------------------------~------~,

CALIFORNIA STATE UNIVERSITY, NORTHRIDGE

PLANT LAYOUT I i

FOR A WillNUFACTURING COMPANY

A project submitted in partial satisfaction of the requirements for the degree of Master of Science in

Engineering

by

Gurcharan S. Soni

May, 1975

The project of Gurcharan S. Soni is approved:

California State University, Northridge

May, 1975

ii

ACKNOWlEDGEMENT

I would like to express my thanks to A. Rubendall

excecutive Vice President for providing me the oppor­

tunity to work on this project; to all members who

participated in the discussion of this program, and

to the production supervisors for their valuable

suggestions and constructive ideas •

. I also wish to thank Dr. Harish Vaish, Professor

of Industrial Engineering for his guidance, and

especially to my wife, Amrit, for her patience and

encouragement throughout the time required to complete

not only this project, but the entire degree program.

iii

Acknowlegement

List of Tables

List of Figures

Abstract

1. Introduction

TABLE OF CONTENTS

2. Theory of Plant Layout

Page

iii

v

vi

vii

1

.3

2 .1 o Types of Plant Layout 3

2.2 Approach to Plant Layout 6

2.3 The factors influencing Plant Layout 7

2.4 Basic :guide to making a layout 8

3. Data Collection and Organization

3.1 Flow Process Charts

13

15 4. Developement and presentation of new Layout 23

4.1 Additional features in new layout

5. Description of the flow of work.

6. Benefits derived from New Layout

7. Bibliography

8. Appendix Building Layout First Floor

Building Layout Second Floor

Plant Layout Check List

iv

29

.30

37

42

43 44

45

46

LIST OF TABLES

Table

1. Comparison of distance travelled in the old versus new layout. {Formulation, Casting and Tape Fabrication)

2, Comparison of distance travelled in the old versus new layout.

Page

20

{Chip Manufacturing, Preheat, Firing, Silvering and Electrical Check.) 21

J. Tabulation of results 22

v

Figure

1.

2.

3· 4.

6.

7· 8.

9.

10.

11.

12.

LIST OF FIGURES

Flow Process Chart (Formulation I through Calcination)

Flow Process Chart (Calcine through Casting)

Flow Process Chart (Tape Fabrication)

Flow Process Chart of Chip Manufacturing (Screening through Cutting)

Flow Process Chart of Chip Manufacturing (Preheat through Electrical)

New Plant Layout First Floor

New Plant Layout Second Floor

New Flow:of work First ·Floor

New Flow of work Second Floor

Building Layout First Floor

Building Layout Second Floor

Plant Layout Check List

Page

15

16

17

18

19

25

26

27

28

44

45

46

--------------------------------------------------------~

vi

ABSTRACT

PLANT LAYOUT

FOR A MANUFACTURING COMPANY

by

Gurcharan S. Soni

Master of Science in Engineering

May, 1975

In this report, both the theoretical and practical

layout of a manufacturing company has been presented.

Basically, the Scientific method was used to gather,

analyze and evaluate data. This was -required for an

optimum arrangement of facilities, including personnel,

operating equipment, storage space, materials ~

handling equipment and all other supporting services.

The new layout will reduce the handling and

transportation of materials by 74%. i.e. The new

arrangement of facilities will require only 26% of

travel to accomplish the same objectives, This

represents an annual savings of 15.5 million feet

of distance that is presently travelled.

vii

I. INTRODUCTION

In order to satisfy the requirements of graduate

work in Engineering, the project Plant Layout haa been

selected for an electronic manufacturing plant in

California.

It is expected that this layout will show an

arrangement of facilities, including personnel, operating

equipment, storage space, materials handling equipment

and all other supporting services to accomplish the

following objectives:

(1) To provid~ maximum satisfaction to all

parties concerned; that is, the employees,

management, as well as the stockholders.

(2) To provide over all simplification.

(3) To minimize cost of materials handling.

(4) To provide effective space utilization •.

(5) To provide for worker convenience and

safety.

(6) To stimulate effective labor utilization.

(7) To make it flexible., so that adjustments

can be made and also to allot adequate

space so that at least 70'/o expansion can

take place within three years.

1

Due to the competitive nature of the product

confidentiality of information will be maintained.

Therefore,the name of the company will not be

disclosed. Also, comprehensive discussion of any

technical data pertaining to plant layout will not

be presented.

For simplicity sake, the cGmpany will be titled

XYZ and.the product manufactured will be referred to

as Chips.

2

2. Theory of Plant Layout

2.1 TYPES OF PLANT LAYOUT

There are three classic types of layout:

(1) Product Layout

(2) Process Layout

(3) Fixed Position ~yout

These layouts are applicable to both fabrication

and assembly operations.

1. Product Layout is one where one type of product

is produced in a given area. This layout places one

operation immediately adjacent to the next. It means

that any equipment used to make the product, regard-

less of the process it _performs, is arranged accor-

ding to the sequence of operations.

The assembly line which manufactures American

automobiles is a good example of product layout. In

this type of layout the product must be standardized

and manufactured in large quantities in order to

justify the product layout.

Advantages of this layout are:

1. Lower materials handling cost.

2. Lower Production time.

J. More effective use of labor.

4. Easier control, less supervision and allows less paperwork.

5. R.educed congestion, and less floor space required per unit of production .

....._ ___________________________ _

3

2.Process Layout: It is also referred to as functional

layout. This is one which groups together all operations

of the same type in a department. All welding is done

in one area, milling in another, plating in plating

room and all painting in paint shop.

