Money
 Equipment
 Machines
 Storage space
 Material handling equipment
 Transport
 Tools
 fixtures
And all other supporting service along with the design of the best structure to contain these
facilities
It is the technique of locating different machines and plant or facility services within the
plant which is mostly intended to:
 with the lowest possible cost
 with short operating time
 With the customer requirement
Problems of lay out occur when:
 To reduce the cost
 To change the improved product design
 To start a new product
 When market demand changes

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 Accidents occur frequently
 The working environment is not comfortable
 When the plant building becomes obsolete
Lower total material handling the resulting problem involves:
 Rearranging a presently installed layout
 Making adjustments to existing lay out
 Developing a new layout
The aim of a good study of plant layout is:
 Ensure effective space utilization
 Minimize the cost of material handling
 Avoid un necessary capital investment
 Creating job satisfaction to workers
 Foresee future developments of the plant based on rational master plan

2.2.1 Types of layout

The following are basic types of layout
Product or line layout
Process or functional layout
Fixed position layout
Combined or group layout
Product or line layout
• In this type of layout, only one product or one type of product is produced in a given area.
• The product must be standardized and manufactured in large quantities in order to justify
the product layout.
The raw material moves very fast from one workstation to other stations with a minimum
work in progress storage and material handling.
The grouping of machines should be done keeping in mind the following general principles:
a) All the machine tools or other items of equipment’s must be placed at the point
demanded by the sequence of operations
b) There should no points where one line crossed another line.

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 c) Materials may be fed where they are required for assembly but not necessarily at one
point.
d) All the operations including assembly, testing, packing must be included in the line

Product layout is chosen when:

 One or few products are to be produced

 Large volume of product of each item over considerable time is required

 Minimum of inspection is required

 One machine is always used for single purpose

Limitations:

 High initial investment I special purpose machine

 Heavy overhead changes

 Break down of one machine will affect the overall production system

 Lesser flexibility as specially laid out for particular product

Process or Functional Layout

• Similar equipment and similar operations are grouped together in the process or
functional layout.
• It is particularly useful where low volume is required.
The grouping of machines according to the process has to be done keeping in mind the
following principles
• The distance between departments should be as short as possible for avoiding long
distance movement of materials

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• The departments should be in sequence of operations
• The arrangement should be convenient for inspection and supervision

Merits of process layout:

 Lower duplication of equipment, hence lower investment cost
 Greater flexibility of production
 Easier to handle break downs of equipment by transferring work to another machine
 Better control of complicated or precision process
Process layout is chosen when:
 One machine is used for different operation
 Materials or products become too large or heavy to permit continuous flow
 Many types of products on special order
 Many inspection are required during a sequence operation

Fixed layout
 The material or major components remain in a fixed location and tools, machinery
,men as well as other pieces of material are brought to a fixed space
Examples:
 Ship building
 Construction industries
 Air craft building

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  Bench work exercise

This type of layout is not frequently used in industrial enterprises. For this reason we are not
going to look its merit and demerit
Combination Layout
• Certain manufacturing units may require all three processes namely intermittent process
(job shops), the continuous process (mass production shops) and the representative
process combined process [i.e. miscellaneous shops].
• Combination of the product and process layout or other combination are found, in
practice, e.g. for industries involving the fabrication of parts and assembly, fabrication
tends to employ the process layout, while the assembly areas often employ the product
layout.
2.2.2 Major considerations for layout
The basic decision that management must take for effective plant design might be
summarized below
1 Sales planning for requirement: one of the most critical information required for
effective layout is the volume of production layout
2 Acquisition of capital: the capital needs of an industrial concern may fall in to;
 Obtaining capital for the initial establishment
 Raising funds necessary to cover operating costs
The primary source of capital can be obtained from personnel savings
Product design: involves both the determination of which products are to be produced and
the detailed design of the individual products.
The manufacturing process to be utilized is determined by:
 The nature
 The volume
 The quality of the product to be produced
Good product design has three aspects:
i. Design for function
ii. Design for manufacturing
iii. Design for selling

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3. Determination of the product process: refers to a specialized branch of engineering
devoted primarily to planning the process of economic manufacture
4. Make or buy decision: is concerned with making a component with in the factory or
buying it from external supplier buying a component does not require any activity rather
making with in the factory require different activities. The first step in make or buy decision
is the determination of unit cost.
In such decision management is interested in:
Improving the product
Minimizing cash investment
Reducing unit material
Reducing processing costs
5. Plant size the size of the plant is dependent up on the volume of output proposed for it
6. Product price range
The choice competent price range will affect:
 The quality
 The quantity
 The manufacturing process of the product
7. Plant location: is defined as deciding a suitable location, area, and place etc. where the
plant will start its service giving. Is mainly concerned with selecting a region as well as a
specific site with in that region.
8. Consider building type: selecting the type of building is the major aspect of plant design
as it affects the factory. It can be selected during or before the plant layout phase.
9. Diversification: deals with entering of a new field
10. Organization development: The arrangement of plant facility is affected by
 The manner in which the overall objectives are clearly defined
 The objectives of various subdivisions.
A reason to build a new plant arises when the following cases are arise:
 Organizational changes
 A change in the design of product
 A change in the design of process
 Replacement of one or more pieces of equipment

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  Adoption of new safety standards
 Location of departments
 Materials size shape, weight and variety
 Factory building
 Location of the factory
 Community attitudes
 Provision for future expansion

2.3 PRODUCTION PROCCES

2.3.1 Material Flow

Production efficiency of a plant depends upon the swift and the smooth flow of material
and people throughout the plant. Material is required to be moved from the beginning
(i.e. from receiving) to the end (shipping) over the most efficient path. It is therefore
essential to plan the flow pattern for overall efficiency. Although material flow also takes
place prior to receiving from source of supply to the plant, and after the shipping i.e.
distribution and service to the customers, and needs to be controlled for timely supply
and deliveries Inside the plant we are concentrated with material flow from receiving to
the shipping. Some of the advantages of planned material flow pattern are:

 Better utilization of floor space, man power and equipment

 Reduced processing time, chance of accidents and material movements
 Simplified production control
 Minimized back tracking

So planned material flow results in effective arrangement of facilities, efficient

operations, minimum cost of production thus brings better profitability and success of the
enterprise.

2.3.2 Flow pattern

These refer to the systems which involve the movement of raw materials from the beginning
up to the end of manufacturing. The flow pattern system can be classified into horizontal and

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vertical. For our layout design we have chosen horizontal flow pattern in which there are five
basic flow lines. These are;
(1) I – Flow or Line Flow. In this type flow materials are fed at one end and components
leave the line at the other side. It is economical in space and convenient in I-shaped
buildings and also it is the simplest form of all.
(2) L – Flow. It is similar to the I-Flow and is used where I-line cannot be accommodated in
the available space.
(3) U – Flow. This type of flow allows both receiving and dispatching of goods to be done at
one side. Compared to other it is easier for supervision.
(4) S – Flow. For a production system involving long line zigzagging on the plant floor is
necessary and S-Flow provides efficient utilization of space and it allows effective
supervision.
(5) O – Flow. This type is used where process or operations are performed on a rotary table
or a rotary handling system. The components are moved from one working station to the
other.

