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TABLE OF CONTENTS
-Introduction -product design -process design -schedule design -facility area -material handling
1
INTRODUCTION
Manufacturing and Service companies spend a significant amount of time andmoney to design or redesign their facilities. This is an extremely important issue andmust be addressed before products are produced or services are rendered.A poor facility design can be costly and may result in:
•poor quality products, •low employee morale,
•customer dissatisfaction.2
PRODUCT
. Name :Ballpoint pen
Function :Is a pen that dispenses ink over a metal ball at its point.
:it works on two principles
-frictional force between pen and paper .
-gravitational force due to which ink follow in downward direction .
3
Bills of material Assembly chart
Upper body
Retract tube
button
clip
lower body
INK TUBE
INK SUPPLY
SPRING
BALL
Packaging material
I – 1
A-1 SA -1
006
008
007
005
A-2 SA -2
003
002
009
001
004
6
Operation process chart
body button
010010
010010010
Injection molding process
Injection molding process
Injection molding process
Injection molding process
Injection molding process
Ink tube Clip Retract tube
cooling020
labeling030
040 inspect
040
coolingcooling
Filling
inspect
cooling cooling
inspect
020
020020020
040
060
004-009 006 001 002003
SA-1
SA-2
spring ball007 005
A-4
I - 1Packaging material
030 labeling
040 inspect
050
020
040
Ink supply008
Extrusion
cooling
inspect
SA-3
040 inspect
7
SCHEDULE DESIGN
Schedule design provide answers to questions involving how much to produce and when to produce. Production quantity decisions are referred to as lot size decisions; determining when to produce is referred to as production scheduling. In addition to how much and when, it is important to know how long production will continue; such a determination is obtained from market forecasts
Schedule design decisions impact machine selection, number of machines, number of shifts, number of employees, space requirements, storage equipment, material handling equipment, personnel requirements, storage policies, unit load design building size, and so on. 8
Equipment requirements are a function of the following factors:
•Number of shifts (the same machine can work in more than one shift).
•Setup times (if machines are not dedicated, the longer the setup, the more machines needed).
•Degree of flexibility (customers may require small lot sizes of differentproducts delivered frequently – extra machine capacity will be required tohandle these requests.)
•Layout type (dedicating manufacturing cells or focused factories to theproduction of product families may require more machines.)
•Total productive maintenance (will increase machine up time and improvequality, thus fewer machines will be needed.)
9
According to 1-machine characteristics (1.9L x 0.9W) m2
2-standard of conveyor dimension from elcom company
(flat belt conveyor)(width from 20 to 1000 mm)
3-ingress & egress 0.762-1.0668 m for passage between operating machine from standard
4-distance between machines and the closer wall is three times distance between machines (from Reynolds company)
5-distance between machines and the farther wall 6 times
distance between machines (from Reynolds company)
15
MATERIAL HANDLING EQUIPMENTIn the departments
Transport equipment
Used for -transporting light and medium weight loads between
operations, departments and buildings-Provides considerable control over the orientation and
placement of the load
Four or more wheeled hand truck with handles for pushing or hitches for pulling.
Used in injection molding department there is component go to the filling ink department and other component to assembly department
Flat belt convoyer
Floor hand truck
deflector
21
Positioning equipment
Lift/tilt/turn table
manual
Under ideal circumstances, maximum recommended weight for manual lifting to avoid back injuries is 51 lbs Recommendation based on NIOSH (National Institute for Occupational Safety and Health)
1991
Used when positioning involves the lifting, tilting, or turning of a loadCan be used to reduce or limit a worker’s lifting and/or reaching motions .
22
Unit Load Formation Equipment
cartons
pallets
Used to unitize and protect loose discrete items.Large quantities of finished carton blanks or knocked-down cartons can be stored on pallets until needed
Platform with enough clearance beneath its top surface (or face) to enable the insertion of forks for subsequent lifting
purposes
23
Storage Equipment
Sliding rack
Equipment used for holding or buffering materials over a period of time.
-High cube utilization and complete accessibility to all loads
-Provide increase security for items compared to other racks
24
identification and communication
equipment
Bar coding
-Reduction in error
-Saving in time
-Improving operation efficiency
-Overall cost savings.
25
Out of the departments
Fork lift
Forklifts are a type of machinery used primarily for moving heavy things. Since the invention of forklifts, workers are able to move materials easily to different locations. These machines help workers to increase their productivity and eliminate the strain on the body caused by lifting heavy objects
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