FACILITY DESIGN PROJECT 2016-2017 2nd SEMESTER

Group Efficiency Units per Week

(%) ROT CAC
1 92 300 750
2 90 300 700
3 88 300 650
4 85 300 600
5 92 500 550
6 90 350 650
7 88 350 600
8 85 280 620
9 92 400 650
10 90 320 680
11 88 250 700
12 85 250 650

Product Name
The wood manufacturing company has 2 types of product:
1. Rectangular Oak Table (ROT)
2. Casual Armchair

Manual works can be performed on the table/bench, or on the floor.

The scrap of other processes is assumed to be zero defect.
One shift per day, 8 hours per shift, 5 working days in a week, and 4 weeks per month.

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Product Drawing
1. Rectangular Oak Table

Figure 1. Rectangular Oak Table

2
Figure 2. Casual Armchair
3
 Table 1. Product/Part Specification and Other Indirect Material
Part Name Number Part Specification Raw Material
of parts Thickness Length Width
per prod (inches) (inches) (inches)
Rectangular Oak Table (ROT)
110 Top Surface 1 46 38
111 Top Surface Slat 11 46 3 Oak 60 x 3 x
112 Frame Top Surface(B) 2 46 3 Oak 60 x 3 x
113 Frame Top Surface(B) 2 38 3 Oak 60 x 3 x
120 Base Surface 1 46 38 Plywood 4 x 4 x
140 Pedestal 1
141 Pedestal Pieces (E) 4 27 8 Oak 10 x 8 x
142 Feet (F) 4 22 5 Oak 8 x 5 x
143 Pedestal Support (G) 4 2 8 2 Fir 3 x 2x 2
Flathead screw 1 x #8 22 Buy
Flathead screw 2 x #8 36 Buy
Flathead screw 2 x #12 8 Buy
Carriage Bolts x 2 8 Buy
Washer 8 Buy
Nut 8 Buy
Allphatic Resin/Resin Glue Buy
Wood Filler Buy
Sand paper Buy
Clear Polyurethane Finish Buy
Carton, plastics, label Buy
Casual Armchair (CAC)
210 Front Leg (A) 2 25 1 Birch 12 x 2 x 1
220 Stretcher (B) 3 20 1 Birch 12 x 2 x 1
230 Side Stretcher (C) 2 14 1 Birch 12 x 2 x 1
240 Arm (D) 2 19 2 Birch 3 x 3 x 1
250 Rear Leg (E) 2 25 3 Birch 4 x 4 x 1
260 Back 1
261 Back Steel Rood (I) 1 9 Round steel bar x 5
262 Canvas Back 1 23 9 Buy
270 Seat 1
271 Seat Steel Rod (H) 1 17 Round steel bar x 5
272 Canvas Seat 1 23 17 Buy
Dowelling x 4 8 dowels x 3 ; 8 dowels x 1 Buy
Hanger bolt x 2 6 Buy
Washer 6 Buy
Cap Nut 6 Buy
Wood Filler Buy
White Glue Buy
Sand paper Buy
Clear Polyurethane Finish Buy
Carton, plastics, label Buy

4
 Table 2. Machine/Equipment List
Dimension
MACHNE/EQUIPMENT
(length x width) m
Jointer 2.2 x 0.6
Circular Saw
Radial Arm Saw
Router 1.2 x 1.2
Jointer 2.2 x 0.6
Disc. Sand/Power sander
Drill Press
Table Saw 1.6 x 1
Bench/Table
Cut off Saw
Spray Booth/Gun Spray

Hint: other tools, jig and fixtures (such as: square, pencil/marking, clamp, screwdriver, dust
collector, compressor, etc.) should be considered and included in the process design.