Flow diagram of material

This refers to the systems which involve the movement of raw materials from the beginning
up to the end of manufacturing.
Loading raw material into drying
silos

Drying

Loading the raw materials into the press

hopper

Plasticization

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 Injection

Cooling

Discharge

Sub
assembly

Final
assembly

2.4 STORAGE SYSTEM

Ware housing
 Is defined as the holding of goods until they are required.
 It consists: -receiving
-storing
-picking and
-shipping the goods
 The specific methodologies used are naturally dependent on the unique environment in
which the warehouse operates. All ware houses have three resources. It is space, equipment
and people.
 The space requirement depends on the type of material to be received and shipped.
 Quantification of the storage space requirement is its critical element.
 The steps to properly define storage requirement includes; the material to be stored, proper
storage philosophy and space for other alternative methods.

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  Heavy items are kept on the floor and are moved using overhead travelling cranes. Shelves
are used for medium sizes. Also medium and small sizes are kept in containers having piles
with rows and columns.
 There are three basic storage philosophies; -1. Random selection
2. Assigned location
3. Combination location
 The following check may be used to design warehouse. It is the popularity, similarity, size
and characteristics of the materials.

2.5 Transportation
 Transportation is the movement of materials into and out of the production area.
 Can be external or internal transportation:
External transportation
 Occurs outside of the production facility area.
 Includes raw material transportation from suppliers to the production area.
 And delivering the finished goods to customers.
 This can be done using: trucks, air, ship and rail.
Internal transportation
 Also known as material handling.
 Involves the movement and storage of materials inside a given production area.

2.5.1 Material handling

Material handling equipment is all equipment that relates to the movement, storage, control and
protection of materials, goods and products throughout the process of manufacturing,
distribution, consumption and disposal. Material handling equipment is the mechanical
equipment involved in the complete system. Material handling equipment is generally separated
into four main categories: storage and handling equipment, engineered systems, industrial trucks,
and bulk material handling.

Materials handling is concerned with the following:

a) Movement: - Materials handling involves movement of materials mechanically or

manually in

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Batch or one by one within the plant. Movement of materials may be Horizontal, Vertical or

Combination of both.

b) Time: - Materials must arrive at its place at the right time. Materials handling must
ensure that no

Production process or customer (internal as well as external) need is hampered due to late or

Early arrival of material at each location.

c) Space: - Space requirements are influenced by the materials handling flow pattern.
Space is

Required for storage of raw materials, parts and semi-finished or finished products.

In any industry material handling is of the following three (3) types.

 handling of individual part of unit by men

 handling in room, department, or plant
 Handling of materials during entire process of production and distribution, starting from
raw

Material source, going through the factory and distributing network to the ultimate customer

And beyond, to waste disposal and recycling.

2.5.2 Material transporting equipment

 The movement can be from suppliers, within the manufacturing and distribution facility,
and distribution of finished goods to customers. The distance can be short or long.
Depending on the distance the necessary material handling equipment are used. The
material equipment needed in the plant design are:

Industrial tracks: forklift is used to move raw materials from outside to the storage department
then from storage department to the manufacturing.

 And raw materials and spare parts from external suppliers. Forklifts move and
handle containers of cartons, boxes, crates, bags, etc.

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Hand PALLET JACK:

Operational principle

The jack is steered by a 'tiller' like lever that also acts as the pump handle for raising the jack. A
small handle on the tiller releases the hydraulic fluid, causing the forks to lower. The front
wheels inside the end of the forks are mounted on levers attached to linkages that go to levers
attached to the jack cylinder. As the hydraulic jack at the 'tiller' end is raised, the links force the
wheels down, raising the forks vertically above the front wheels, raising the load upward until it
clears the floor. The pallet is only lifted enough to clear the floor for subsequent travel.
Oftentimes, pallet jacks are used to move and organize pallets inside a trailer, especially when
there is no forklift truck access or availability.

Type of pallet jack:

Manual pallet jack

A manual pallet jack is a hand-powered jack, most commonly seen in retail and personal
warehousing operations.

Powered pallet jack

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An electric pallet jack. The recharging lead can be seen.

Powered pallet jacks, [4] also known as electric pallet trucks, walkies, single or double pallet
jacks, or power jack, are motorized to allow lifting and moving of heavier and stacked pallets.
Some contain a platform for the user to stand while moving pallets. The powered pallet jack is
generally moved by a throttle on the handle to move forward or in reverse and steered by
swinging the handle in the intended direction. Some contain a type of dead man's switch rather
than a brake to stop the machine should the user need to stop quickly or leave the machine while
it is in use. Others use a system known as "plugging" where in the driver turns the throttle from
forward to reverse (or vice versa) to slow and stop the machine, as the dead man's switch is used
in emergencies only.

Typical dimension

The North American industry seems to have 'standardized' pallet jacks in several ways:

 Width of each of two Forks: 7"

 Fork Width, i.e. The dimension between the outer edges of the forks: Available as 20¼"
(51.4 cm) and 27" (68.6 cm)[5]

 Fork Length: Available as 36" (91.4 cm), 42" (106.7 cm), 48" (122 cm)[5]

 Lowered Height: 2.9" (7.5 cm)[5]

 Raised Height: At least 7.5" (19.1),[5] but some will raise higher

In Eurasia the overall dimensions are similar, as modern container palletisation has forced
standardization in the dimensional domain globally.

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 2.6 Pallets

A pallet is a flat transport structure that supports goods in stable Fashion while being lifted by
any material handling device. A pallet is the structural Foundation of a unit load which allows
handling and storage efficiencies.

Most pallets are wooden, while others are made of a plastic, metal, and paper. Each
material has advantages and disadvantages relative to the others. All pallets fall into two very
broad categories: “stringer” and “block” pallets.

1. Stringer pallet: stringer pallets use a frame of three parallel pieces of timber (called
stringer). The top deck boards are then fixed to the stringers to create the pallet structure.
Stringer pallets are also known as “two-way” pallets, since a pallet-jack may only lift it
from two directions instead of four.

2. Block pallet—block pallets are typically stronger than stringer pallets. Block pallets
utilize both parallel and perpendicular stringers to better facilitate efficient handling. A
block pallet is also known as a “four-way” pallet, since a pallet-jack may be used from
any side to move it.

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We can make wooden pallets to any size, the standard sizes are listed below:

 0,8m X 1,2m

 1,0m X 1,0m

 1,0m X 1,2m

 1,2m X 1,2m

3. Perimeter base pallet

All stringer and some block pallets have "unidirectional bases," i.e. bottom boards oriented in
one direction. While automated handling equipment can be designed for this, often it can operate
faster and more effectively if the bottom edges of a pallet have bottom boards oriented in both
directions. For example, it may not need to turn a pallet to rack it, and operation is less sensitive
to pallet orientation.

2.7 Dock system

Dock is place in a factory or facilities were trucks are loaded and unloaded. They are commonly
found on commercial and industrial building and warehouse in particular.

Loading docks may be exterior flash with the facility envelope or fully enclosed. They are part of
facility’s service or utility infrastructure typically providing direct access to staging areas,
storage rooms and freight elevators.

The designer’s first goal is to get the trucks off the highway safely. The first step is determining
where the facility and docks should be positioned on the building site and designing safe access
roads to the dock area.

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 2.8 Supporting services

Plant services such as medical, food services and environmental comfortableness while working
in the production area such as air conditioners, hot and cold water are basics to one plant layout.

Medical services

• A productive worker must be kept in good health.

• Industrial medical services may be provided in the following situation:

– Physical examination for job applicants and periodic check-up examination.

