Facility Planning for Fire extinguisher

Alexandria University Faculty of Engineering Production Engineering

Department

3rd Year2nd Semester (2014/2015)

Facility Planning

Group Members

الرقم الفصل االسم

رشاد عثمانرشاد أمان 3 59

5 90 مازن عالء الدين زكي محمد

إسماعيلمحمد إسماعيل محمد 5 94

6 117 محمود أحمد حسان أحمد

6 124 محمود محمد فرج أحمد

7 138 مصطفى محمود محمد أحمد

Final Report

Group ID : 20

Group project : Fire extinguisher

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Facilities planning Report 1 Fire extinguisher

Table of Contents Introduction ............................................................................................................................ 4

Task 1 ...................................................................................................................................... 4

Detailed design of product component .............................................................................. 4

1‐Body of control valve ............................................................................................................................................. 4

2‐Swivel ..................................................................................................................................................................... 4

3‐Locking nut (2) ....................................................................................................................................................... 5

4‐Swivel nut ............................................................................................................................................................... 5

5‐handle .................................................................................................................................................................... 6

6‐Trigger .................................................................................................................................................................... 6

7‐Check valve spring ................................................................................................................................................. 7

8‐Check valve ............................................................................................................................................................ 7

9‐Locking nut (1) ....................................................................................................................................................... 8

10‐Powder tube ........................................................................................................................................................ 8

11‐Fire extinguisher body ......................................................................................................................................... 9

12‐ Fire extinguisher horn ......................................................................................................................................... 9

13‐Locking pin ......................................................................................................................................................... 10

14‐Pressure gauge ................................................................................................................................................... 10

Exploded assembly drawing .............................................................................................. 11

Parts List ............................................................................................................................ 12

Bill of material ................................................................................................................... 13

Route sheet ....................................................................................................................... 14

Part (1) Control valve .............................................................................................................................................. 14

Part (5) Handle ........................................................................................................................................................ 15

Part (6) Trigger ........................................................................................................................................................ 15

Part (8) Check valve ................................................................................................................................................. 16

Part (11) Fire extinguisher body .............................................................................................................................. 16

Assembly chart .................................................................................................................. 18

Operation Process chart .................................................................................................... 19

Task2 ..................................................................................................................................... 20

List of machines required to produce the product ........................................................... 20

Annual demand for part and its components ................................................................... 20

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Annual demand for part .......................................................................................................................................... 20

Annual demand for the components ...................................................................................................................... 20

Scrap estimate ................................................................................................................... 21

Worker efficiency and reliability of each machine ............................................................ 21

Number of machines required of each type ..................................................................... 22

1‐CNC (Machining) .................................................................................................................................................. 23

2‐Power hacksaw (Cutting) ..................................................................................................................................... 23

3‐Induction furnace (Melting) ................................................................................................................................. 23

4‐Mechanical and hydraulic press (Drawing) .......................................................................................................... 23

5‐Automatic sandblast equipment (Finishing) ........................................................................................................ 23

6‐Capstan lathe (Machining) ................................................................................................................................... 23

7‐Center lathe (Machining) ..................................................................................................................................... 24

8‐Screw press (Drawing) ......................................................................................................................................... 24

Task3 ..................................................................................................................................... 24

Approximate number of employees in the production area ............................................ 24

Task4 ..................................................................................................................................... 25

Name of departments in the production area .................................................................. 25

Appropriate layout (cellular layout) .................................................................................. 25

Guide ....................................................................................................................................................................... 26

Final layout .............................................................................................................................................................. 27

Material flow diagram within the area ............................................................................. 28

The production area layout ............................................................................................... 29

Labels ...................................................................................................................................................................... 30

The required production area ........................................................................................... 30

Task 5 .................................................................................................................................... 30

Employee parking .............................................................................................................. 30

Food service ...................................................................................................................... 32

Locker rooms ..................................................................................................................... 32

Layout ................................................................................................................................ 33

For workers who need to change their clothes ...................................................................................................... 33

For workers who don't need to change their clothes ............................................................................................. 34

Health Services .................................................................................................................. 34

Restroom ........................................................................................................................... 34

Final layout ........................................................................................................................ 36

