An-Najah National University
Faculty of Engineering and Information Technology
Mechanical Engineering department
Project of
Industrial Plants Layout and management(67430) for AL-Hizam Company for Carton industry
Team #6 :: Omar Rizq-allah ahmed
Oday Amouri Abdul-qader salameh Jehad shamlouli Ahmed istatieh Tareq khrim Submitted to Dr. Mohammed Othman 29/11/2013
1.0 Introduction
AL-Hizam Company for Carton industry specializes in carton industrial processes, such as cutting and printing. The factory faces some problems in arranging its machines, and also in storing raw materials and delivering it to the machines. As shown in the following figures.
Finally, we get information and limitations for this specific project and take it as constraints, after that we compare our results with these constraints and make some recommendations.
Fig (1): Al Hizam Company.
Fig (2): Printing Machine.
Fig (3): Store.
2.0 Description Department | Description | Area(m^2) | D1 | Printing | 33.15 | D2 | Pasted | 51.1 | D3 | Printing +cutting | 109 | D4 | Cutting | 60.8 | D5 | Shipping | 28 | D6 | Cutting | 41 | D7 | Printing +cutting | 49 | D8 | Pasted | 21.6 | D9 | Printing+cutting+pasted | 75.32 | D10 | Spline cutting | 34.8 | D11 | Striation | 33.89 |
3.0 Existing Layout
The factory was arranged in random arrangement which cost the owner many time , money, effort to add or replace machines.
Fig (4): Old Layout.
* Distance within facility was taken for existing department
Table(1): From to chart (distance matrix in mm) | D1 | D2 | D3 | D4 | D5 | D6 | D10 | D1 | - | 8.9 | 15.5 | 9.7 | 16 | 6.6 | 18 | D2 | - | - | 7.7 | 12.5 | 15.8 | 7 | 13 | D3 | - | - | - | 13.5 | 15.1 | 11 | 4.5 | D4 | - | - | - | - | 5.3 | 16.6 | 9.6 | D5 | - | - | - | - | - | 21 | 3.1 | D6 | - | - | - | - | - | - | 18 |
* Flow or quality relation was taken by a experts and flow.
Table (2): relation ship Chart | D1 | D2 | D3 | D4 | D5 | D6 | D10 | D1 | - | O | O | E | O | O | U | D2 | - | - | A | A | A | X | O | D3 | - | - | - | I | E | O | I | D4 | - | - | - | - | I | O | U | D5 | - | - | - | - | - | O | U | D6 | - | - | - | - | - | - | U |
* Score for existing layout .
Table(3) : score rate Rate | A | E | I | O | U | X | Equivalent | 10 | 6 | 3 | 0.5 | 0 | -10 |
Table(4) : score chart | D1 | D2 | D3 | D4 | D5 | D6 | D10 | score | D1 | - | 0.5 | 0.5 | 6 | 0.5 | 0.5 | 0 | 8 | D2 | - | - | 10 | 10 | 10 | -10 | 0 | 20 | D3 | - | - | - | 3 | 6 | 0.5 | 3 | 12.5 | D4 | - | - | - | - | 3 | 0.5 | 0 | 3 | D5 | - | - | - | - | - | 0.5 | 0 | 0.5 | D6 | - | - | - | - | - | - | 0 | 0 | Total score | 44 |
* Cost for existing layout.
According to cost = f c d where d: distance , f :flow , c: moving cost =1
Table (5) : cost matrix | D1 | D2 | D3 | D4 | D5 | D6 | D10 | TOTAL | D1 | 00 | 4.45 | 7.75 | 58.2 | 8 | 6.6 | 0 | 85 | D2 | 00 | 0 | 77 | 125 | 158 | -70 | 0 | 290 | D3 | 00 | 0 | 0 | 40.5 | 90.6 | 11 | 13.5 | 155.6 | D4 | 00 | 0 | 0 | 0 | 15.9 | 16.6 | 0 | 32.5 | D5 | 00 | 0 | 0 | 0 | 0 | 21 | 0 | 21 | D6 | 00 | 0 | 0 | 0 | 0 | 0 | 0 | 0 | total | 00 | 4.45 | 84.75 | 223.7 | 272.5 | -14.8 | 13.5 | 584.1 |
4.0 Layout Facility 4.1 improvement Layout The improvement was governed by the owner Budget, difficult machine change and moving.