– Emergency first-aid for minor injury or illness.

– Professional medical services for major injury or illness.

– Control of occupation diseases.

– In general it can be anticipated that 3 to 6% of the total plant force will be treated daily
by the medical facility in an eight hour day.

– First aid facilities should be provided throughout a large plant to take care of very minor
injuries scratches and abrasions and should be located within 200 to 300 feet's (61 to
91m) of all employees.

– The nature and time of occurrence and the treatment for every accident should be noted
on permanent record, which can be passed over to the company’s doctor and personnel
department.

Food services

• The company must provide or outsource the service.

• Tea and lunch time is a time not only for nourishment but also for recreation.

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 • The location of food services should be such that it is convenient to all the employees of
the plant.

• It is important that the location be centralized, all employees will be able to reach the
lunchroom, eat their meals and return to their work places without having to rush.

• Factors to be considered in determining the type and size of cafeteria suitable for a given
plant are:

1. Proximity to outside lunchrooms and restaurants

2. Number of workers in each shift

3. Number of meals to be prepared

4. Length of lunch periods

5. Plant are available for catering use

6. Distribution of employees throughout the plant

2.9 Plant services

The factory to day requires a wide variety of plant services. These may include electricity,
sewerage, compressed air, and steam, a variety of industrial gases, heating, ventilation, and
air conditioning, hot and cold water. The layout man planning the arrangement of a plant
will become involved with providing facilities for plant services in some organizational
structures he/she may even be responsible for fairly technical work in planning adequate
plant services. Plant services require constant maintenance where high initial cost services
have low cost maintenance, while the opposite is true for plant service installations
involving low initial investment.

Some of the important activities are:

• Receiving, storage/warehousing and shipping

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 • Tool crib

• Inspection

• Maintenance

• Employees facilities

• Administrative or offices

• Factory services or utilities, etc.

Employee facilities

• Organizational successes

– efficient management, better planning, good market, efficient personnel, etc.,

– The most important factors is the morale of the workers and their productivity.

• Comfort, convenience and safety of the employee must be under consideration.

• Facilities should be planned based on employment procedure being used and the volume
of employment.

• The employment procedure usually consists of certain sets such as filling of an

application form, interview with the officer, physical and/or written tests, medical
examination before employment, assignment of the employee to job, training or
orientation to the work, counseling the employee regarding his/her work, etc.

Personnel employment

• Should be located such that it be accessible for the main road, so that applicant can enter
it without having to be processed through the protective systems, and reasonable
accessible to the medical center for convenience in securing medical examination.

Lockers and washrooms and toilets

• The personal facility most frequently used by the employees.

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 • Well lighted and well ventilated so that the workers will not experience unpleasant
sensation in them.

• Factory acts of all states provide for a minimum number of facilities, depending upon the
number upon the workers.

• These facility can be placed in populated work centers but should be located to avoid
disturbing the layout of production facilities.

• It’s advisable to locate locker room, washroom and toilet in each division of the plant
rather than to provide one or two main facilities.

• It’s desirable to locate these facilities within 200feet (61

meters) of all workers.

• If the work is particularly dirty, the workers will require more time to wash or they will
need to take a shower before leaving, for safety and health reasons, the required facility
should be increased from 20 to 50 percent.

• Workers clothes quickly become soaked with perspiration and locker rooms soon become
filled with very objectionable odor, should be well ventilated.

Provisions of Factory Act

• Ventilation and Temperature

– Effective and suitable provisions shall be made

– Walls and roofs should be of such materials and so designed that temperature shall not be
exceeded but kept as low as practicable.

• Artificial humidification

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 • Overcrowding – 14.2m3 must be provided for every worker.

• Lighting

– Sufficient and suitable lighting where natural or artificial or both shall be maintained.

– All glazed windows and skylight shall be clean.

– Glare and formation of shadow should be prevented.

• Drinking water

– Drinking water should be made available to all workers at all working hours and
maintained at suitable points.

“DRINKING WATER”

• Precautions against fire

– Every factory shall be provided with means of escape,

– Doors affording exist from any room shall not be locked or fastened,

– Every window, door or other exit affording means of escape,

– Effective way of giving warning ,

– Free passage way giving access to escape shall be maintained in case of fire.

Space planning

• For a proper layout, it is necessary to analyze space available, required, or to be allocated

to each activity or function of the enterprise.

• For this, first task is to identify the production, service and auxiliary activities necessary
for the enterprise.

• Production activities are necessary for every enterprise but vary with the type of industry,
however a number of supporting services are also required in each enterprise but in
varying degree of importance.

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Activity centers

1. Production 2. Administration

 Production control  General manager

 Industrial engineering  Sales and marketing

 Quality control  Finance and accounting

 Maintenance  Purchasing

 Receiving, storage  Personnel management

 Warehousing, shipping  Reception, conference room,

data processing etc.
 Tool room
 Library, time keeping
 Tool crib

 Scrap and waste disposal

3. Welfare 4. Colony

 Medical  Residences

 Guest house  Parks, landscaping etc.

 Lavatory  Rest rooms, community halls

 Recreation  Shopping complex

 Parking  Power generation

 Fire fighting  Communication

 Canteen  Education facilities

Main activities which needs considerable part of the space are

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  Offices  Parking

 Receiving  Recreation facilities

 Storage  Maintenance

 Production  Warehousing

 Tool room, tool cribs  shipping

 Medical services

1. Offices

Offices for the purpose of plant layout means administrative and personnel services, and includes
work-space and space required for other amenities.

Space for these are determined by a detailed analysis. The office space includes:

 Work-place  Storage  Air Conditioning,

shafts, electric room,
 Reception area  Canteen
etc.
 Conference area  Dispensary
 Lawn and other
 Time keeping  Security landscaping

 Lavatories  Communication

 Record room  Passages, stairs, lifts

etc.
 EDP room
 Parking and
 Internal services
transportation
facilities

27
 • Offices in a small industry are generally made in the front, while in large industries a
separate administrative block is preferred.

• Exact area for office is calculated considering all relevant factors for each aspect
mentioned above. However, as a thumb rule it is near 20sq. m per person. This includes
area for work space and for amenities etc.

• While carrying out detailed analysis, area requirement of each activity should be
considered.

• While planning the layout, electric needs, direction of natural light, spacing between rows
of desks and chairs, size of rooms of senior executives in relation to their status, width of
aisles should be considered

2. Receiving and Storage

a. Receiving

Receiving is concerned with the receipt of materials and includes following activities:

 Unloading material from transport carriers.

 Unpacking the containers.

 Sort out the material after identifying them.

 Checking the material from packing slips.

 Enter into the receipt records and note the shortages and damages.

 Arranging inspection of material and note defects etc.

 Maintain records and handover the acceptable material to storage.

Therefore, receiving must include space for:

 Unloading space, ramps, parking for carriers etc.

 Temporary but orderly storage of material awaiting inspection

 Storage, handling and work areas for inspection

28
  Storage for inspected items delivery to stores

b. Storage

Storage space is required for the following activities

a. Safe keeping of raw material and purchased parts till they are issued for
production.

b. Storage of non-productive items i.e. supplies etc.

c. Storage of in-process materials

d. Storage of salvage material, part of products for reprocessing.

e. Storage of scrap or wastages etc.

f. Storage of miscellaneous items like equipment, tools etc. which are required at a
later date

2.10 EXPANTION AREA

Growth of the plan should be properly planned otherwise expansion will not be an orderly growth.