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 ROUTE SHEET FOR RECTANGULAR OAK TABLE (ROT)

111 Top Surface Slat (11)

Prod.
Op Process Name Machine Time Capacity Scrap Requirement Number
No (min) theoretic Actual (%) In Out of M/C
Mark using square for
10 whole raw material 10.0
20 Cut to the length 46.5" circ. saw 2.0 1
30 Sand all surfaces disc sand 4.0

112 Frame Top Surface B (2)

Prod.
Op Process Name Machine Time Capacity Scrap Requirement Number
No (min) theoretic Actual (%) In Out of M/C
Mark using square for
10 whole raw material 10
20 Cut to the length 46.5" circ. saw 2.4 1
Cut for the joining
30 edges jointer 1.8 2
40 Sand the edges disc sand 2.6

113 Frame Top Surface C (2)

Prod.
Op Process Name Machine Time Capacity Scrap Requirement Number
No (min) Theoretic Actual (%) In Out of M/C
Mark using square for
10 whole raw material 12
20 Cut to the length 38.5" circ. saw 2.4 1
Cut for the joining
30 edges jointer 1.8 2
40 Sand the edges disc sand 2.6

120 Base Surface

Prod.
Op Process Name Machine Time Capacity Scrap Requirement Number
No (min) theoretic Actual (%) In Out of M/C
Mark using square for
10 whole raw material 3.00
20 Cut to the width 38.5" jointer 0.48 2
30 Cut to the length 46.5" circ. saw 1.5 1

141 Pedestal Piece (4)

Prod.
Op Process Name Machine Time Capacity Scrap Requirement Number
No (min) theoretic Actual (%) In Out of M/C
Mark using square for
10 whole raw material 4.00
20 Cut to the length 27" circ. saw 1.4 1
30 Mark for the pilot
screw 2.2

6
 40 Drill 2" screw for 5
holes drill press 2.4 1
50 Sand all surfaces disc sand 3.2

142 Feet (4)

Prod.
Op Process Name Machine Time Capacity Scrap Requirement Number
No (min) theoretic Actual (%) In Out of M/C
Marking using square
10 for whole raw material 4.00
20 Cut to the length 22" circ. saw 1.4 1
30 Mark for the pilot
screw 2.2
40 Drill 2" screw for 4
holes drill press 2.1 1
30 Sand all surfaces disc sand 2.8

143 Pedestal Support

Prod.
Op Process Name Machine Time Capacity Scrap Requirement Number
No (min) theoretic Actual (%) In Out of M/C
Marking using square
10 for whole raw material 4.0
20 Cut to the length 8" circ. saw 1.4 1
30
Mar for the pilot screw
2
40 Drill 1/4" bolt holes drill press 3 1

Assembly Top Surface (110)

Prod.
Op Process Name Machine Time Capacity Scrap Requirement Number
No (min) theoretic Actual (%) In Out of M/C
10 Apply glue & attach all
11 top surface slats jointer 15 2
20 Apply glue on top of
base surface circ. saw 3.6 1
30 Join the base surface
with top surface 1
Drill 1" by #8 screw,
40 7.75" from each end drill press 12 1
50 Put all screws 8
60 Trim off all ends table saw 5
Join all frames using
70 glue 4.8
80 Fill all the holes and
gaps with wood filler 5.6
90 Sand all surfaces 4
100 Apply two coat of
polyurethane gun spray 1.6

7
Assembly Pedestal (140)
Prod.
Op Process Name Machine Time Capacity Scrap Requirement Number
No (min) Theoretic Actual (%) In Out of M/C
10 Apply glue and attach 4
pedestal pieces jointer 0.8 2
20 Hold and clamp circ. saw 1.4 1
30 Fasten with 2" screws 6
40 Put off the clamp 0.6
50 Attach all the pedestal
supports using glue 4
60 Fasten using 2.5" bolts 3.6
70 Attach all the feet
supports using glue 8
80 Fasten with 2" screws 3
90 Fill all the holes and
gaps with wood filler 3.2
100 Sand the dry filler 4
110 Apply two coat of
polyurethane gun spray 2

Assembly Final Product

(ROT)
Prod.
Op Process Name Machine Time Capacity Scrap Requirement Number
No (min) theoretic Actual (%) In Out of M/C
Inspection of 110 and
10 140 0.9 1
30 Final coating gun spray 1.8
40 Final inspection circ. saw 1.4 1
50 Packaging 0.8