The Process Layout is particularly useful where

low volume is required. If the product is not stand­

ardized, the process layout is more desirable because

it has greater flexibility than the product layout.

Other advantages are:

1. Better machine utilization allows lower machine

investment.

2. It is adapted to a variety of products and inter­

mittent demand.

3. It is easier to mainta·in continuity of production

in event of:

(a) Machine or equivalent breakdown

(b) Material shortages.

(c) Absent workers.

J. Fixed Position LaYQut: This is the layout where

material or major component remains in fixed place. It

does not move. Tools, machinery, and men as well as

other pieces of material are brought to this location.

Of the three classical types of layout, the fixed

4

position layout is the least important for today's

manufacturing process. In actual practice, most

layouts are a combination of these classic types.

They are made to utilize the advantages of all three

types.

In the case of company XYZ a combination of

process and product layout was selected due to the

following reasons:

(1) Production volume high

(2) Design of product is more or less

standardized.

(3) Demand for the product is steady.

(4) Most of the machinery is highly expensive

and not easily moved.

(5) Also, it is possible to maintain a balance

in manufacturing operations and continuity

in the flow of materials.

Most significant of all, in this company since

there is one product with hundred~ of variations, the

layout could be classified as a product layout,

although principles of process layout were utilized

in many instances.

··-·-----------....J

5

2.2 APPROACH TO LAYOUT ENGINEERING

The scientific method is appiied quite successfully

to layout engineering. Tt is similar to the procedure

applied to any management problems, because plant

layout is a management responsibility.

The procedure is as follows:

1. State the problem.

2. Get the facts.

3. Restate or clarify the problem in the light

of facts.

4. Analyze and decide on the best solution.

5. Take action for approval and the next phase.

6. Follow up.

6

2,3 FACTORS INFLUENCING PLANT LAYOUT

Richard Muther in his book Practical Plant Layout

states eight factors that influence any plant layout.

Briefly these are

(1) "The Material Factor: includes design, variety quantity, necessary operatinns and their sequence.

(2) The Machinery Factor: includes producing equipment,tools and their utilization.

(3) The Man Factor: including supervision, serv.~ce help, and direct workers.

(4) The Movement Factor: including inter and intra­departmental transport and hand handling at the various operation, storages and inspections.

(5) The Waiting Factor: including permanent and temp·orary storages and delays.

(6) The Service Factor: including employees facilities, maintenance, inspection, waste control, and production control.

(7) The Building Factor: including outside and inside building features and utility distribution and equipment.

(8) The Change Factor: including versatality, flexibility and expansion.~

Each of the eight factors brea~s down into a

number of features and considerations. These can

be found in plant layout guide lists in most

handbooks. The author found this reference extremely

helpul while making the plant layout.

7

2.4 BASIC GUIDE TO MAKING A LAYOUT

These are some of the fundamentals that the

author applied while making the plant layout.

They are:

( 1)

(2)

(3)

(4)

(5)

(6)

(7)

( 8)

Prepare a general plan prior to details.

Plan the ideal and from it the practical.

Plan the process and machinery around the

material requirements.

Plan the layout around the process and

machinery.

Plan the building around the layout.

Plan with the help of others.

Check the layout in each phase.

Sell the layout plan.

In order to carry out the first four steps, a

lot of facts have to be gathered. These facts are

not opinions, but data on the material and products,

the machinery and equipment, the men, and the other

factors involved.

In the case of company XYZ, with the exception

of step 5; the rest were all successfully carried out.

It was not possible to plan the building around the

layout because the space available for the new

facility in terms of area was already defined.

(For building layout see page 44)

~-------------------------------------------------------------~

8

In an attempt to follow the guidelines established,

first the general space requirements in relation to the

volume of production anticipated was determined. This

included space requirements for not only the existing

machinery but also ne~ds for future expansion was

defined. Next, the basic pattern of flow for material

movement was considered. From this was developed

a general over all layout.

A meeting was next arranged between management

personnel to discuss this, and to further restate

the problem. At thQs meeting, it was decided to look

into the possibility of attaining an expansion

scheme of minimum 70%. Also, some detailed require­

ments were spelled out like the need for cafeteria,

· to incorporate the two new departments Silvering

and Electrical Check. Also, to incorporate service

centers such as Silver Making, Jel and Ink Formulation

areas, and also to plan for at least one Conference

Room.

The overall layout was presented for approval.

It was rather conceptual at this stage, but very

clearly stated as to the type of arrangement it will

represent. (See discussion on Types of Plant Layout)

A mutual decision was made on the selection or type

of layout, and the author proceeded to work on the

...__ __________ _

9

detailed plan of integrating men, materials, machines

and supporting activities. In this endeavor, the foll­

owing steps were taken to gather all the ·facts.

(1) Made up flow charts (see.page 15 through 19)

(2) Prepared a listing of equipment and their

measurements.

(3) Capacity study of each operation.

Step 2 An ideal plan was next developed without

regard for existing conditions and costs. This was

a very theoretic scheme. It depicted immediate

operations adjacent to each other and the f:low of

work unidirectional from inception to completion.