 The firms whose future expansion is well planned. will better organized and will grow
faster and will enjoy lower operating costs
 An important rule of thumb concerning the future expansion is to expand the ware house
without disrupting the dock operation. That is shipping and receiving operation.
Note: the future area (expansion) is most of the time allocated with green.

29
 CHAPTER THREE

PLANT DESIGN

3.1 MACHINE CALCULATION (NUMBER OF MACHINE REQUIRED)

Technical data table

Injection Holding Operation Time standard Set up time hour [min]

[pressing per hour]
Body 25 7.5 [450]
Exterior cover 25 7.5 [450]
Glove compartment 65 1 [60]
Glove compartment bracket 180 1 [60]
Vent frame 250 1 [60]
Fin 250 1 [60]
Shutter And control wheel 350 1 [60]
Instrument frames 100 1 [60]
Assembly operation Time standard Set up time hour [min]
[items per hour]
Air vent assembly 50 -
Body and exterior cover 25 -
assembly
Sub assembly, glove 60 -
compartment,glove
compartment bracket
assembly
Final assembly 20 -

Production Pcs per day-------1500

30
Efficiency-------------------------90%

Machine capacity= working hour*time standard

# of machine=production Pcs per day/machine capacity * 90%.

3.1.1 Injection molding operation

So using the above to calculate the machine capacity and # of machine.

1. Body

Machine capacity= working hour*time standard

7.5*2*25375

# number machine required = production Pcs per day/machine capacity * 90%.

= 1500/(375 * (90/100))

=4.4445

# Number of machine required is [5].

2. Exterior cover

Machine capacity= working hour*time standard

=7.5*2*25375

# Number of machine required=1500/(375*0.9)

=4.445

# Number of machine required is [5].

3. Glove compartment

Machine capacity= working hour*time standard

7.5*2*65=975

# Number of machine required=1500/(975*0.9)

31
 =1.72

# Number of machine required is [2].

4. Glove compartment braket

Machine capacity=15*1802700
# Number of machine required=1500/(2700*0.9)
=0.61
5. Vent frame

Machine capacity=15*2503750

# Number of machine required=1500/(3750*0.9)

=0.41

# Number machine required is [1].

6. Fin

Machine capacity=15*2503750

# Number of machine required=[1] same as vent frame.

7. Shutter and control wheel

Machine capacity=15*3505250
# Number of machine required=1500/(5250*0.9)
=0.321
# Number of machine=[1].
8. Instrument frames

Machine capacity=15*1001500

# Number of machine required =1500/(1500*0.9)

=1.11

# Number of machine =[1]

3.1.2 Assembly operation

32
In the assembly operation we are going to change the machine capacity to station capacity.

1. Air vent assembly

Station capacity=15*50750
# number of station required=1500/(750)
=2
# Number of station = [2]
2. Body and exterior cover assembly
Station capacity=15*25375
# Number of station required=1500/(375)
[4]
# Number of station is [4].
3. Sub assembly, glove compartment, glove compartment bracket assembly
Station capacity=15*60900
# number of station capacity=1500/(900)
=1.6  [2]
# Number of station is [2].
4. Final assembly
Station capacity=15*20300
# Number of station=1500/300
[5]
# Number of station is [5].

Finally to the above calculations values are listed below with table.

Injection Holding Operation A Machine Capacity Total Required

Body 7.5*25*2=375 5

33
Exterior cover 7.5*2*25=375 5
Glove compartment 15*65=975 2
Glove compartment bracket 15*180=2700 1
Vent frame 15*250=3750 1
Fin 15*250=3750 1
Shutter And control wheel 15*350=5250 1
Instrument frames 15*100=1500 1
Assembly operation Station capacity Total Required
Air vent assembly 15*50=750 2
Body and exterior cover 15*25=375 4
assembly
Sub assembly, glove 15*60=900 2
compartment,glove
compartment bracket assembly
Final assembly 15*20=300 5

34
 3.2 MATERIAL REQUIRMENT AND CALCULATION

3.2.1 Raw material requirement analysis

Because of the production rate (amount of products) of the components are the same but the raw
material requirement for each components is different. Let’s determine the material requirement
for the different components.

1. BODY

Given data

 Rate of production = 100 Psc/hr

 Rate of production =1500Psc/day
 Working hour = 15 hr/d
 Body gross weight =2.75 Kg
 Body net weight = 2.5kg
 Each Octabin packaging contains = 1000 Kg
 Volume of the octabin = 1*1.2*1.5=1.8m3
 Raw material type=(HD PP)

Calculation:

Number of body pieces that can out from 1000kg

Let’s take the gross weight =2.75kg

(1pis*1000kg)/2.75 kg

=363.64 364pic

To calculate the amount (Kg) of raw material for one day production is

(1000 kg*1500pic/d)/364pis

35
 =4120.884121kg/day

Therefore one octabin contain 1000kg so we need (5 octabin/day) for one day production.

2. Exterior cover

The difference between the above given data is.

 Acrylonitrile butadiene styrene (ABS).

 Gross weight =1.87kg
 Net weight =1.7kg

Calculation:

Number of pices that can be produced from 1000kg

Lets take the gross weight 1.87kg

(1pic*1000kg)/1.87kg

=534.75535pic

The amount (Kg) of raw material for one day production.

(1500pic/day*1000kg)/535pic

2803.74kg/day

To calculate the number of octabin for one day production

(1 octabin*2803.74kg/day)/1000kg

=2.8 (3 octabin/day).

3. Glove compartment

The glove compartment has the same type of raw material to the exterior cover.

 Gross weight =0.265kg

36
  Net weight =0.252kg

Calculation: lets take the gross weight =0.265kg

The number of pieces that can be produced from 1000kg

(1pic*1000kg)/0.265kg

=3773.583774pic

the amount (Kg) of raw material for one day production

(1500pic/day*1000kg)/3774pic

397.46kg/day

the amount of octabin for one day production

(1octabin*397.46kg/day)/1000kg

=0.51/2 octabin/day

4. Glove compartment bracket

 The raw material is polyamide (PA)
 Gross weight=0.026kg
 Net weight =0.025kg

The rest of the given data is the same.

Calculation: lets take the gross weight=0.026kg

The number of pieces that can produced from 1000kg

(1pic*1000kg)/0.026kg

=38461.5438461pic

The amount (Kg) of raw material for one day production

(1500pic/day*1000kg)/38461pic

39kg/day

37
the amount of octabin for one day production

(1octabin*39kg/day)/1000kg

0.039octabin/day

5. Vent frame (central, side, right and left)

 Raw material (PA)
 Gross weight =0.051kg
 Net weight =0.05kg

Calculation: let’s take the gross weight=0.051kg

Number of pieces that can produced from 1000kg

(1pic*1000kg)/0.051kg

=19607.819608pic

The amount (Kg) of raw material for one day production

(1500pic/day*1000kg)/19608pic

76.5kg/day

the amount of octabin for one day production

(1octabin*76.5kg/day)/1000kg

0.0765octabin/day

6. Fin (central, side, right and left)

 Raw material type (PA)
 Gross weight= 0.0102kg
 Net weight=0.01kg

Calculation: lets take the gross weight=0.0102kg

Number of pieces that can be produced from 1000kg

(1pic*1000kg)/0.0102kg

38
 98039pic

the amount (Kg) of raw material for one day production

(1500pic/day*1000kg)/98039pic

15.3kg/day

The amount of octabin for one day production

(1octabin*15.3kg/day)/1000kg

0.0153octabin/day

7. Shutter (central, side, right and left)

 Raw material type (PA)
 Gross weight=0.0255kg
 Net weight=0.025kg

Calculation: lets take the gross weight=0.0255kg

Number of pieces that can produced from 1000kg

(1pic*1000kg)/0.0255kg

39216pic

The amount (kg) of raw material for one day production

(1500pic/day*1000kg)/39216pic

38.25kg/day

amount of octabin for one day production

(1octabin*38.25kg/day)/1000kg

0.03825octabin/day

8. Control wheel (right and left)

The control wheel has the same type of raw material and weight to the shutter

39
So the calculation is the same

 39216pic
 38.25kg/day
 0.03825octabin/day
9. Instrument frames (display, Radio and navigator)

The insturement frames has the same type of raw material with the exterior cover and glove
compartment.