Task 6 .................................................................................................................................... 37

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First from raw material or bought parts storage to the plant ........................................... 37

List of raw material and parts needed .................................................................................................................... 37

List of bought parts needed .................................................................................................................................... 37

Second flow of product parts in the plant ......................................................................... 39

In each department: ............................................................................................................................................... 39

Between the departments: ..................................................................................................................................... 39

Third flow of final product from the plant to the warehouse and inside it ....................... 40

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Introduction A fire extinguisher, or extinguisher, is an active fire protection device used to

extinguish or control small fires, often in emergencies. It is not intended for use on

an out‐of‐control fire, such as one which has reached the ceiling, endangers the

user (i.e., no escape route, smoke, explosion hazard, etc.), or otherwise requires

the expertise of a fire department. Typically, a fire extinguisher consists of a hand‐

held cylindrical pressure vessel containing an agent, which can be discharged to

extinguish a fire.

Task 1 Detailed design of product component (Every part has isometric view, front view, side view and top view)

1-Body of control valve

Fig 1 Body of control valve

2-Swivel

Fig 2 Swivel

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3-Locking nut (2)

Fig 3 Locking nut 2

4-Swivel nut

Fig 4 Swivel nut

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5-handle

Fig 5 handle

6-Trigger

Fig 6 Trigger

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7-Check valve spring

Fig 7 Check valve spring

8-Check valve

Fig 8 Check valve

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9-Locking nut (1)

Fig 9 Locking nut (1)

10-Powder tube

Fig 9 Powder tube

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11-Fire extinguisher body

Fig 10 Fire extinguisher body

12- Fire extinguisher horn

Fig 11 Fire extinguisher horn

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13-Locking pin

Fig 12 Locking pin

14-Pressure gauge

Fig 13 Pressure gauge

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Exploded assembly drawing

Fig 14 Exploded assembly drawing

Part Number PART NAME 1 Body of control valve

2 Swivel

3 locking Knut (2)

4 swivel Knut

5 Handle

6 Trigger

7 Check valve spring

8 Check valve

9 locking Knut (1)

10 powder tube

11 fire extinguisher body

12 fire extinguisher horn

13 locking pin

14 pressure gauge

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Parts List

Part Number

Part Name

Drawing Number

Quantity Per Unit

Material Size (Dimensions in

mm.)

Make or Buy

01 Valve 1 1 Brass Diameter: 15.88 Diameter: 14.73

Make

02 Swivel 2 1 Cast Iron Diameter: 7.92 Length: 39.70

Buy

03 Locking Nut 2

3 1 Low Carbon Steel

Diameter: 14.73 Diameter: 22

Buy

04 Swivel Nut 4 1 Low Carbon Steel

Inner Diameter: 6.86

Thickness: 5.56

Buy

05 Handle 5 1 Aluminum Length: 131.93 Pin hole

Diameter: 4.78

Make

06 Trigger 6 1 Aluminum Length: 82.03 Pin Hole

Diameter: 4.78

Make

07 Check Valve Spring

7 1 Steel Diameter: 5.08 Buy

08 Check Valve

8 1 Aluminum Length: 83.62 Diameter: Small: 5.08 Large: 14.68

Make

09 Locking Nut 1

9 1 Low Carbon Steel

Diameter: Inner: 14.73 Outer: 15.88

Buy

10 Syphon Tube

10 1 Aluminum Diameter: 11.13 Length: 361. 54

Buy

11 Body 11 1 Steel Length: 368 Diameter: 109

Make

12 Horn 12 1 Plastic Opening Diameter: 50

Hose Diameter: 7.92

Buy

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13 Locking Pin

13 1 Cast Iron Length: 46.02 Diameter: 3.18

Buy

14 Gauge 14 1 Plastic Length: 13 Diameter: 10

Buy

Bill of material

Pin

Spring

Fire

Extinguisher

Body

Handle Locking

Nut 2

Check

Valve Swivel

Valve

Pressure

Gauge

Locking

Nut 1

Horn

Trigger

Level 0

Level 1

Level 2

(1) (1) (1) (1)

(1) (1)

(1)

(1) (1) (1)