This plan carefully was analyzed. It was discovered

that the weight of certain equipment for second floor

was inappropriate. This was due to the fact that the

floor strength of the second floor made of wood

construction and 1-!" light weight concrete will not

withstand-all the loads. Therefore, a practical plan

started to take shape by confining the area

Formulation to the first floor.(Heavy equipment in

Formulation referenced are Ball Mills.) It was also

discovered that the spray drier was too high for the

second floor. An analysis made for the kiln room

that accomodated preheat and firing operations also

~------------------------------------------------------------~

10

. (. '"'·f.'·•'.' ...... ~ .....

revealed that due to several reasons, it was mo1·e

pragmatic to place the kiln department on the first

floor.

Third, the process and machinery was more clearly

defined and it was planned around the materials

requirements. After the proper production processes

were selected, the layout began. The factors influencing

the layout were all considered.

(See page 7 for factors influencing plant layout)

Once a preliminary plan was completed, a

meeting was scheduled to solicit ideas of technical

staff, management and production supervisors who

actually work in the areas and possess a detailed

working knowledge about the job. Given this chance

to participate in planning this layout, a very

harmonious and cooper,qtive atmosphere developed.

Some constructive questions were raised that did

put the author back to the drafting board for further

researchJevaluation and planning.

Since s~veral meetings were called prior to the

completion of the-project, each phase of the project

was checked to ensure that the layout is sound, or

has revealed further improvements that could be

made. Also, see plant layout check sheet in

appendix •

11

Finally, selling the plan after its completion was

accomplished without much problem. Due to several

meetings held with management the layout turned out

to be a success.

12

). DATA COLLECTION AND ORGANIZATION

An inventory of all equipment in house was first

taken. A full listing was generated by each department.

The actual physical dimensions were recorded under

length and width in feet and these converted to inches

by using the scale 1/8" to a foot.

Next, information regarding materials and

processes was gathered, analyzed and evaluated.

The production volume was explicitly defined in terms

of (1) Number of different i terns (product mix)

(2) Quantity of each item per unit time

(J) Variation in output

(4) Variation in demand

From the process analysis, machine capability

study was performed.· This is simply determining

the production rate per hour on a certain operation

given a standard and an efficiency factor. Knowing

the future volume in demand with expansion; in a

matter of seconds the total quantity of equipment

needed was established. Also, from the output rates

it was possible to compute the operating personnel

that would be needed. Similarly, the space require­

ments for storage were figured out.

Other information sought was on the flow of work,

product design and building plan. The flow of work was

13

best represented by making flow charts. The flow process charts are broken down in

three categories:

(1) Formulation and Casting

(2) Tape Fabrication

(3) Chip Manufacturing

The first category entails all activities

performed in formulation and casting. For specific

breakdown see the listing below.

The second category Tape Fabrication entails

operations from Detentioning through Punching.

The third category Chip Manufacturing is the

largest. This encompasses operations from screening

through electrical check.

Formulation and Casting Tape Fabrication Chip Manufact.

Formulation(Weighing, mixing and blending)

Drying 1

Sifting,Grinding

Calcining

Sweco Milling

Spray Drying

Post Oven Drying II

Formulation 2

Ball Milling

Casting

Detentioning

Drying -~III

Candling

Stripping

Punching

Gaging

Screening

Drying IV

Lamination

Cutting

Preheating

Firing

Silvering

Electrical check

93% of Vol.

Main Stock.

5% Vol.

Kiln

Formulatin I '"IIi---# Weigh, Mix &

Blend

Grinding

Calc ining

80% Vol.

Tunnel

' Q .c.

Calcine Stor.

15% Vol.

Furnace

Fig. 1 Flow Process Chart(Formulation I through Calcination)

15

Fig. 2 Flow Process Chart (Calcine through Casting)

9.3% of volume

Calcine Stor.

Formulation II Premix

Ball Milling

Slurry Star.

7% of vol. Main Stock

Q .c. for Moisture

Test

16

Figure 3 Flow Process Chart of Tape Fabrication

Large Oven

·Punch.

Circular ..--Tape

Stor.

r1pp1ng

Detention. (I.R.)

Shrink. Test

50% vol. 50% vol. Manual Auto.

Cd'le.

Punch

Gaging

Inspection

Stk.

17

Fi • 4 Fow

Manual Auto. Screening

.Lamination

Cutting

Preheat Stor.

18

Fi . Flow Process Chart of Chi Manufacturin (Preheat through Electrical

eheat

Inspection

Manual Auto.

Silvering

Silver

'4!--.u F 1r 1 ng

Electrical check

( 1 OO%)

Final Storage

~------------------------~---------------·------------------~

19

20

TABLE I Com~arison of distance travelled in the

Old versus New la;yout

Description of Work Distance Trips ~ot. Dist.

From l To (Ft.) made travelled

Area/Oper. One Way per day (Ft.)

