Facilities Planning Essay Example for Free

Facilities Planning Essay* To understand the basic fundamentals and importance of Facilities as applied in the Small or Medium-Scale Manufacturing industries* To understand and yield the concepts of product and process design in terms of MANUFACTURING* To develop alternative materials in to yield cost-reduction and productivity* To understand and apply the concepts of evaluating, selecting, preparing, presenting, implementing and maintaining the workplace and formulate preventions and resolve repairments.* To conduct improvements in product mix and design processing and materials technology handling, store, and control technology proceeds volumes, schedules, and routings, and Management philosophies. * To come up with assessment, findings, analyses and recommendations on how to pronto respond to varying customer requirements.* To propose changes whether in the process, methods, or materials with the end view of improving the reduction of work-in-process and just-in-time man ufacturingREVIEW OF RELATED LITERATUREMachines Can exclusively Produce as Efficiently as the People Who Operate ThemSummaryU.S. manufacturers are making a strong effort to gain back approximately of the consumer loyalty lost to their foreign competitors, who since the late 70s have been offering Ameri spate consumers higher quality products at lower costs.U.S. companies believed that foreign competitors were subject to achieve more than efficient proceeds by dint of technological advances, when in fact the competition abroad was actually achieving increased drudgery by relying on more fertile heap, not machines. Addressing this misconception, U.S. manufacturers have begun to concentrate efforts on making people more productive and machines more employr friendly.Manufacturers are beginning to realize the best delegacy to improve quality and increase force is through better training and more informed operators. A person who is given a clear counselling as to what the corp orate objectives are for his or her function, as well as responsibility and authority, get out produce a far superior product than a person who has no ownership in their job. There is no one better equipped to improve a process than the person working juxtaposed to it.Modernizations have reduced the overall number of machine operators, a greater majority of those remaining are being asked to take a more accountable and participatory role in the manufacturing control process. Rather than being blindly driven by new manufacturing technologies, companies are inquireing better ways for operators to interact with their machines or processes. Operators are being asked to become managers, to be more referd in the decision-making process, they are being trained to utilization tools designed to finalize whether the manufacturing process leave result in a quality product.Effectively operators need fast access to accurate data. Since the operator workstation is at the heart of each man ufacturing information dust, the submersion has been to make workstations more responsive. Operators are demanding higher levels of information presentation in their workstations, so design engineers have been forced to seek technology that not whole allows for a more sophisticated display of information, but also permits the operator to act on the information quickly, accurately and easily.The demand for increased productivity and efficiency on the fancyt floor has prompted factory floor automation suppliers to develop more open relationships to identify effective methods of integrating new technology into the production process. Suppliers are beginning to realize the advantages of sharing their proprietary design information. While there is a risk associated with releasing technological information, the benefit to suppliers working cooperatively to give operators the tools they need to be more productive is increased market share domestically and worldwide. As we strive to d eliver more information to the factory floor in less time through advances in computer technology, we should never forget that our or so sophisticated technologies must eventually flow through the hands of a single operator. Thats why companies are devoting resources to bringing products to market which make the connection between man and machine easier, faster and better.COMPANY background signalThe Rotessas Garment was owned by Mr. Rogelio Habacon Sr. The consummation started at the year 2003. They found out that the demand of denims or known as pants can be a good business. They sub contract the different kinds of pants like Diesel, Guess, Nafnaf, Abercrombie and many more. As of now their main client was the Swan Lake which is amenable for distributing in the market.According to Mr. Rogelio Cu Sr., the assistant, being in the garment business is hard to manage. You really have to put more attention to be able to have a large profit. One of the main problems they are encounte ring was the sewers. They must be trained properly and there must be discipline.Existing demand 152 pieces/day (Standard) 19 units per hourNo. of workers 25 workersNo. of machines 22 machines6 Special Machines* FOA* Pipe laurel wreath* Loop Machine* Bartaxs* Waist cover machine* Button holes16 High Speed Sewing MachinesMachine CostAll machines were second handPHP 20,000 High Speed Machine(per machine)PHP 25,000 ButtonholesPHP 15,000 Pipe threadPHP 20,000 Waist Binding, Bartax, Loop MachinePHP 15,000 FOAWorking Time* 4 Hours per day* 8 Hours per day* Unlimited or 24 hoursSales per UnitPHP one hundred twenty-fiveSTATEMENT AND DESCRIPTION OF THE PROBLEMRotessas Garments main problem is manual material handling in transferring their products. They generate waste from the time on hand (waiting), dispersion and processing of garments.By assessing the companys workplace the team found out that these problems were generated due to the lack of workers performance, the equipment bein g used, material handling and transportation techniques.Since cutting, sewing, and pressing of buttons are involve in the operation, handling of materials play an important role. Work done causes difficulty since the method