(1) (1) 0901

0401

0501

0301

0801

0701

1101

0601 0101

1201

1401

1301

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Route sheet

Part (1) Control valve

Company: Maanshan Tianrui Industrial Co., Ltd. Product: Fire extinguisher

Part name: Control valve Part # 1 Raw material: Brass rods

Oper. #

Operation Name

Machine Tool Department Operation time

Setup time

0101 Cutting Power Hacksaw

300 mm hacksaw blade

Machining department

10 sec 30 min

0102 Heating Melting

Induction Furnace

950 C furnace

Special furnace room

10‐30 min 30 ~ 90 min

0103 Forging Mechanical Press

200 ton Press die press

Press department

10 sec 30 min

0104 Cutting of flanges (shearing)

Mechanical Press

30 ton die Press

Press department

10 sec 30 min

0105 Straight Turning

CNC Straight‐lined tool

CNC department

5 sec 20 min

0106 threading CNC Multi‐ diameters threading tools

CNC department

3 sec per process

20 min

0107 Drilling 6 holes for ( handle‐trigger‐bypass ball‐Pressure gauge)

CNC Multi diameters twist drills

CNC department

10 sec 20 min

0108 Sand blasting Automatic Sandblast Equipment

Aluminum oxide granules

Sand blasting Unit

3 minutes 60 min

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Part (5) Handle


Part name: Handle Part # 5 Raw material: Aluminum Sheets

Oper. #

Operation

name

Machine Tool Department Operation

Time

Set-up

Time

0501 Punching and

Blanking

Hydraulic

press

Punch

and Die

Press

Department 3 Sec 30 min

0502 Bending Screw

press

Punch

and Die

Press


Part (6) Trigger


Part name: Trigger Part # 6 Raw material: Aluminum Sheets

Oper. #

Operation

name

Machine Tool Department Operation

Time

Set-up

Time

0601 Punching and

Blanking

Hydraulic

press

Punch

and Die

Press


0602 Bending Screw

press

Punch

and Die

Press


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Part (8) Check valve


Part name: Check valve Part # 8

Raw material: Aluminum

Oper. #

Operation name


Setup time

0801 Facing Capstan Lathe

spot facing tool


5 sec 10 min

0802 Straight turning (multi Sections) (5.08 &14.68 mm diameters)

Capstan Lathe

Straight‐lined tool


2 min 10 min

0803 Cutoff Capstan Lathe

83.62 mm cut off


5 sec 10 min

0804 Straight turning (5.08 mm diameter)

Center lathe

Straight‐lined tool


2 min 1 min

Part (11) Fire extinguisher body

Company: Maanshan Tianrui Industrial Co., Ltd. Product: Fire extinguisher Part name: Body Part # 11 Raw material: Steel Blanks

Oper. #

Operation name


Set-up Time

1101 Drawing (Second part)

Hydraulic press

punch and die (109.72 mm) diameter

Press Department

15 Sec 30 min

1102 Trimming (Second part)

Hydraulic press

punch and die

Press Department

5 Sec 30 min

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1103 Blanking (Second part)

Hydraulic press

punch and die

Press Department

5 Sec 30 min

1104

Facing, Drilling, External, Internal turning , internal threading and cutoff (First part)

Capstan lathe

Drill, External, Internal and Thread cutter

Machining Department

2 min 10 min

1105

Drawing (Third part)

Hydraulic press

punch and die

Press Department

5 Sec 30 min

1106 Punching (Third part)

Hydraulic press

punch and die

Press Department

5 Sec 30 min

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SSA‐

1

SA‐2

SA‐1

0201

A‐3

A‐2

SA‐3

A‐1

A‐4 1501

0701

0901

1001

1201

1401

0401

Control

Valve

I‐1

Packing Material

Check

Valve

Swivel

Locking

Nut 2

Body Syphon Tube

Swivel Pressure

Gauge

Horn

SSA

‐1

1301

Locking

Pin Trigger

Check

Valve

Locking

Nut 1

Assembly chart

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Operation Process chart

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Task2

List of machines required to produce the product

Machine number Machine name

1 CNC

2 Power Hacksaw

3 Induction Furnace

4 Mechanical and hydraulic

Press

5 Automatic Sandblast

Equipment

6 Capstan Lathe

7 Centre Lathe

8 Screw Press

Annual demand for part and its components

Annual demand for part About 90,000 units from fire extinguisher is required per year.