 Gross weight=0.082kg
 Net weight=0.08kg

Calculation: lets take the gross weight=0.082kg

Number of pieces that can produced from 1000kg

(1pic*1000kg)/0.082kg

12195pic

The amount (Kg) of raw material for one day production

(1500pic/day*1000kg)/12195pic

123kg/day

The amount of octabin for one day production

(1octabin*123kg/day)/1000kg

0.123octabin/day

3.2.2 Raw material warehousing design

To design the raw material warehousing, it should be known the type of material, dimension and
amount of the material to be stored. As it is given, the raw material is different for each parts those
are for body (HD PP), exterior cover, glove compartment, and instrument frames have (ABS) and
glove compartment bracket, vent frame, fin, shutter and control wheel have (PA). The raw material
requirement for daily production of the four components was determined in the raw material

40
requirement calculation. Therefore, the total amount of raw material for each component can be
determined by considering the stock (days).

Given data for all components is

 Production 1500 pieces/day

 Raw material stock 17 days
 Finished product stock 8 days

1. Body
 Number of for daily production was determined to be 5 octabin box which contains
1000kg of (HD PP).
 Number of octabin that shoud be put as inventory in the raw material warehousing will
be.
(5octabin/day*17days)
85octabin or 85000kg of HD PP put as an inventory rawmaterial.
 It is given that the raw material is put is a octagonal-shaped box (octabin)
 Dimension of the octabin is given 1*1.2*1.5(high) m.
2. Exterior cover, glove compartment and instrument frames.

The three components has the same type of raw materials which is Acrylonitrile-butadiene-styrene
(ABS). Therefore we sum up the daily need

 Exterior cover (3octabin/day) + glove compartment (0.5octabin/day) + instrument frame

(0.123octabin/day)

=3.6 4 octabin/day.

 There for daily production was required 4 octabin box which contains 1000kg of (ABS).
 Number of octabin that should be put as inventory in the raw material warehouse will be

(4octabin/day*17 day)

68 octabins or 68000kg of (ABS)

41
  The dimension is the same for all.
3. Glove compartment bracket, vent frame, fin, shutter and control wheel.

The five componenets has the same type of raw material which is Polyamid (PA). therefor we
sum up the daily need.

 Glove compartment bracket(0.039octabin/day) + vent frame(0.0765octabin/day) +

fin(0.0153octabin/day) + shutter(0.03825octabin/day) + control
wheel(0.03825octabin/day)

0.2079octabin/day or 207.3 kg/day

 There for daily production was required 0.2079octabin box which contains 1000kg of (PA)
 Number of octabin that should be put as inventory in the raw material warehouse will be
(0.2079*17)
=3.54octabin or 3524.1 kg of (PA).

3.2.3 Finished products warehousing design

 Finished product stock 8 days.
 Number of product pieces per day is 1500pic/day
 Form the given data the sum of production scrap rate is 9.03%.
 The finished dashboard is placed with large metal bin with maximum number of complete
dashboards of [4] per large metal bin.

Calculation: (1500pic/day-(9.03/100))

1499.9pic/day

 Number of finish product that should be put as inventory in the finish material
warehousing will be.
(1499.9pic/day*8day)
1199.9pic
 The dimension for the large metal bin is 1.5*0.8*1.28(high) m.
 # Number of large metal bins for the finished dashboard is

42
 (1199.9pic/day/4 max)

=299.9300 large metal bins for the dashboard.

3.2.4 Number of pallets and unit loads needed

We need pallets mainly in the raw material warehouse there for each octabin contain 1000kg so
its placed in the pallet for each octabin we need pallet.

 Based on the inventory capacity of the warehouse

 For body we have 85octabin
 For exterior cover, glove compartment, and instrument frames we have
68octabin
 For Glove compartment bracket, vent frame, fin, shutter and control wheel
we have 4 octabin.

Therefore for each octabin we need a pallet adding the number of octabin is going to give as the
Number of pallets in the raw material warehouse.

# Number of pallets= 85+68+4

157 pallets

3.2.5 Unit load

Large metal bin for (body, exterior cover, sub-assembly 1 & 2, complete dashboards)

Large metal bin specifications:

 Max number of bodies a bin can carry 6

 Max number of exterior cover a bin can carry 6
 Max number of sub-assembly 1 a bin can carry 4
 Max number of sub-assembly 2 a bin can carry 6
 Max number of finished dashboard a bin can carry 4
Calculation:

43
 Number of large metal bin for body, exterior cover and sub-assembly 2.
1bin==6pics
X==1500pics
X250/2125 bins per 2 round.

Small metal bin for glove compartment

Small metal bin specification:

 Max number of glove compartment a bin can carry 100

Calculation:

Number of small bin for glove compartment

1bin==100pics x15 small metal bins

X==1500pics

Large ODETTE Box for (glove compartment brackets, air vent frames and instrument
frames)

Large metal ODETTE Box specification:

 Max number of glove compartment bracket a bin can carry 100

 Max number of air vent frames a bin can carry 50
 Max number of instrument frames a bin can carry 30

Calculation:

Number of large ODETTE Box

For glove compartment brackets

1bin==100pics

X==1500pics x15 large ODETTE box

44
For air vent frames

1bin==50pics

X==1500pics x30 large ODETTE box

For instrument frames

1bin==30pics

X==1500pics x50 large ODETTE box

Total number of large ODETTE box95 large ODETTE box.

Small ODETTE Box for (fins, shutter and control wheels)

Small ODETTE box specification: according to weight

Calculation:

Gross weight kg

Fin 0.0102

Shutter 0.0255

Control wheel 0.0255

For fins number of ODETTE box

1bin==1.33kg

X==0.0102kg x130 number of ODETTE box

For shutter and control wheels number of ODETTE box

1bin==1.33kg

X== 0.0255kg X52 number of ODETTE box for each

104 Total number of small ODETTE box

45
Total number of small ODETTE box 234 small ODETTE box

3.2.6 MACHINE COST

Machine Qty Total Birr [k,birr]

Press 1200t 4 5*35,100=175,500
Press 800t 4 5*29,380=146,900
Press 400t 2 2*14,820=29,640
Press 200t 1 1*8,060=8,060
Press 200t 1 1*8,060=8,060
Press 200t 1 1*8,060=8,060
Press 100t 1 1*4,160=4,160
Press 100t 1 1*4,160=4,160
Press 400t 1 2*14,820=29,640
Assembly station equipped 2 3*260=780
with rotating table
Assembly station 4 5*208=1,040

Assembly station 2 2*208=416

Assembly station 5 6*182=1,092

Total cost =337,558,000

3.3 Production area design

Space requirement for production mainly depends on the sum of the areas of individual’s work
places and total production space is determined after determining the areas for all workplaces,
machines and operators engaged for each operation or activity

The size of equipment has a huge impact on plant layout. Smaller machines not only save money,
they are also better suited to cell design and can be put on wheels — with wheel locks, of course

46
— for ease of re-arrangement. Also for ease of movement, "all connections should be made via an
overhead distribution with flexible lines and an extra loop of wire/hose," Business will continue
to evolve and change, and companies need to be able to adapt their manufacturing facility to these
demands as efficiently and cost-effectively as possible. Having a flexible and properly laid-out
plant floor enables companies to re-arrange without needing outside contractor.