Area/Oper ·~ OLD NEW OLD NEW OLD NEW

Formulation and Casting

Formulation Stock(Routine) 125 5 4 4 1000 40 Formulation Stock(Special) 125 5 1 1 250 10 Form. I Blending 15 24 3 1 45 48 Blending Drying I 180 48 3 1 1080 96 Drying I Grinding 180 5 3 1 1080 10 Grinding Calcining 75 12 5 2 750 48 Calcining Calc. Stor. 75 60 2 1/5 300 24 Calc. Stor~ Sweco Mill. 16 12 2 1 64 24 Sweco Mill Oven Dry 130 48 2 1 520 96 Oven Dry Sweco Stor. 130 48 2 1 520 96 Sweco Stor. Premix 12 12 2 2 48 48 Premix Ball Milling Dis tance abou[t the same Premix Casting(Cir.) 50 36 4 2 400 144 Premix " (Vert.) 40 36 8 2 640 144 Premix II (Horiz ~ 20 36 4 2 160 144 Dirty Jars Cleaning Room 36 24 15 15 1080 720 Cleaned Jars Formulation 36 24 15 15 1080 z2o Formulation Solvent P.U. 150 50 8 4 2400 00

Ta~e Fabrication

Horiz. Cast. Detentioning 220 ;;30 6· 3 2640 180 Vert: Cast. Stripping 80 36 5 3 800 216 Circ. Cast. Stripping "30 25 2 2 _120 100 Detentioning Drying Ovens 25 36 6 2 JOO 1L!-4 Stripping .Detentioning 80 36 6 3 960 216 Detentioning I Punching 90 72 4 2 720 288 Punching Gaging 40 20 8 4 640 160 Gaging Q.C. Check 60 16 .8 4 960 128 Q.C. Stock 60 30 8 4 960 240

--------1..-..--~--l---·--'---- ------·· L-

TABLE 2 Comparison of distance travelled in the

Old versus New layout . f

--------------------------~·~-------=Y~------·~--~---pistance "" . Description of Work

From

Area/Oper.

To

Area/Oper.

CHip Manu~acturing (Scr. through Cutting)

Stock Hand Screening Stock Auro. II

Screening Drying IV Drying IV Q.C. Q.C. Stock Stock Lamination Lam. Q.C. Q.C. Lam. Lam. Cutting Cutting Q .c. (1st Art.) Cutting Q • C • ( Prod . ) Auto. Scr. Cleaning Booth

Preheat and Firing

Q.c. Setters Sto~ Setters Ld. Setters Ld. Preheat Travel Firing

Preheat Load. Area Preheat(Tunnel:::) Preheat(Boxes) Firing For paperwork Q.C.

Silvering and Electrical Check

Q.8. Q.C. Q.C. Silvering E .C.

All Depts.

E .C. (Sample) Prod . ( R e j • ) Silvering E .C. Packaging

Stock

Trips ~ot. Dist. (Ft.)

One Way

I

made !travelled per day l (Ft.)

OLD NEW OLD NEW · OLD NEW

40 60 60 50 40 25 70 70 25 75 60 56

15 wi 50 45

120 100

80

350 80

240 120 150

75

36 6 2 : 480. 144 48 8 2 960 192 24 1 1 120 48

8 1 1 . 100 16 72 1 1 *80 144 12 8 2 : 400 48 20 20 20 2800 800 20 20 20 2800 800 16 20 20 1000 640 16 15 15 2250 480 16 15 15 .1800 480 30 12 12 1320 720

4 15 15 450 120 1 be the :::arne

25 12 12 1200 600 30 15 15 1350 900 25 30 30 7200 1500 50 30 30 6000 3000 36 15 15 2400 t080

! 1

I i

32 15 15 1050( 960 24 5 5 800' 240 16 15 15 . 720d 480 48 15 15 . 360~1440 36 10 10 300C 720

30 15 15 225C' 900

* Old distance in this instance is lower. '-·-·· ·-·-------·----~---------------1-___j

21

TABIE·3

Tabulation of Results

The following table shows results summarized from pages

Dept.

Trips Made/Day Old New

A B.

Form. ~Cast. 83 55

Tape Fab. 53 27 Chip Mfg. a)Scr.

Lam. and cutting 127 111

b)Preheat and Fir. 117 117

c)Silvering and 5 Elect. Ch. 7 75

Grand Tot. 455 385

·%tage Tot.DI~st. Tot. %tage ~ot.Dist. of Trip::Trave&led Dist of dis"~. Saved Saved per ~ay SavecSaved Per Yr.

(1-B/A) Old . New E-F (1-F/E 1 Xx22x12 · x100 E F X x100 Z

" 33% 11~17 2812 8605 75% 2,271720

49% , 8100 1672 642 8 79% 1, 6961 992

13% 14110 4512 9598 6~ 2,533', 872

0 18600 7200 11400 61% 3,009,600

0 27350 4740 22610 83% 5,969,04C

15% I

79577 20936 5 864-1 74% 15 '481 '224

Note: All distances are represented by Feet •

...__ _______________________________ , ___ ___.

4. DEVELOPEMENT AND PRESENTATION OF NEW LAYOUT

After all the data had been collected, a rigorous

analysis was done. It was found from the flow process

charts that due to the inefficiency of present layout

a considerable amount of time was being spent un-

necessarily.

From the actual dimensions of the equipment a

scale of 1/8" to a f.oot was chosen so that the entire

coverage of each floor could be shown on a sheet

size 2Ft. x 3Ft. This sheet being oversize for

the report, it was reduced to 8l"x11". This .. approximately represents 33% of the original. Hence,

the new scale would be about 1/8" to 3Ft. or

1" to 24Ft.