Therefore, the daily requirement is about 36 unit/8 hour's shift.

9000012 ∗ 26 ∗ 8

36 8

Annual demand for the components

Part Annual requirement 1‐Valve 90000

2‐Swivel 90000

3‐Locking Nut 90000

4‐Swivel Nut 90000

5‐Handle 90000

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6‐Trigger 90000

7‐Check Valve Spring 90000

8‐Check Valve 90000

9‐Locking Nut 90000

10‐powder Tube 90000

11‐Body 90000

12‐Horn 90000

13‐Locking Pin 270000

14‐Gauge 90000

Scrap estimate

Worker efficiency and reliability of each machine

Machine Name Reliability Efficiency

(per average worker)

CNC 96% 98%

Power Hacksaw 94% 96%

Induction Furnace

88% 95%

PART operations scrap Percentage Body of control valve Turning, threading,

drilling 2%

Handle Cutting 1% Trigger HeatingMelting 2%

Check valve Punching, drawing, blanking, trimming, shearing, forging

4%

fire extinguisher body Sand blasting

1%

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Mechanical and Hydraulic Press

98% 97%

Automatic Sandblast Equipment

94% 95%

Capstan Lathe 98% 96%

Center lathe 99% 96%

Screw press 99% 98%

Number of machines required of each type

Number of units to be processed (Q) =

Where

P: percentage of scrap

Machine Fraction (F) =

Where

F: Number of machine required per unit time

Q: Number of units to be processed

H: Amount of time available

E: Worker efficiency

R: Machine reliability

S: Standard time per unit product

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1-CNC (Machining)

Q =. =36.73

F = ∗ .

∗ ∗ ∗ . ∗ .

∗

∗ ∗ = 0.066 =1

2-Power hacksaw (Cutting)

Q =. =36.73

F = ∗ .

∗ ∗ ∗ . ∗ .

∗

∗ ∗ = 0.076 = 1

3-Induction furnace (Melting)

Q =. =36.73

F = ∗ ∗ .

∗ ∗ ∗ . ∗ .. ∗ ∗

∗ ∗ = 1.83 = 2

4-Mechanical and hydraulic press (Drawing)

Q =. =73.11

F = ∗ .

∗ ∗ ∗ . ∗ .

∗

∗ ∗ = 0.09 = 1

5-Automatic sandblast equipment (Finishing)

Q =. =146.93

F = ∗ ∗ .

∗ ∗ ∗ . ∗ .

∗

∗ ∗ = 1.15 = 2

6-Capstan lathe (Machining)

Q =. =36.73

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F = ∗ .

∗ ∗ ∗ . ∗ .

∗

∗ ∗ = 0.04 = 1

7-Center lathe (Machining)

Q =. = 36.73

F = ∗ ∗ .

∗ ∗ ∗ . ∗ .∗ ∗

= 0.16 = 1

8-Screw press (Drawing)

Q =. =75

F = ∗

∗ ∗ ∗ . ∗ .

∗

∗ ∗ = 0.08 = 1

Task3

Approximate number of employees in the production area

Machine number Machine name No of workers

1 CNC

2

2 Power Hacksaw

2

3 Induction Furnace

3 X 2 = 6

4 Mechanical and hydraulic

Press 3

5 Automatic Sandblast

Equipment 2 X 2 = 4

6 Capstan Lathe 3

7 Centre Lathe 3

8 Screw Press 3

Assembly number of workers = 10

2 2 6 3 4 3 3 3 10 36 .

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We have another production area with the same layout, number of workers = 36 worker.

For two production areas cleaners, number of workers = 10 worker.

Security, number of workers = 10 worker.

Administrative Officer = 20 worker.

Cafeteria, number of workers = 8 workers.

Store, number of workers = 10 workers.

Number of engineers = 10 engineer.

Total number of workers = 36+36+10+10+20+8+10+10=140 worker.