8
 ROUTE SHEET FOR CASUAL ARMCHAIR (CAC)

210 Front Leg (2)

Prod.
Op Process Name Machine Time Capacity Scrap Requirement Number
No (min) Theoretic Actual (%) In Out of M/C
Mark using square
for whole raw
10 material 2.60
20 Cut to the width 1.5" jointer 0.86 1
30 Cut to the length 25" circ. saw 0.36 1
Mark of 0.75" from
40 edge and pilot holes 0.24
Remove of 0.75"
50 rounded edge router 0.40 1
60 Drill the holes drill press 0.40 1
70 Sand all surfaces disc sand 0.66

220 Stretcher (3)

Prod.
Op Process Name Machine Time Capacity Scrap Requirement Number
No (min) Theoretic Actual (%) In Out of M/C
Mark using square
for whole raw
10 material 3.00
20 Cut to the width 1.5" jointer 0.90 1
Cut to the length
30 20.5" circ. saw 0.40 1
40 Drill 0.25" holes drill press 0.60
50 Sand all surfaces disc sand 0,84
60 Apply two coat of
polyurethane gun spray 0.45

230 Side Stretcher (2)

Prod.
Op Process Name Machine Time Capacity Scrap Requirement Number

No (min) Theoretic Actual (%) In Out of M/C

Mark using square
for whole raw
10 material 3.00
20 Cut to the width 1.5" jointer 0.90 1
Cut to the length
30 14.5" circ. saw 0.40 1
40 Drill 0.25" holes drill press 0.60
50 Sand all surfaces disc sand 0.84

9
240 Arm (2)
Prod.
Op Process Name Machine Time Capacity Scrap Requirement Number
No (min) Theoretic Actual (%) In Out of M/C
Marking using square
for whole raw
10 material 2.00
20 Cut to the width 2.5" jointer 0.68 2
30 Cut to the length
19.5" circ. saw 0.55 1
40 Mark of 0.75" of
edges 0.44
50 Remove of 0.75"
rounded edges for
notches Router 1.10 2
60 Drill 3/8" holes on
rounded edges Drill press 0,88 1
70 Sand all surfaces disc. Sand 0.92

250 Rear Leg (2)

Prod.
Op Process Name Machine Time Capacity Scrap Requirement Number
No (min) Theoretic Actual (%) In Out of M/C
Mark using square
for whole raw
10 material 1.80
20 Cut to the width 3.5" jointer 0.80 1
30 Cut to the length 25" circ. saw 0.36 1
Mark of 0.75" from
40 edge and pilot holes 0.38
Remove of 0.75"
50 rounded edge router 0.40 1
60 Drill the holes drill press 0.80 1
70 Sand all surfaces disc sand 0.72

260 Back (1)

Prod.
Op Process Name Machine Time Capacity Scrap Requirement Number
No (min) Theoretic Actual (%) In Out of M/C
Mark the bars to
10 length 9.5" 4.00
20 Cut steel bar to
length 9.5" cut off saw 1.4 1
30 Attach canvas sling to
bars 2.2

10
270 Seat (1)
Prod.
Op Process Name Machine Time Capacity Scrap Requirement Number
No (min) Theoretic Actual (%) In Out of M/C
Mark the bars to
10 length 17.25" 0.80
20 Cut steel bar to
length 17.25" cut off saw 0.3 1
30 Attach canvas sling to
bars 0.72

Sub Assembly Arm and Leg (2)

Prod.
Op Process Name Machine Time Capacity Scrap Requirement Number
No (min) Theoretic Actual (%) In Out of M/C
Attach 4 dowels
(1.5") into edges of
10 arm using glue 0.75
Assemlbe front and
20 rear legs to arm circ. saw 2.82 1
Assemble side
stretcher using 4
30 dowels (4") & glue 2.00 2
Inspect and fill all
40 gaps with wood filler 1.30
50 Apply two coat of
polyurethane gun spray 0.78