When we design a production house we have to consider different things like

 Machines arrangement
 Machines dimension and aisle space between them
 Material handling systems [forklift and hand pallet jack)
 Internal temporary storage (work-in-process storages)
 Working aisle space
 Main gates and safety gates
 Foreman’s offices.
 Maintenance area
 Temporary storage for the externally supplied components.

Having machines grouped together — but not in rows — enables one operator to attend to multiple
machines with minimal walking .The idea is to have the space open so that operators can see what's
happening overall.

So, in order to design area requirements for production we have calculated the dimension of
machines as follows.

 We selected a combined type of layout. It is the combination of product and process layout.
The process layout is used for fabrication and product layout is used for the assembly
section.

3.3.1 Injection molding machine

1. Injection molding machine for BODY

 Total number of machines 5
 All dimension are in (m)

47
  The space the machine occupied x=11.5m, y=3.4m
 The aisle space b/n the machines is 1m

Calculation: for one machine

Area=width*length

Area=x*y11.5m*3.4m39.1m2

2. Injection molding machine for exterior cover

 Total number of machines 5
 All dimension are in (m)
 The space the machine occupied x=8.6m, y=3m
 The aisle space b/n the machines is 1m

Area=width*length8.6*325.8m2
3. Injection molding machine for glove compartment and instrument frames
 Total number of machines 1 for glove compartment and 1 for instrument.
 All dimension are in (m)
 The space the machine occupied each x=7.88m, y=2.35m
 The aisle space b/n the machines is 1m

Calculation:

Area=width*length7.88m*2.35m18.52m2

4. Injection molding for glove compartment bracket, vent frame and fin.
 Total number of machines for glove compartment bracket 1 ,for vent frames 1 and
for fin 1
 All dimension are in (m)
 The space the machine occupied each x=5.5m, y=1.6m
 The aisle space b/n the machines is 1m

Calculation:

48
Area =width*length5.5*1.68.8m2 for each machins.

5. Injection molding machine for shutter and control wheel

 Total number of machines for shutter 1and for control wheel 1
 All dimension are in (m)
 The space the machine occupied for each x=4.2m, y=1.5m
 The aisle space b/n the machines is 1m

Calculation:

Area=width*length4.2m*1.5m6.3m2 for each machine.

3.3.2 Assembly operation

6. Air vent assembly

 Assembly station equipped with rotating table
 Number of tables 2
 The space the rotating table occupied x=1.8m and y=1.8m

Calculation:

Area =width*length1.8m*1.8m3.24m2

7. Body and exterior cover assembly

 # Number of assembly station 4
 The space of the assembly station for each occupied x=1.8m and y=0.9m

Calculation:

Area=width*length1.8m*0.9m1.62m2 for each station.

8. Sub-assembly 2 (glove compartment and glove compartment bracket)

 # Number of assembly station 2
 The space of the assembly station for each occupied x=1.8m and y=0.9m

49
Calculation:

Area=width*length1.8m*0.9m1.62m2 for each station.

9. Final assembly
 # Number of assembly station 5
 The space of the assembly station for each occupied x=2m and y=1.3m

Calculation:

Area=width*length2m*1.3m2.6m2 for each station.

3.4 Transport system design

Transport system selection should be according to the following requirements of the job.

 Physical state of the material (solid, liquid, gas)

 Size (length, width, height)
 Weight (per piece, per unit volume)
 Condition (hot, dry, sticky) etc. to be handled.
The typical examples of transport system in a manufacturing facility are industrial vehicles,
conveyors, and cranes. Based on the above considerations we have selected the following material
handling transport systems.

3.4.1 Forklifts: Are used in transporting materials in warehouse departments, finished

warehouse and finally to loading area. The forklift has the following properties.

50
  Have a lifting height of equal or less than 3m.
 Its height should be less than 3 m
 have load capacity of 5000kg

3.4.2 Hand pallet tracks

 are mostly non-powered

 Can be easily manufactured in field or ordered from factory
 Mostly used to temporary handling of materials and disposal of materials.
Based on the above material handling equipment’s properties for our design we used in to
transport materials from the injection molding department to the assembly area.

3.5 Material handling flow chart

Raw material Finished

warehouse warehouse

Forklift

Buffering area Packaging

51

Final assembly
d/t injection
 Hand pallet jack

By hand live roller or hand

Hand pallet jack hand

3.6 AREA EXPANSION CONSIDERATION

Following steps are taken for area allocation:

1. After having determined the area required for different activities, templates are prepared to
the scale on pieces of thick paper for each activity to represent its gross space requirement

2. These are then set in logical relationship of material flow, equipment flow, information
flow, personnel flow or in an activity relationship

3. Adjust them considering various factors, like:

• Economic utilization of space

• Ease of expansion

• Potential of flexibility

• Ease of supervision

After estimating the space requirement for different functions, activity inter-relationships and these
space requirements are integrated in the area allocation process. The area allocation diagram then
becomes the basis for the detailed layout and the building design. The main objective of the area
allocation process is to design an efficient arrangement of the space required by each activity.

Factors to be considered for area allocation procedure

• Expansion

52
 • Activity inter-relationships

• Value of space

• Space available

• Funds available

• Locations of services

• Building characteristics

• Flexibility

• Use of all levels of floor

• Inter building handling

• Points of use storage i.e. decentralize storage

• Aisles

3.6.1 Expansion

If building is not having sufficient space, then expansion will mean disruption in work, inefficient
production, unsafe working, and unplanned additional construction. Therefore, planning for
expected expansion is always necessary. Expansion becomes essential due to the following
reasons:

• Increased demand

• Addition of a product

• Addition of services or facilities

• Activities previously subcontracted are taken by the firm

• Diversification of activities

53
 Designing a new facility considering for expansion

• Pre-plan for expansion in at least two directions

• Plan aisles arrangement for ease of extension, keep them wider

• Keep at least 25% more space for production and about 50% more for office

• Use wider machine spacing, keeping provision for inserting another one during
expansion.

• Keep some land attached to present building as vacant

• Predict diversification, change in product-mix, and technological development

• Plan for additional parking

• Foundation be designed to take care of additional floors in future.

3.7 DOCK DESIGN

The in and out of facilities is critical in today’s competitive worlds. Special attention must be given
to the loading dock area design for this to happen. A number of factors must be considered when
coordinating dock heights, door sizes and when selecting the proper loading dock equipment.

Today’s work place will not tolerate unsafe work practices. In staling loading dock safety is the
first step towards minimizing hazardous and costly accidents.