Figure( 5) : improvement layout
* Distance within facility was taken for improvement department
Table(6): From to chart (distance matrix in mm) | D1 | D2 | D3 | D4 | D5 | D1 | - | 9.10 | 14 | 12.42 | 18 | D2 | - | - | 10.31 | 12.46 | 18.5 | D3 | - | - | - | 12.3 | 14.65 | D4 | - | - | - | - | 5.1 | D5 | - | - | - | - | - | * Flow or quality relation was taken by a experts and flow.
Table (7): relation ship Chart | D1 | D2 | D3 | D4 | D5 | D1 | - | O | O | E | O | D2 | - | - | A | A | A | D3 | - | - | - | E | I | D4 | - | - | - | - | I |
- Score for existing layout .
Table(8) : score rate Rate | A | E | I | O | U | X | Equivalent | 10 | 6 | 3 | 0.5 | 0 | -10 |
Table(9) : score chart | D1 | D2 | D3 | D4 | D5 | score | D1 | - | 0.5 | 0.5 | 6 | 0.5 | 7.5 | D2 | - | - | 10 | 10 | 10 | 30 | D3 | - | - | - | 6 | 3 | 9 | D4 | - | - | - | - | 3 | 3 | Total score | 49.5 |
* Cost for existing layout.
Table (9) : cost matrix | D1 | D2 | D3 | D4 | D5 | TOTAL | D1 | 00 | 4.55 | 7 | 74.52 | 9 | 95.07 | D2 | 00 | 00 | 103.1 | 124.6 | 185 | 412.7 | D3 | 00 | 00 | 00 | 73.8 | 43.95 | 117.75 | D4 | 00 | 00 | 00 | 00 | 15.3 | 15.3 | D5 | 00 | 00 | 00 | 00 | 00 | 0 | total | 00 | 4.55 | 110.1 | 272.92 | 253.25 | 640.82 |
4.2 Left part of factory (new layout for new machines) This area was studied to satisfy the comfort moving of material and foremen , and absorb the new machines and replaced machines Figure( 6) : new layout * Distance within facility was taken for improvement department
Table(10): From to chart (distance matrix in m) | D6 | D7 | D8 | D9 | D10 | D11 | D6 | - | 8.4 | 8 | 12.5 | 20.3 | 22.2 | D7 | - | - | 2.7 | 15.75 | 5.4 | 1 | D8 | - | - | - | 6 | 10 | 7 | D9 | - | - | - | - | 18.4 | 4 | D10 | - | - | - | - | - | 4.7 | D11 | - | - | - | - | - | - |
* Flow or quality relation was taken by a experts and flow.
Table (11): relation ship Chart | D6 | D7 | D8 | D9 | D10 | D11 | D6 | - | E | O | U | I | U | D7 | - | - | A | U | I | I | D8 | - | - | - | A | E | E | D9 | - | - | - | - | I | I | D10 | - | - | - | - | - | A |
- Score for existing layout .
Table(12) : score rate Rate | A | E | I | O | U | X | Equivalent | 10 | 6 | 3 | 0.5 | 0 | -10 |
Table(13) : score chart | D6 | D7 | D8 | D9 | D10 | D11 | total | D6 | 0 | 6 | 0.5 | 0 | 3 | 00 | 9.5 | D7 | 0 | 0 | 10 | 0 | 3 | 3 | 16 | D8 | 0 | 0 | 0 | 10 | 6 | 6 | 22 | D9 | 0 | 0 | 0 | 0 | 3 | 3 | 9 | D10 | 0 | 0 | 0 | 0 | 0 | 10 | 10 | Total score | 66.5 |
* Cost for existing layout.
Table (9) : cost matrix | D1 | D2 | D3 | D4 | D5 | TOTAL | D1 | 0 | 50.4 | 4 | 0 | 60.9 | 115.3 | D2 | 0 | 0 | 27 | 0 | 16.2 | 43.2 | D3 | 0 | 0 | 0 | 60 | 60 | 120 | D4 | 0 | 0 | 0 | 0 | 55.2 | 55.2 | D5 | 0 | 0 | 0 | 0 | 0 | 0 | total | 0 | 50.4 | 31 | 60 | 192.3 | 333.7 |
5.0 Material Handling
There are two type of material handling existing 1- forklift (within storages , very limited inside workplace) Recommended 2- Crane (within the workplaces and department)
Figure( 7) : new Crane
6.0 Warehouse and Storage 6.1 storage spare part of machines , printing ink and other needed things were recommended to be store in new storage.
Figure( 8) : new storage
6.2 Warehouse
Figure( 9 ): Warehouse
7.0 Pictures of improvement
Figure( 10 ): improvement Layout Figure( 11): improvement Layout Figure(12 ): foremen Closet Figure( 13 ): new machine layout Figure( 14 ): storage recorder table 