of work is time-consuming.Signs are situated at the left area of the vicinity. It is post on the wall where some workers cant see. Because of this, some workers forgot to follow proper procedures and policies inside the building. This creates difficulty with respect to the processing sequence of the industry.We have observed that the operation in the shop environment is manual creating complexity with the tasks being utilized by the workers. There is an improper placement of raw materials and low-down layout of the orderly flows of material, equipment, people and information.We can say that the equipments being used are over-depreciated, which can no longer be used to utilize production effectively. The reason why poor equipments are present is because of improp er maintenance of equipment.Tools like scissors, cutters and screwdrivers are not properly secured. This happens because there are on policies that involve good handling of equipment. precise OBJECTIVES OF THE STUDYThe following objectives of this tuition should be considered* Create an environment that results in the production of high-quality products* Provide planned and orderly flows of material, equipment, people and information* Design a layout and material handling scheme that can be easily adapted to changes in product mix and production volumes* Reduce work-in-process and provide controlled flow and storage of materials* Reduce material handling at and between workstations* Utilize space most effectively, considering overhead space and impediments to cross trafficSCOPE AND LIMITATIONS OF THE STUDYThis study focuses on the methods, layout and processes used in the Garment industry. We limit our scope within the product mix and design processing and materials technology han dling, storage, and control technology production volumes, schedules and routings and management philosophies. All the data collected in this study must meet the requirements stated in the objective of the study. However, each study has its limitations that will be discussed below.* Inflexible in the number of products manufactured* Improper labeling, storage and arrangement of materials* Inflexible layout* Large deviation in production rates in field of study of equipment failure in the line* Waste arising from unnecessary motion (unlikely event)* Waste arising from producing defective products* Waste arising from transporting* Waste arising from processing itself* Waste arising from unnecessary stock on handDESCRIPTION OF THE OPERATIONSTEPS IN MAKING PANTS DRAFTING PATTERN MAKING CUTTING CODING SEWING1. Marking or Stamping2. Edging of pockets3. Heaming4. Watch pocket to bird-scarer pocket5. Front pocket to lining6. Lining to front ornament7. Staynant8. Zipper to ply9. Zipper to panel10. hook zipper11. Connecting riser12. Back seam13. Attach back pocket to back panel14. In seam15. Side seam16. Tap side (side binding)17. Waist band18. Closed band19. Making loops20. Heam leg21. Button holes22. Bartaxs / loops attaching23. Trim24. Revise and fold WASHING FINISHINGFLOW graph(PRESENT SYSTEM)DATA PRESENTATION AND ANALYSISIn order to determine what specific problem we will be focusing on, we will use the Pareto principle to determine the significant few (80%) of the main problems in the company. We will focus on the significant few problems of the company however, we will still propose an improved plan for the trivial many after payback period of the first investment in order to fully utilize production rates effectively. The reason hindquarters this is because the company does not have enough funds to support the entire plan that will be proposed. After saving enough money from the minimisation of the top problems, the company will implement the entire plan th at will be proposed.Identifying the reasons of the impact on the facilities design function, the researchers surveyed the reasons of such event. The survey resulted as follows destinationWe design a plan in order to solve the significant few problem of the company. This program is designed to provide the smoothest flow of materials, achieve flexibility, improve quality, increase productivity and space utilization, and simultaneously reduce facilities and operating costs. The following trends can be utilized* Eliminate or minimize non-value-adding activities* Simultaneously use Material Handling* Improve design* Proper storage and arrangement of materials* Anticipate unlikely events* Proper labeling* Need for test/ inspection* Ergonomic orientation* Minimize the use of time and space resources* Manufacture in the shortest cycle time possible* Stockless production* Material as needed and required* Continuous-flow manufacturing* Zero-inventory production systemsIn conclusion, we recom mend this plan that we designed to improve the performance of the company and to improve the impact of the facilities design function. The continued trend toward just-in-time manufacturing puts the material handling and layout functions to the front line. By designing and implementing the plan we were able to meet out objective and creates the essence of the material handling function by 50%. The following elements will be further discussed* Right AmountHow much inventory is needed?What is needed?What is not anticipated?* Right MaterialSimplifying the parts numbering system and maintaining the integrity and accuracy of the database system are more fundamental tasks* Right SequenceEliminate unnecessary operations or improving those that remain.* Right penchantMeans positioning the material for ease of handling* Right PlaceAddresses both transportation and storage. It is desirable to directly transport material to the point of use rather than store the material at some intermediate l ocation.* Right TimeIt means on-time delivery. The goal is to develop a material handling system that will result in lower production cycle times, and not to lower material handling delivery times.* Right CostTo design the most efficient material handling systems at the most reasonable cost. This would entail the lowest possible cost that can be acquired from the From-To Chart.* Right Method apply more than one method is generally the right thing to do