The loading dock personnel must then be educated and trained on how to use the equipment and
identify the warning signals. Authorized blue giant representatives can then for employers with
recommendation and after sales training to ensure proper equipment selection and use. Throughout
the planning process future requirements should always be addressed. The need for more door
openings and more strange capabilities should be incorporated in to the layout of the new building
prior to its construction to save a great deal of cost and frustration later. Designing the dock area
requires the consideration of the following variables:

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  dock approach

 dock positioning

 apron space

 dock height

 door sizes

 trailer configurations

 Dock approach is the topographical configuration of the area used when backing trucks
into position. This area can be level depressed or inclined.

Therefore for our design we have selected a slightly inclined approach that does not inhabit the
positioning of the trailers, but allows water runoff away from the building. In addition to this it
also helps to prevent from damage to the building from trailers that are severely positioned by
trucks a shown in the fig below.

Fig 6 dock system

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 I. Bumpers: are used to protect the dock from truck damage and as a guide by the truck driver
when backing up.

II. Dock leveler: a height adjustable plate form used as a bridge between dock and truck can
be operated through mechanical, hydraulic or air powered system. A dock leveler is a fixed
bridge designed to permit the safe and efficient flow of goods in to and out of building.

In order to accomplish this, a dock leveler must be able to support the extremely heavy loads,
service wide range of truck heights and compensate for tilted truck.

Based on the method of activation there are two basic types of levelers:

1. mechanical levelers or spring mechanism

2. hydraulic mechanism

1. mechanical or spring mechanism

Mechanical dock levelers are spring biased upwards and incorporate a hold down mechanism as
shown in the figure below .

2. Hydraulic mechanism these units are powered by an electro powered system.

They are simple to operate and require no bending or pulling on the part of the operator.
Activation is simply achieved through push buttons. Because of this reasons we have selected
this type for our design.

II. Dock lift: serves similar to leveler but operates a scissor lift to allow for greater height.

Dock seals: special consideration should be given to shelters for 10inch high.

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Dock seal or compressible foam blocks against which the truck presses when parked. They are
used at exterior trucks bays in colder climates where this will provide protection from the weather.

Dock light: a movable articulated light mounted inside the dock used to provide lighting inside the
truck during loading operation.

Door size: the most versatile door size is 10 inch high .this height will service the full range of
loading /unloading operations.

The general selection criteria are the maximum grade percentage from dock to vehicle. When using
electric power handling equipment it is 10% and for diesel powered equipment it is 15% exceeding
these grade parentage may result in equipment “hang up “damage to handling equipment and load
spillage.

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 3.8 Supporting service allocation

3.8.1 Cafeteria

is one of the basic necessities of one industry an employee needs suitable refreshment area and
good working condition for his/her being effective and productive that is why we underline the
requirement of cafeteria in our design thus we have one complete and wide cafe which gives
the following services:-

 as a restaurant
 as a lounge and refreshment hall
 as a cafe
The number of workers or employees which get the access or service from the café is 100 with
allowance.

In our case the cafeteria area is 1.6m2/employee.

3.8.2 Toilets and shower rooms

These are some of the auxiliary service areas which are mandatory for the employee, guests and
other community of the industry. These rooms should not much far away from the work stations
and offices in addition to the main cafe. As a result we have enough shower rooms and toilet rooms
for both the female and male. Locally we have such services inside the production area, around
the administrative office and near the main cafe.

In our case the restrooms and toilates area is 0.25m2/employee.

3.8.3 Locker rooms

In addition to the shower and toilet rooms changing rooms are mandatory for the whole workers.
That is why we have designed wide locker room not far away from the work station’s.

In our case the locker rooms area is 1.6m2/employee.

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 3.8.4 Parking area

Planning employee and others parking area is very similar to planning stores or warehouses areas.
With the improvement in living standards it is becoming an increasingly difficult problem to
provide an adequate parking space these should be regulated both from the ecological and
appearance point of view.

The Procedures to be followed are:

 Determine the number of automobile and trucks to be parked.

Assume 13cars/day of employee, 3cars/day of guests,2 lorries/week of receiving and
shipping.

 Determine the space required for each automobile

 Small car=13*2.70=35.1m2
 Lorries and low bed=7*4=28m2
Decisions

Therefore in our design we have around three parking areas namely:-

1. for the employees

2. for the receiving and shipping or trucks

3. for the trucks and forklifts which requires maintenance (in the garage).

3.9 Department relationship

Though there are different departments in our production some of the departments are as follows.
The relationship between these departments is done by computing the total closeness rating. The
numerical values for the assigned letters are:

A=100 O=1
E=50 U=0
I=10 X=-100

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Dep. Department/activity
number
1 Raw material warehouse
2 Mini storage
3 Injection molding area
4 Assembly area
5 Office
6 Service area
7 Testing area
8 Cafeteria & lunch area
9 Medical facility
10 Tool & maintenance
room
11 Finale product
warehouse
12 Buffer storage area

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 dep 1 2 3 4 5 6 7 8 9 10 11 12 A E I O U TCR
1 - U A O U U E U U O U I 1 1 1 2 6 162
2 O - I I U U O U U U O U 0 0 2 3 6 23
3 A I - A U U E U U I U E 2 2 2 0 5 320
4 O I I - U U E U U I A U 1 1 3 1 5 181
5 U U U U - U U I O U U U 0 0 1 1 9 11
6 U U U U U - I U O I U U 0 0 2 1 8 21
7 E O E E U I - U U O O U 0 3 1 3 4 163
8 U U U U I U U - U U U U 0 0 1 0 10 10
9 U U U U O O U U - O U U 0 0 0 3 8 3
10 O U I I U I O U O - O U 0 0 3 4 4 34
11 U O U A U U O U U O - U 1 0 0 3 7 103
12 I U E U U U U U U U U - 0 1 1 0 10 69

Therefore based on the value of the total closeness rating the arrangement of the departments are
as follows for the main departments.

12 1

3
10

11 4 2
Chapter four

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 Chapter four

Production flow and working condition

4.1. Production flow

Raw material

Processing of raw material

Differentiating raw material in to main product and scrap (waste)

Shipping

Storage

4.2. Working condition

Proper working conditions are considered important by management because they increase
production effectiveness. Employee working conditions are influenced by many factors, over
which the employee has very little or no control. A good layout considers the factors influencing
working conditions.

 Lighting

Good lighting facilitates accuracy and ease of seeing. A lighting system that aids these two
demands means that the worker is able to see the critical details required in his job without

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excessive visual strain. The lighting fixtures are described according to the way they distribute
light. Factors that affect quality illumination include contrast, luminance ratios, uniformity,
distribution, shadows and glare. The following ranges are accepted internationally

Table 4.1

TYPE OF WORK ILLUMINATION VALUE IN FLUX

Store and rarely accessible working places 100 – 200

Rough work (Brewery) 200 – 500

Medium work (automobile assembly) 500 – 1000

Precise work (wool work) 500 – 1000

Fine work (Radio and TV assembly) 1000 – 2000

Very fine work (controlling wool work) 1000 – 2000

Working on a very small pieces(watch assembly) 2000 - 7500

 Air conditioning

Air conditioning is used for many plants to control contamination by dust, bacteria and toxic
gases in addition to air temperature and humidity. It is primarily the control of the latter that
provides comfortable working conditions. Air conditioning is systems which provides an
atmosphere comfortable to the human being and maintain an atmospheric environment
demanded by a manufacturing process or storage of products.