In presenting thi's layout, the transparent

plastic templates were used as opposed to the

conventional drafting techniques. This not only .

saved hours of layout time, but it was possible

to consider more than one alternative due to its

nature of flexibility. For lines, the Chartpack

opaque pressure sensitive tapes were utilized which

were also adhesive backed similar to templates. In

a matter of seconds both tape and templates could

be pasted to represent anything desired. The paper

-------·------------------------------------~----------~

23

used was mylar grid sheet. It was cross sectioned

with l inch squares which made it excellent to

scale everything.

(For detailed plant layout see Fig. 6 & 7

For flow of work see Fig. 8 & 9)

24

~ I

• -----

I

H

RAMP

I-of.

DOWN~~ );·

ON

•

< 0

"

@

SWECO MILLING

SPRAY DRYING

FDRMU LATION

E BALL HILLING Bt. =••I --~ ..

a a~li.~1••111

:=:.___ -]

w C~LC.IN~NG_ .m

. :~=~=~~~_]!! ~-------_j

1-----------r------o

L-

§.~ '. >o "' \

\

[l

~ w ---~0 f- L _ _j

iliC~ I

25

Fig. 6

NEW PLANT LAYOUT

First Floor

• ~##ll#I#R#l+lfflff!#:

II ffifflillllllllllllllll! 11111111 fffltffittttt!=

#l##Fflffi#I#±!UIItllllllllllllllllllll • •

1!11 0 0

Ll ..

~ ,'lll'l;lllllill;;;;;;;; ,,,+l+ftffi' ' ' •••• _q F< R ST ST • ll ~. ~ ;;;;;;;;;;;~ . ~-- 1 DUMPWAITER ,

··-· ··-··

lllllllllllllHifltlllm±llmll

•

C m 1 a ~ I· -- Qil_~~ __ l -- !1J ~~ C· at

•

CAFETERIA •

----JERRY ~ON! AI'RIL I5. !975

•

•

fl -~ ~~~~~ ~~r~ ~ ~

'-, c_~ ___ jc __ ~ __ j • ~---~--~.: :---r§j--~.:

~~~e .. ;11. MANUAL SCREENING

•••• •

'\

..±±±ill±±LSCR MACH N0,3 '!!!!!!!![!!~

~~~ N0.4 .~:RJJIJ ITfTITfiEIJf{jj

AUTmiATIC SCREENING

ltiiFWI£Hiffi-j II I I IIIIi Iii I r$

-lilbmt II II lllllll Ill jlll(jj)

SCREENING

26

Fig. 7

NEW PLANT LAYOUT

Second Floor

!..=c_JII c:::::5· I! 'S" 1 c __ ~ ___ Jc_~~---1~--~---J~--~---J~--~---J'

IIBl IIBl IIBl IIBl

P-1~ l::ll 1!1!1 Ell ii!ll

I§! §i] IIBl IIBl IIBl li!llJ ... ~ Ell Ell B ~

IIBl IIBl g;) IIBl

IIP.IIP.I 1!1!1. 1!1!1 l::ll ~ B B

CUTTING

•B•"; .. :~.·.:JRiii.:_ .• _. .-e.ll •• ___ ifitw bF1ij 111 2.ECONt1 }'f.OOR PL,\.N

SCREEN

REPAIR

11

D

~ . ~ Ul ~ -1 . §

• :-, r-l rl

! i i i i i ! ! ! ! I i

·~1111-ii I I 1 LJ

·I I

I i i ___________ . ___ !

•

1-Ij I-'· 1-i til c+

1-Ij I-' 0 0 1-i

. ..

D )>

~ 1l

0 0 ~ z

/ gj/ 2.;

1-Ij f::-1 §i 1-Ij

I-'· oq

0 1-Ij

2.; co

0 ~ ?-:

•

CAFETERIA •

J~.FY ~c:ci ArRIL IS. n?5'

~

~

"

