JUSTIFICATIONS

The second objective will be justified from the following narrations.

O1. Streamline the flow of materials.

The ELSOFARIE Cassava Flour Factory will adopt a product layout because it

has a repetitive processing system and produce standardized products in large volume.

The resources are arranged sequentially based on the routing of the product. The raw

material storage room is located at the start of the process and is equipped with machines

and equipment which could easily process the production. Further, the warehouse is

located at the end of the process for ease of packaging and distribution of the final

products. Through this layout, bottlenecks are avoided and the production of cassava flour

is maximized. The advantages considered are the following:

1. Smooth flow of production: The entire production process is integrated.

Therefore, the possibility of stoppage of production at different stages of production

is eliminated. So smooth flow of production is ensured.

2. Lower material handling costs: Since machines are arranged based on the

sequence of operations, there is no backtracking (back and forward movement) or

crisscrossing of materials. Therefore, cost and time involved in handling of materials

is minimized. Transportation cost involved in transporting materials from one

machine to another is eliminated

3. Lesser work-in-progress: Since the production process is continuous and

uninterrupted, work-in-progress is less. Investment in work-in progress is less and the

storage space required is also minimized.

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 4. Optimum space utilization: Since all machines are arranged sequentially, space

available can be utilized in an optimum manner.

5. Effective utilization of resources: Product layout ensures effective utilization of

resources by ensuring:

 minimum movement of workers

 continuous production process and reduced wastage

 less working-progress and

 mechanization of materials handling

6. Effective supervision: Since production process is integrated and continuous,

supervision and control of the manufacturing process is easy. Inspection points are

integrated into the production line.

7. Production control: Since the production process is continuous, production control

is facilitated. The management can plan for the operations and adopt measures to

complete the work according to the plans.

8. Savings in time: Time spent for transporting materials can be minimized. Since

machines are arranged based on the sequence of operations, mechanized equipment

such as conveyor belts can be used for transporting materials. This results in

significant saving of time.

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O2. Facilitate smooth flow in the manufacturing process.

The factory adopts and install machines which are automated to ensure the smooth

flow of materials. The capacity per machines as discussed in the previous chapter are

directly proportional to the estimated capacity of cassava flour per day by the factory.

Also, the product to be manufactured spends most of the time in moving and waiting. For

reduction of this moving and waiting time of product, the ELSOFARIE Cassava Flour

Factory consider having proper layout and proper scheduling procedure. Plant layout

specifies the position of the overall arrangement of the various facilities such as

equipment, material, manpower, materials handling, service facilities, and passage

required to facilitate efficient operation of production system of the plant within the area

of the site selected previously. Through such considerations, facilitating smooth flow in

the manufacturing process were possible.

O3. Maintain high turnover of in-process inventory.

To maintain high turnover of in-process inventory the factory will install

machines that can produce cassava flour in fast pace but with a good quality and quantity

to meet the consumer’s demand. This means that whenever the ELSOFARIE Cassava

Flour Factory get an order from a customer it can provide them the goods much quickly

than other firms can. This is because the factory has semi-finished goods and can convert

them quickly into goods thereby increasing the efficiency. The company's inventory of

work-in-process materials is turned several times throughout the measurement period,

within the procurement function which indicates a relatively high turnover of in-process

inventory.

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O4. Minimize materials handling and cost

The factory will use three type of conveyors which are belt, bucket and 90°

conveyor. This material handling system and processes of the factory are put in place to

improve customer service, reduce inventory, shorten delivery time, and lower overall

handling costs in manufacturing, distribution and transportation. The conveyors are used

to aid the movement, protection, storage and control of materials and products throughout

manufacturing, distribution, consumption and disposal of cassava flour.

O5. Effective utilization of men, equipment and space

The factory will hire employees according with the standard needed by the

factory. All employees should be well equipped, are willing to be trained and to learn the

whole process. Through this, the men, equipment and space can be effectively utilized by

the management. Employees will be the heart and focus of the factory to ensure efficiency

and effectiveness of the performance as a whole. Also, the factory will ensure utilizing

automated machines which will become the instrument to earn profit. Lastly, spacing are

considered during the planning and designing stage to ensure the right placement of the

machines.

O6. Make an effective utilization of cubic space

Cube utilization is an industry term that refers to the amount of the total available

space that is actually utilized, expressed as a percentage. The factory utilizes effectively

the cubic space according to the space requirements. This is to ensure ease of the process

and no backtracking. Storage facilities make use of sophisticated racking systems to

optimize storage density, an important aspect of warehouse cube utilization. The other

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cube utilization is the elimination of pallet overhang, which ensures that loads fit onto the

trailer as planned - with no pallets left behind.

 Analyzing Department Space

Identify functions that do not require high ceilings in areas where lower stacking

heights are dictated by the clear height. We often see unused overhead space where

large departments like packing and shipping are performed.

 Consolidate Locations

For the multiple locations for storing the same item, the researchers consider

combining them to create better warehouse space utilization. This can be done during

the put away process and as a standalone function.

 Use Off-Site Location for Overstock

When storing large quantity of excess inventory for a few items, the researchers

considers some type of offsite storage for the excess, thus freeing up space for

supporting the fulfillment operation.

 Aisle Widths

The design of the aisle width was done according to the standard space

requirements. The aisle width is 9 ft for 1-ton forklift, 3 ft for personnel passage ways,

6 ft for passage ways with doors opening in the aisle from one side and 8 ft for passage

ways with doors opening into the aisle from two sides. The factory tries to design the

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 minimum width required to match the material handling equipment used without

compromising operating efficiency.

O7. Provide for employee convenience, safety and comfort

One of the main goals of the factory is to ensure employee’s convenience, safety

and comfort through following the ISO standards. The factory will provide personal

protective equipment to all employee in the production area and multiple trainings

and seminar in relation to the safety towards work. Enough ventilation and

illumination are also considered during the planning and designing of the factory to

ensure the comfortability of the employees.

O8. Minimize investment in equipment

In order to minimize the investment in equipment, the management has ensured

appropriate machines and equipment through following the steps and requirements in

machine selection. The machine selection stage is one of the main focus of the factory

in order to produce good quality of cassava flour and right quantity to meet the

demand of the consumers.

O9. Minimize overall production time

Through installing automated machines, the overall production time are

minimized. The production capacity of the company that the researchers had

benchmark is 3-5 tons per day while the researchers proposed process can produce 20

tons per day. Also, the following items were considered.

 Increase and improve staff communication.

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  Hold regular staff evaluations.

 Setting specific manufacturing plant goals.

 Conduct regular manufacturing equipment maintenance.

 Upgrade manufacturing equipment.

 Track manufacturing downtime carefully.

 Properly train production line employees.

O10. Facilitate the organization structure

The factory will help the employees to maximize their capabilities and talent

through a good management. The persons employed in higher position are well-trained

and good leaders which can uplift and enhance the workers to maximize the

productivity and overall performance of the ELSOFARIE cassava flour factory.

O11. Promote ease of maintenance

To promote ease of maintenance, the researchers consider correct defects of their

cause, repair or replace faulty or worn-out components without replacing parts that still

work, prevent unexpected working conditions and maximize products useful life.

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