 Noise

A wide variety of sound exists in industry. Continuous exposure to high noise levels frequently
results in temporary or even permanent loss of hearing. But there is no clear cut line to indicate

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how much noise results in hearing loss. The following are standard measurements for different
sound sources in decibels:

SOURCE dB

Hydraulic process at one meter 140

Automobile horn push at one meter 120

Automatic lath at one meter 100

Conversation at one meter 70

Workshop (mechanical) 80

The reduction of noise may be brought about by a variety of methods. Some of these methods
are:

- Control of the noise at the source.

- Isolation of the noise.

- Use of baffles and sound absorbers.

- Acoustical treatment.

- Use of ear protection devices.

 Use of color

The objective of utilizing scientifically selected colors is to bring about a clear three dimensional
vision.

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Color codes have been developed for particular uses. The red, yellow and green of traffic lights
are a well-known example of color coding.

Red - danger; stop

Yellow - caution

Green - safety equipment

 Different colors have different psychological effects.

 Red - Hot and heavy, exciting, stimulating.

 Orange - Hot, exciting and stimulating less than red.

 Yellow - Hot, exciting lovely.

 Green - Fresh and light, pacific.

 Blue - Light, pacific.

 Violet - Light, loneliness.

 White - Cold, brilliant (seems to increase volume).

 Black - Hot (seems to decrease volume) depressing.

Space requirement

The layout man often finds himself involved in work space arrangement; at any rate, he must
determine the floor space that will be required by an operator. The study of floor space needed
considers the following points:

 While at work, the operator's arms and hands should move as easily as possible and he
ought to reduce, to the minimum the movement of his shoulders, his body and his person
from one position to another.

 Fixed posts for utensils and materials should be assured.

 The disposition of utensils, materials and organs of maneuver near and in front of the
operator.

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  Avoidance of the standing operator wherever possible. The study of the working area
should consider a proper and comfortable position for the legs of the operator in an
armchair or on a stool.

 When the operator is transporting material, or when he is in a position to push, or pull he

should do it in such a way that:

 He is in an equilibrium position and He applies the possible minimum force to produce

the effect.

 Position of workers in transporting pulling and pushing

From the very beginning of the study one has to determine the corridors within the building.
Their width is determined according to the internal transport system selected and according to
the clearance needed for passages. Principal corridors which normally start from one end of the
building and end at the other end are 3 to 5 meter wide. Corridors within the department; passage
for one person is 60cm ,passage for two persons 120cm and passage for three persons 170 cm.

4.3. SAFETY

A good plant layout should consider the safety of all personnel. Lack of adequate storage space
which is beyond the control of the foreman, can lead to unsafe practices in the storage of
materials. Some of the safety hazards to be watched for in plant layout are:

 inadequate passage,

 insufficient storage space allowance for safe handling procedures,

 insufficient handling equipment capacity,

 floor load capacity,

 floor obstructions,

 slippery finish floors,

 inadequate exits,

 inadequate stairs, ramps and ladders,

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  inaccessible fire extinguisher and first aid boxes

 unguarded moving parts of equipment ,

 workers located under the above hazards and

 improper ventilation for removal of dangerous or toxic gases

The layout man should give due consideration to the problem of safety. Overlooking the problem
will lead to lower morale of the workers, lower productivity and heavy accident liability costs.
The factory to day requires a wide variety of plant services. These may include electricity,
sewerage, compressed air, and steam, a variety of industrial gases, heating, ventilation, and air
conditioning, hot and cold water. The layout man planning the arrangement of a plant will
become involved with providing facilities for plant services .in some organizational structures
he/she may even be responsible for fairly technical work in planning adequate plant services.
Plant services require constant maintenance .in general, high initial cost services have low cost
maintenance, while the opposite is true for plant service installations involving low initial
investment.

Warehouse

Warehouses, defined here, are facilities that provide a proper environment for the purpose of
storing goods and materials that require protection from the elements. Warehouses must be
designed to accommodate the loads of the materials to be stored, the associated handling
equipment, the receiving and shipping operations and associated trucking, and the needs of the
operating personnel. The design of the warehouse space should be planned to best accommodate
business service requirements and the products to be stored/handled. The economics of modern
commercial warehouses dictate that goods are processed in minimal turnaround time.

The different types of warehouses include:

 Heated and unheated general warehouses—provide space for bulk, rack, and bin storage,
aisle space, receiving and shipping space, packing and crating space, and office and toilet
space;

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 Refrigerated warehouses—preserve the quality of perishable goods and general supply
materials that require refrigeration. Includes freeze and chill space, processing facilities,
and mechanical areas; and

 Controlled humidity (CH) warehouses—similar to general warehouses except that they

are constructed with vapor barriers and contain humidity control equipment to maintain
humidity at desired levels.

For our design of the ware house we selected heated and unheated general
warehouses. In our ware house design we designed it so that it will provide space
for the necessary rack and packaging of goods available.

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CHAPTER FIVE

5.1 INVESTMENT COST

# Name of the machine Number of Unit price Total price
NUM machine [k, birr] [k, birr]
Injection molding machine for
1 Body[press 1200 t] 5 35,100 175,500
2 Exterior cover[press 800 t] 5 29,380 146,900
3 Glove compartment[press 400 t] 1 14,820 14,820
4 Glove compartment bracket[press 200 1 8,060 8,060
t]
5 Vent frame[press 200 t] 1 8,060 8,060
6 Fin[press 200 t] 1 8,060 8,060
7 Shutter[press 100 t] 1 4,160 4,160
8 Control wheel[press 100 t] 1 4,160 4,160
9 Instrument frames[press 400 t] 1 14,820 14,820
Assembly operation
10 Air vent assembly [rotating table] 2 260 520
11 Body and exterior assembly 4 208 832
12 Sub- assembly 2,glove compartment 2 208 416
and glove compartment bracket
13 Final assembly 5 182 910
total 30 211,718

5.2 Construction cost

no Description Area Unit Total cost[birr]

cost[birr]
2 Production area 1,159.84m2+207.08m2 25,740 35,184,520.8
3 Maintenance room 300m2 25,740 7,710,000
4 Locker room 124.8m2 22,100 2,758,080

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 5 Toilet 19.5m2 22,100 430,950
6 Store 85m2 25,740 2,187,900
7 Office 200m2 22,100 4,420,000
8 Clinic 20m2 22,100 442,000
9 Cafeteria 124.8m2 25,740 3,212,352
Total 56,345,802.8

5.3 Transportation system cost

No Description No Unit Total Price

price[Birr]

1 Forklift(lifting height 2 627,900 1,255,800

<3)

2 Hand pallet jack 9 52,000 468,000

3 Large metal box 125 5,720 715,000

4 Small metal box 15 4,680 70,200

5 Large ODETTE box 95 832 79,040

6 Small ODETTE box 234 260 60,840

Total 2,648,880

The total investment cost =machine cost+ construction cost+ transportation cost
59,206,400.8 birr

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 5.4 Gantt chart
The whole working of the project is made by the group members’ contribution. During the work a
member is given its share to do, then when all the members finish their work we gather and talk
what we have done and generalize it. A little bit this makes difficult to make the Gantt chart easily.

And also doing the tasks of project normally does not take weeks

introduction&objective

litrature review

machine calculation

draft drawing

warehousing design

transport, pallet, rack design

department relation design

production flow and working condition

AuthoCAD draft drawing

investment cost Gantt chart

plotting

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