•

•

tl -~ at .. ~ ,.~,.

~~~~~

n'la·-.· ~-~" .. ~. ·c' ..

t'~ .

28

'\ Fig. 9

New Flow of Work

Second Floor

"·~>.IN t ~llfu:.;~:;:::!:;;:;:::~:~r:

~' ~~~:~~:JI ~ I

AUTN1A1'IC :;cREENI:f)

SCREENING

c;·o·oo r=~ ::.:.l:;r ~ ~~ ~1-l'lttt:J 857d .. ----- -

:.£COll'i:< io'T..OOFI Pt.o\lf

4.1 ADDITIONAL FEA':PURES PLANNED IN

NEW LAYOUT

These are some of the outstanding additional

features planned for thenew facility.

Conference Rooms

Cafeteria

Jel Making facility

Silver Making facility

Electrical Check

Cleaning Facility

Planned Storage Spaces

Lobby

Seperate Security office

Elevator

Dumbwaiter

Better rest room facilities

Better cot rooms for emergency needs

More clocks and racks for punching

Emergency safety features like eyewash and shower

29

5. DESCRIPTION OF THE FLOW OF WORK (See Fig. 8 and Fig.9)

The first department which is Formulation is set

on the first floor shown on the northeast part of the

building. There were numerous reasons for confining

this department to that locality. These are

(1) Being the first operation, it utilizes a

great number of solvents which come in standard

55 gallon drums. The storage area for drums is

located outside the building in the vacant lot close

to the elevator. There is a door between the property

line and the elevator ·just added recently. This

opening will provide an easy access to the solvents.

It is impractical to place .: this department up on the

second floor because there would be a continuous

task of conveying these solvents up. Als~ these

solvents Acetone and Trichloroethelene which are

both volatile and flammable would make it unsafe

to stor·e inside.

(2) This department contains equipment known as

ball mills which are too heavy for the second floor

to withstand this load.

(3) It has heat generating equipment which

have to be seperated from volatiles that are '

combustible. It makes it most practical to group

30

all the heat generating equipment in one location.

In order to keep the commuting distance short, they

are placed at a. minimum distance possible but yet to

comply with OSHA r~gulations.(OSHA defined as Occupa­

tional Safety and Health Administration) Also, these

heat generating equipment the so called drying ovens

and calcine tunnels are located adjacent to the

formulation area which makes it readily accessible.

Above all, the proximity to the dock and the

incoming materials makes formulation location on

first floor most convenient.

The first operation in this department is pre­

weighing of dry chemicals and. then mixing and blending

them together in the Sweco Milling room. After blending,

the slurry is poured in trays, and conveyed· into the

heat generating room to be dried in ovens. The drying

cycle is about 12 hours. When dried1

the white crystals

are .ground and then sifted through the vibration process ..

After the completion of grinding, the white powder is

loaded on to the saggers and placed in the calcine

tunnels for calcination (a heat process of ceramic

powders to temperatures below that required for

sintering in order to pre-react certain ingredients.)

At times calcination is also done in the furnace and

the periodic kiln on the left. This is a batch

31

handling technique and is applicable to certain

materials only. In the process of tunnel calcine the

material is fed from one end and the conveyor transports

it to the other side. Provision for in process

storage is made at the end of the tunnel. At the

end of the day the calcined powder is dumped into

the barrels and transported to the calcine storage

area.

The next operation after calcining is sweco

milling. After milling, the slurry is redried

either through means of spray drying or oven drying

depending on the moisture content specifications. As

an average, 50% of the volume is spray dried and the

rest is placed in the ovens. When drying is complete1

the ceramic powders are sealed and stored in glass

jars ready for use.

Once these swecoed powders are available, the

premix .operation takes place with the addition of

solvents and plasticizers. This solution is put

into the ball mills and milled for a least 24 hours.

When the cycle is complete, the liquid is cooled

and poured into containers. This completes major

operations of formulation. Other service activities

inspection, cleaning of jars and containers and

materials handling of solvents is done where ever

32

necessary.

The slurry from here is next conveyed up to the

casting area. Means of conveyance has not been

finalized yet. Some research is still being done

to see if pumping is the ultimate answer. The

biggest drawback is to resolve the potential danger

of contamination of materials from the residue left

in the tubes. At any rate, this slurry will be used

to cast tape by different means; horizontal, vertical,

and circular.

Upon the-completion of this operation the material ··

will be in roll form. About 65% of the ~olls will

have tape cast on the polypropolene which will be

stripped. The remaining 35% which is cast horizontally

on the belts will go directly into the area of

detentioning. The stripped material will also be

detentioned eventually. After the detentioning

pro~ess there is post drying in the ovens for few

hours. This completes the mild heat process used to

stabalize the shrinkage of tape.

After · detentioning when the tape passes

shrinkage test, most of it is ready for punching.

Some of the tape has to be candled on a bright light

to mark off any visual defects that may have occured

on the tape while casting.

33

Punching is accomplished both automatically

and manually. The manual process is used when the

tape breaks too often mainly for the thin dielectrics

that are less than 1 mil thick. After punching, the

product is in a rectangular wafer of size 3.87.5" X 1.625"

These wafers are gaged and sorted for different

thicknesses.

After grinding and sorting, the material is

placed in stock. At this point the orders that

come from the order desk through Engineering and

Production Control are given the design specifications,

and all the pertinent information required co produce

this part.

Next operation in sequence is Screening. This is

also accomplished both manually and automatically.

Manual machines are used for very small runs, and

the automatics for large volume orders. This is

essentially printing the ceramic wafers with ink,

after which parts are dried in the oven overnight, .•

When drying is complete, a pilot run is initiated.

Upon reviewing the results, the production of lots