Task4 Name of departments in the production area

Department Symbol

Machining department A

Mechanical Press' department B

Induction Furnace Room C

Automatic Sandblast Equipment

room

D

CNC Machines E

Forging department F

Assembly Process G

Appropriate layout (cellular layout) We choose cellular layout because of cellular manufacturing is suitable for our product

because of variety of fire extinguisher volumes.

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Guide

Machine number Machine name Part number Part name

1 CNC 1 Control Valve

2 Power Hacksaw 2 Handle

3 Induction Furnace 3 Trigger

4 Mechanical and hydraulic Press

4 Check valve

5 Automatic Sandblast Equipment

5 Fire extinguish body

6 Capstan Lathe

7 Centre Lathe

8 Screw Press

Machine number

1 2 3 4 5 6 7 8 Sum

1 1 1 1 1 1 5

2 1 1 2

3 1 1 2

4 1 1 2

5 1 1 2

sum 1 1 1 4 1 2 1 2

7 5 3 2 1 8 6 4

1 1 1 1 1 1

5 1 1

4 1 1

3 1 1

2 1 1

Part N

um

ber

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1 2 3 5 4 6 7 8

1 1 1 1 1 1

5 1 1

4 1 1

3 1 1

2 1 1

Final layout

5 4 3 2 1 4a 6 7 4b 4c 8

1 1 1 1 1 1 1

5 1 1 1

4 1 1

3 1 1

2 1 1

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Material flow diagram within the area

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The production area layout

Fig 15 production area layout

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Labels

Letter name A Hacksaw

B Capstan lathe

C Induction Furnace

D Induction Furnace

E Centre lathe

F Sandblast unit (2)

G Hydraulic press

H Screw press

I CNC

J Hydraulic press

The required production area

25.445 ∗ 17.55 446.55975~450

Task 5 Employee parking Cars Number= 140/1.25= 112 cars

1. Standard cars= 112*.55= 62 cars

PW= 6’

W= 45’3’’

2. Compact cars+ 112*.40= 45 cars

PW= 5’40’’

W= 36’8’’

3. Handicapped cars= 112*.05= 6 cars

θ = 45˚

Y= 16*cos(45)= 11’19’’

Width= 160’ (Assumption)

Total depth= (1*36’8’’) + (2*45’3’’)= 127’

Row 1: No. of spaces = (160‐11.31)/5.66= 26 spaces for compact cars

Row 2:

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No. of spaces = (160‐11.31‐15‐15)/5.66= 20 spaces (but 19 just 19 spaces are needed)

Row 3: No. of spaces = (160‐11.31‐15‐15)/ 6= 19 spaces for standard cars

Row 4: No. of spaces = (160‐11.31‐15‐15)/6= 19 spaces for standard cars

Row 5: No. of spaces = (16011.31‐‐15‐15)/6= 19 spaces for standard cars

Row 6: Total space= 160‐11.31=148.69’

Actual space = 5 standard cars + 6 HC= (5*6) + (6 *12) = 102’ < 148.69’

Fig 26 production area layout

127

160

26 Compact

19 Compact

19 Standard

5 Standard Cars +

19 Standard

15’

26

19 Standard

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Food service 140 workers will require 140 vending machines and a cafeteria

1 Vending Machine = 1 square feet

Vending Machines Area = 140 square feet

Cafeteria Area= 12 x 140 = 1680 square feet

Total Area = 1680 + 140 = 1820 square feet = 169 m2

Locker rooms According to reference "Facilities Planning ‐Tompkins ‐ 3rd Edition"

For workers who need to change their clothes

Location for storage of personal belongings should be provided between the

employee entrance and work area.

In our case, we have 120 employees that need to change their clothes

Numberofworkersinonrptoductionline 2 2 6 3 4 3 3 310 36worker. We have another production line with the same layout, number of workers = 36

worker.

For two production areas cleaners, number of workers = 10 worker.

Security, number of workers = 10 worker.

Cafeteria, number of workers = 8 workers.

Store, number of workers = 10 workers.

Number of engineers = 10 engineer.

Total number of workers = 36+36+10+10+8+10+10=120 worker.

For workers who don't need to change their clothes

They typically store lunches, briefcases, and purses at their place of work.

Their storage location may be located in an adjacent to the employee entrance.

In our case, we have administrative Officer = 20 worker.