Assembly CAC
Prod.
Op Process Name Machine Time Capacity Scrap Requirement Number
No (min) Theoretic Actual (%) In Out of M/C
Connect 3 stretchers
to 2 SA Arm and Leg
using washer, hanger
10 and cap nut 3.2
Fill all gaps with
20 wood filler 0.88
Sand the filler
30 contained 0.56
40 Final coating gun spray 0.90
50 Assemble the seat 2.40 1
60 Assemble the back 1.80 1
70 Final inspection 1.00
80 Packaging 0.8

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 Table 3. Material Handling Cost
Unload Load
Cost Speed Speed
No Volume MHE (Rp/m) (m/hr) (m/hr)
1 0 20 kgs Manual 300 5,000 2,000
2 Max 130 kgs Hand truck 4,000 5,000 3,000
4 Max 2,500 kgs Hand Pallet Truck 12,000 10,000 8,000

Table 4. Material Density

No Material Density
1 Plywood 500-650 kg/m3
2 Oak 749 kg/m3
3 Paper 450 kg/m3
4 Birch 670 kg/m3
5 Plastic 8.50 kg/m3
6 Iron 7,250 kg/m3
6 Paint 3,750 kg/m3
7 Glue 1,250 kg/m3
8 Thread 100 kg/m3
Mild steel
9 (screw, nail, etc) 7.75 8.05 kg/m3
10 Polyurethane 25 55 kg/m3

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Space Requirement for Storage

Calculation of Material Requirements

Finished Product Dimension Material Dimension

Part L W T/ L W T/ Demand Req. Req.
No Code Part Name (inches) (inches) (inches) (inches) (inches) (inches) (unit/hr) (units/hr) (units/LT)

Aggregation of Material Requirements

Material Dimension Actual

Material L W T/ Part Req. Req.
N0 Code Material Name (inches) (inches) (inches) Part Code Name (units/LT) (units/LT)
1 RL01 Rough lumber (") 40 40 TC 01 Chassis 23.56 24
TC 06 Wheels 21.2 22
46

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 Space Requirement Calculation for Storage (Direct Material)
Pallet dimension
Actual
Material Reg Vertical Horizontal L W Area Allowance Total Area
No Code Material Name (units/LT) Stacks Stacks (ms) (ms) (m2) (200%) (m2)
1 RL01 Rough lumber (") 46 10 5 1.5 1.5 11.25 22.5 33.75

*Notes: using pallet or rack

Please draw the pallet or rack for the
illustration

Hint:
Calculation of Storage Space Requirement includes Direct Raw Material and Indirect Raw Material (Glue, sand paper, thread, bolt, nut, screw, plastics,
label and other packaging materials). The indirect material should be keep in a container such as box, tin, gallon or bottle, etc. and all those containers
should be drawn and explained in detailed.
Other information:
Lead time for material is 10 working days
Lead time for Finished Goods is 5 working days

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From to Chart
Calculation of the Material
Material L W T/ Volume Density Weight
No Name (inches) (inches) (inches) (m3) (kg/m3) (kgs)

Calculation of the Part's Weight

Part L W T/ Volume Density Weight

No Code (inches) (inches) (inches) (m3) (kg/m3) (kgs)
TC01 2 1/8 1/2 6 1/8 0.000107 600 0.063986

Chassis
Op Process Name Machine Scrap Prod. Requirement
No (%) In Out
O-1 Plane flat surface Planner 2 459.9611 450.7619
O-2 Cut to the width Jointer 1.5 450.7619 444.0004
O-3 Cut to the length Circle saw 2 444.0004 435.1204
Sand with sand
O-4 paper Disc sand 1 435.1204 430.7692
O-5 Coat Spray gun 2.5 430.7692 420

The total movement from planner to jointer is 450.7619 units

The total movement in kgs = 450.7619/unit x 0.063986 kg/unit
= 28.84261 kgs/hour

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Aggregate of the material of flow

Total
Part Weight/hour
No From To Code (kgs)
1 Storage Planner C1 20.5
C2 20.6
C3 30.9
C4 40.4
C5 70.5
182.9
2 Planner Jointer TC01 28.84261

Warehouse

From to Chart

To
From Storage Planner Total
Storage 182.9
Planner

Total

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