takes place in lamination where alternate layers are

stacked and pressed together to form a fusion. These

laminates are next cut into the configuration and

size of the pattern that was originally used for

.34

screening.

At this stage, the product is known as chips

commonly referred to as greenware. These chips are

next transferred to the kiln room below situated

on the far right hand side of the building. This area

being directly located below cutting; chips are

conveyed by means of a dumbwaiter near the stairwell

where the cutting operation terminates. This means

of transport will save a considerable amount of manual

handling and it will be safe and satisfying to

employees as well. At the present, due to 100%

manual handling of chips used for conveyance, the

operation is prone to accidents.

Chips are next received in the Preheat area. They

are loaded into the· boats or saggers and put into

either the preheat tunnel or boxes. The tunnels all

have conveyors and the material is moved forward

autqmatically until the operation is complete. After

preheat, the chips go into firing tunnels or periodic

boxes. The same principle of sintering is applied

here. Note: The preheated parts do not go back.

Therefore, there is no backtracking.

After firing of chips, the units go into Silvering I

via quality control. This is a termination process

where silver is applied to the ends. Silvering

3.5

is also accomplished by several means. Two most

commonly employed techniques are(1) Hand Silvering

(2) Automatic using the rotary machines that automati­

cally dips the chips in silver pots. After the

application of silver the parts are cofired in

silvering tunnels. These are again segregated from

the airconditioning area, but placed into the heat

generating room to save energy. The placement is

made such that it provides an easy access to the

silver kilns without a lot of travel.

When silvering is accomplished the parts are

subjected to elect~ical check for value and other

characteristics being sought. This final operation

completes this unit which is ready for dispatching

and shipment, except in some cases it will go to

another division for encapsulation.

6. BENEFITS DERIVED FROM NEW LAYOUT

1. Reduction in handling and transportation of

materials.

Handling and transportation of materials is

reduced by 74% See Table 3 for comparison of

distance commuted per day between the old and

new layouts. The new distance to travel has

been down to 20,936 feet per day from 79,577

feet or a net savings of 58,641 feet per day.

This represents an annual savings of 15.48

million feet. This savings in commuting will

lower the labor time considerably,. a~1d thus

would yield a lower product cost.

This savings is gained due to the following

reasons:

(1) The flow of work being methodic and

unidirectional, in most cases this type of

arrangement has eliminated backtracking and

crisscrossing. Since operations are placed

adjacent to each other in a sequential manner,

it has reduced all unnecessary travel distances.

(2) Service centers are placed near the

point of use as much as possible. e.g. The

ink making facility is located near screening

which utilizes inks; quality control inspection

--------------------------·--------------------~--·--------~

37

stations placed out on the line rather than in one

. centralized location. Also, the in process storage

centers are well planned and are situated in most

appropriate areas near the manufacturing operations.

(3) All tunnels are laid out in the direction

of work flow, thus serving the purpose of materials

handling equipment as well. e.g. All preheat tunnels

that average 30 feet in length will convey material

30 feet without the need for any additional handling.

A further reduction of materials handling is made

possible by arranging the firing tunnels just where

the preheat operations terminate. Thus an average of

32 feet per tunnel is saved again.

Similarly, the same principle has been applied

in laying out the horizontal casting machines and

the automatic screening machines whose average is

40 feet in length. Material in each case starts

at one end and goes to another and always moving

forward to the next operation in sequence. This concept

has indeed minimized the cost of materials handling.

(4) Efficient means of materials handling equip­

ment utilized. e.g. The dumbwaiter for transpor­

ting of chips from second floor to ,the first floor,

and also the elevator for any bulk heavy item.

38

2. Less congestion, confusion and better supervision.

Due to the improved layout, there will be less

congestion and confusion. It will make supervision

much easier as the supervisors can have more visual

contact with the employees. At present due to

seperations of each department, it makes supervision

very ineffective.

3. Will improve worker morale and worker satisfaction.

(1) There are more services provided in the

new layout as compared to the old.

(See listing of additional features incor­

porated in the new layout.)

The cafeteria itself will provide

hot food for lunches and breaks. Thus it will

satisfy all those who do not like to eat out.

(2) The conference room will be an excellent

place for supeNisors to meet and discuss

daily problems.

(3) Restroom facilities are·more modern and

and updated. Drinking fountains will be

placed in several locations.

(4) Telephone services will be available ln

the cafeteria.

(5) Better lighting conditions, new tools and

fixtures and better seating arrangement

39

will be provided for all employees.

(6) By segregating and centralizing all heat genera­

ting equipment in one area, better air condition­

ing services will automatically result. Also,

improvement has been made for heating service

required during winter months·.

(7) Seperate punching clocks in each floor will

reduce the length of line and will save

employees 6-7 minutes prior to lunch and

working hours.

4.Flexibility of expansion possible.

The layout arranged has been planned for 100%

expansion. In most cases, a minimum of 66%

additional space and equipment are already

reflected in the new layout. It is anticipated

that 100% expansion is possible with some

improvements in process that will further

r~duce space utilization.

Other benefits that can be derived from

this improved layout are:

(1) Reduced risk to health and safety of

employees.

(2) Increased output •

. (3) Fewer production delays.

(4) Greater utilization of machines,

40

manpower and services.