Common rules

Locker rooms are provided for each sex even if clothes changing is not required.

Each employee should be assigned a locker.

For planning purposes, 6 should be allocated for each person using the locker room.

If toilet facilities are to be included, they must be physically separated from the locker

room area should lunches be stored in the lockers.

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Locker rooms are often located along an outside wall adjacent to the employee

entrance. This provides excellent ventilation and employee convenience while not

interfering with the flow of work within the facility.

Layout For workers who need to change their clothes Every wall contain 30 lockers suitable for 30 employees

singlewalllenght 30 ∗ 6 180ft We have male workers only

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Fig 17 (Locker rooms layout)

For workers who don't need to change their clothes

Every wall contains 10 lockers suitable for 10 employees. singlewalllenght 10 ∗ 6 60ft

Fig 18 (Entrance layout)

Health Services Our facility must have first aid kit with program for workers to learn and use first aid

treatment and small hospital with major medical treatment.

Restroom Layout with typical fixture clearance for 140 employees, which use it.

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Fig 19 (Restroom layout)

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Final layout

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Task 6 To determine material handling system we must specify materials characteristics and the

paths between buildings that the materials flow through it. In our facility we have storage,

plant, and warehouse.

First from raw material or bought parts storage to the plant

List of raw material and parts needed No Part Raw material

1 Valve Brass Rods

2 Handle and Trigger Aluminum sheets

3 Body Steel sheets

List of bought parts needed No Part

4 Swivel

5 Nut ( for locking and swivels )

6 Check Valve Spring

7 Syphon Tube

8 Horn

9 Locking Pin

10 Gauge

1‐Brass rods

Type of material handling:

Manual Pallet Jack

Fig 20 (Manual Pallet Jack)

Reason:

Brass rods have small dimension, (light weighted), and require no stack capability.

Principle:

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Ergonomic Principle (Fitting the job to the abilities of the worker reducing the weight

of a load that the worker carries.

2.3 Aluminum and steel sheets (for Handle, Trigger, and body)


Forklift.

Fig 21 (Fork lift)

Reason:

variable paths, with no restrictions on the area covered by the movement

Insufficient (or intermittent) flow volume such that the use of a conveyor cannot be

justified.

Principle:

Unit Load Principle( A unit load is one that can be moved or stored as a single entity

at one time, regardless of the number of items in that load).

For parts 4~10:


Wheel Handed Truck

Fig 22 (Wheel Handed Truck)

Reason:

• Provide more flexibility in movement than conveyors and cranes.

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• Move materials over variable (horizontal) paths with no restrictions on the area

covered (i.e., unrestricted area).

Principle:

Standardization Principle(Less variety and customization in the methods and

equipment employed).

Second flow of product parts in the plant

In each department: Conveyors.

Since we need to transport a large number of products through a short distance from a

machine to the other.

Fig 23 (Conveyors)

Between the departments: We use different types due to different reasons.

Fork lift.

Is used to transfer the heavier parts (Extinguisher Body) and the large number of parts for

large distances to the assembling station.

Fig 24 (Fork lift)

Manual Hand Trucks.

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As the “Shelf Economy Wire Cart” can also be used for the transportation of the less

number of parts through the shorter distances.

Fig 25 (Manual Hand Truck)

Third flow of final product from the plant to the warehouse and inside it Product which will be handling is the final product (Fire extinguisher).

The methods used and available:‐

Automatic Guided Vehicles.

Fig 26 (Automatic Guided Vehicles)

Reason:‐

1‐Easy to use it for transport products inside the store and between the rows.

2‐Products will be heavy so use AGV.

3‐good for finish work quickly and high safety.

4‐Safe time.

Principle:

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Ergonomic Principle (Fitting the job to the abilities of the worker reducing the weight of

a load that the worker carries.

Fork Lift.

Fig 27 (Fork lift)

Reason:

Variable paths, with no restrictions on the area covered by the movement Insufficient

(or intermittent) flow volume such that the use of a conveyor cannot be justified.

Principle:

Unit Load Principle( A unit load is one that can be moved or stored as a single entity at

one time, regardless of the number of items in that load).

Documents

Facility Planning for Fire extinguisher