(5) More efficiency will warrant deliveries in

time. This will keep the customers happy.

All the above benefits will inevitably result

in potential savings to the company.

41

1.

2.

3·

4.

5·

6.

7·

8.

9·

10.

11.

BIBLIOGRAPHY

Apple,J.M., Plant Layout and Materials Handling, The Ronald Press Company, New York, 1951.

Muther, R., Systematic Layout Planning, Industrial Educational Institute, Boston, 1961.

Muther, R., Practical Plant Layout, McGraw-Hill Book Company, Inc., New York, 195-5

Gaudreau, A.T., Mallick, R.W., Plant Layout Planning and Practice, John Wiley & Sons, Inc., New York, 1951.

Maynard, H.B. , Industrial Engineering Handbook McGraw-Hill, New York, 1963.

Moore, J.M., Plant Layout and Design, Macmillan company, New York, 19b2.

Shubin and Madeheim, Plant Layout, Prentice-Hall, Inc., 1951.

Murphy, G.H., Labor Code, State of Calif., 1973

Brennan, P.J., General Industry Standards and Interpretation, United States Dept. of Labor, OSHA 1972.

Ireson, W.G., FactoiX Planning and Plant Layout, Englewood Cliffs, N.J.: Prentice Hall, 1952.

Immer, John R., Layout Planning Technique, New York: McGraw-Hill Book Company, 1950.

42

APPENDIX

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Fig.

,PLANT LAYOUT CHECK SHEET

Cpmpany. Plant I Checked By Date

Before submitting the layout for official approvals, check against the following items

INDUSTRIAL ENGINEERING

; 1. Machinery and equipment arranged to make full use of capacity?

/ 2. Machinery and equipment accessible for material supply and removal?

-' 3, Machinery and equipment located for maximum operator efficiency?

4. Line production used where practical? 5. Proper use made of mechanical handling? 6. Processing combined with transpo~tation? 7. Minimum walking required of operators? 8. Finished work ·of one operator easily accessible to

next? 9. Machinery and equipment "block in" any operators?

10. Machine overtravel extend into aisles or interfere with operat'Jr?

11. Adequate storage space at work stations? 12. Efficient work place layouts? 13, Service areas conveniently located: (tool room, tool

crib, maintenance, etc.) 14. Easy for supervisor to oversee his area? 15. Machine arrangement permit maximum flexibility in

case of product change? 16. Space allocated for foremen and production control

records? 17. Related activities located near each other? 18. All required equipment included in layout? 19. Floor area fully utilized? 20, Provisions made for expansion? 21. Provisions for. scrap removal? 22. Crowded conditions anywhere?

MATERIAL HANDLING

1. Incoming materials move directly to work area? 2. Processes involving heavy or bulky materials close

to receiving area? 3, Sub-assemblies flov. into final assembly? 4. Plans for auxiliary material flow in case of tie-up? S. Minimum of backtracking? 6. Obstacles in material flow?

not applic. OKiremarks

12 46

not OK remark a MATERIAL HA~WLING (cont'd) applic. 7, Excessively long moves? 8. Conveyors "box in" anyone? 9. Material handling equipment bring materials to

operators? 10. Material handling equipment remove materials from

operators? 11. Each material handling method integrated into

overall system? 12. Conveyors from receiving to processing areas? 13, Conveyors from assembly to shipping area? 14, Minimum of manual handling? 15, Material handling equipment carry materials in a

position to conserve space? 16, Widely separated areas connected by suitable

mechanical handling system? 17, Aisles and doors wide enough for maximum loads

and fire equiprr:ent? 18, Ramps at lowest possible grade? 19, Proper use of conveyors for efficient handling? 20. Adequate storage space for containers and material

handling equipment? . 21. Use of conveyors for floats and banks of material? 22, Adequate storage for materials in process? 23. Shipping and receiving docks covered? 24. Proper dock heights and/or levelling devices? 25. Maximum use made of building cube? 26. Aisles straight and clearly marked?

PERSONNEL AND SAFETY

1. Exits, fire doors and fire escapes ade.quate and properly located? Free of obstruction?

2. Easy exit from any location in building? 3, Plans checked by local fire, police and safety

officials? 4, Plans approved by insurance companies? 5. Lifts and hoists provided for loads over 50 lbs,? 6. Adequate work area for each operator? 7, Easy access to all safety devices.? 8, Hazardous and unpleasant operations isolated? 9, Adequate storage for inflammable materials?

10, Drinking fountains in enough lqcations? 11. Maximum use made of natural light? 12. Adequate artificial light provided for? 13, Proper ventilation provided where required?

PERSO~~EL A!'.""D SAFETY (cont'd)

14. Employee service areas provided for and conven• iently located:

a, first aid b. toilets c, locker rooms

e, coat racks ~ f, food service

g. time clocks d. smoking areas h. stretchers

15, Parking space provided for employees?

PLANT ENGINEERING

-1. Floor loads within allowable limits? 2. Overhead clearances adequate? 3. Proposed overhead loading within limits? 4. Special foundations or equipment mountings

required? 5. Floor and roof drains provided for? 6, Elevators required, located, specifie!f? 7, All possible use made of under-floor, overhead, and

on-the-roof space? 8, Layout make efficient use of building shape, size,

cube? 9, Machinery and equipment accessible for mainten•

ance? 10. Layout conducive to good housekeeping? 11. Provisions for rubbish collection, storage, and

removal? 12. Utilities provided for and properly located:

a. air g, sprinklers b. gas h. sewers c. water i. air conditioning d. electricity j, heating e, steam k. ventilation

, f, telephone 1, lighting 13, Detailed drawings of special equipment or installs•

tions? 14. Fire extinguishers and fire protection equipment

provided for? 15. Layout sati:;fy all safety codes?

PRODUCTION CONTROL

1. Inventory checking easy? 2. Adequate space and facilities for salvage opera•

tions? 3, Proper protection for material and finished goods

storage? 4. Valuable materials pro.ected from pilferage? S. Adequate space for shipping and receiving?

Fig, 12 47 not OK remark a

PRODUCTIO~ CO~TROL (cont'd) applle. not

applie. I OK I ret:~ arks

6. Adequate area for trucks waiting at shippin~ and receiving?

7, Layout pennit operations to be per(onned in logical se(J.uence?

8. Easy' adjustment to changing schedules? 9, Layout permit paced production?

10, Will equipment breakdown shut down line or plant? 11. Inspection points located at strategic points? 12. Straight flow lines?

OTHER COMMENTS OR SUGGESTIONS

.