Report Ko Kelvin (FD)

4/17/2018 FINAL PROJECT
Subject : Facility Design
Lecturer : Anastasia Lidya Maukar, S.T., M.Sc., M.MT.
Created by,
1. Chrisshyaren (0042
2. Kelvin (0042
3. Rivi Sofia Ayu (0042
4. Tantyo Edo Wicaksana (0042
5. Liu Quo Zhang (0042
PRESIDENT UNIVERSITY
INDUSTRIAL ENGINEERING BATCH 2015
Jababeka Education Park, Ki Hajar Dewantara Street, Kota Jababeka,
West Cikarang, Bekasi 17550 – Indonesia
Phone (021) 8910 9762-6 - Fax (021) 8910 9768 - Email:
enrollment@president.ac.id - http://www.president.ac.id
Module 1 : Product and
Process Analysis
1/23/2018
PROJECT ASSIGNMENT
Created by,
2. Kelvin (0042
Phone (021) 8910 9762-6 - Fax (021) 8910 9768 - Email:
TABLE OF CONTENTS
CHAPTER I ......................................................................................................... 1.3
INTRODUCTION ............................................................................................... 1.3
1.1 Background ........................................................................................... 1.3
1.2 Objectives .............................................................................................. 1.3
1.3 Tools and Equipment(s) ........................................................................ 1.4
1.4 Steps ........................................................................................................... 1.4
CHAPTER II ........................................................................................................ 1.5
COMPANY PROFILE ........................................................................................ 1.5
2.1 Company Profile ........................................................................................ 1.5
2.2 Vision ......................................................................................................... 1.5
2.3 Missions ..................................................................................................... 1.6
2.4. Company Logo.......................................................................................... 1.6
2.6. Structure of Company ............................................................................... 1.7
CHAPTER III .................................................................................................... 1.10
LITERATURE STUDY..................................................................................... 1.10
3.1. Engineering Drawing .............................................................................. 1.10
3.1.1. 2 Dimension Projection........................................................................ 1.10
3.1.2 3 Dimension Projection......................................................................... 1.11
3.2. Operation Process Chart.......................................................................... 1.11
3.3 Assembly Chart ........................................................................................ 1.12
3.4 Product Structure and Bill of Material ..................................................... 1.13
3.5 Part Specification ..................................................................................... 1.13
CHAPTER IV .................................................................................................... 1.14
DATA COLLECTION AND ANALYSIS ........................................................ 1.14
4.1. Product’s Engineering Drawing .............................................................. 1.14
4.2. Bill of Material ........................................................................................ 1.14
4.2.1. Rectangular Oak Table (ROT) ............................................................. 1.15
4.2.2. Casual Arm Chair (CAC)..................................................................... 1.17
4.3. Material and Parts Specification ............................................................. 1.19
4.4. Machine Specification and Dimension ................................................... 1.20
4.5. Assembly Chart ....................................................................................... 1.35
1.1
4.5.1. Rectangular Oak Table (ROT)......................................................... 1.35
4.5.2. Casual Arm Chair (CAC) ................................................................ 1.36
4.6. Operation Processing Chart (OPC) ..................................................... 1.36
4.6.1. Rectangular Oak Table (ROT)......................................................... 1.36
4.6.2. Casual Arm Chair (CAC)..................................................................... 1.36
CHAPTER V...................................................................................................... 1.37
CONCLUSION .................................................................................................. 1.37
REFERENCES................................................................................................... 1.38
APPENDIX ........................................................................................................ 1.39
CHAPTER I
INTRODUCTION
1.1 Background
In the global competition, rapid changes in technology and the necessity to
respond quickly to a cost and quality conscious customer have changed the
dynamics of facilities planning. Nowadays, manufacturing facility needs to be
responsive to the frequent changes in product mix and demand while minimizing
material handling and machine relocation costs. The manufacturing company
should dealing with industrial risk issue consist of the design, management, and
control of production systems. The improvement of facility design layout are
contribute to avoid, prevent or reduce certain types of industrial risk. Everyone
that working with industrial environment is perfectly aware that production
systems are the main of risk that can yield important consequences, typically in
terms of safety, costs, performance or customer satisfaction. Facility layout is
known to be an important aspect in the design of these systems and has been
addressed in numerous research works.
Facility layout and design is an important component of a whole operations both

in terms of maximizing the effectiveness of the production process and the needs
of employees. The basic objective of facility design is to ensure a smooth flow
work, material, an information through a system. The good facility design and
layout is the integration of the needs of customer, materials, materials, and
machinery.
1.2 Objectives
The objectives in this report are:
a. To determine the weaknesses of the flow of the production in the company.

b. To improve the business performance in terms of industrial things such as
the layout design and facility design.
c. To drawing the engineering drawing of the product such as Rectangular
Oak
Table (ROT) and Casual Arm Chair (CAC).
d. To determine and drawing the Operation Processing Chart (OPC).
e. To determine and drawing the assembly chart.
f. To determine and drawing the Bill of Material (BOM).
1.3 Tools and Equipment(s)

The tools and equipment that were used for this assignment are:
a. Gather all of the information that required to the facilities design

b. Create the engineering drawing of the product consist of Rectangular Oak
Table (ROT) and Casual Arm Chair (CAC).
c. Determine the list of each component in each product.
d. Make a Bill of material of each product.
e. Determine specification and dimension of material and machine each
product.
f. Draw the assembly chart of each product.
g. Draw the Operation Process Chart (OPC) each product.
h. Determine the weaknesses of facility design or layout design.
i. Improve the facility design.
1.4 Steps
There are several steps to determine the data, which are:
a. Pencil
b. HVS paper
c. Printer
d. Laptop
e. Microsoft Word
CHAPTER II
COMPANY PROFILE
2.1 Company Profile

Waltz Company has been established on January 2017 as a manufacturing
consultant company in Indonesia. The purpose of Waltz Company is to make the
other parties become easier when make the layout design whole of company. The
company located in Cikarang, West Java. The company has an important role in
the industry such as resolver of improvement the design, making a design of the
company, system design and manufacturing process, product management design,
material handling services, etc. The founder of Waltz Company are students of
President University majoring in Industrial Engineering, who are Chrisshyaren,
Kelvin, Liu Quo Zhang, Rivi Sofia Ayu, and Tantyo Edo Wicaksana.
According to the market analysis, Waltz Company demand will exceed the
forecast and is expected to see a huge demand in numerous areas of Cikarang over
the next
5 year. The company believes that every project will exceed the expectation of
customer in making a good company.
The tagline of the company is “Your expectation is our reality”. It means that the
company want to exceed the expectations of customer to make the customer
become satisfy.
2.2 Vision
The vision of Waltz Company is “To provide planning & design services that
exceeds the expectations of esteemed customer”.
2.3 Missions
The missions of Waltz Company is to build the long relationship with customers
and clients and provide the exceptional customer services by pursuing the facilities
design through innovation and advanced technology.
2.4. Company Logo

A logo represents what is inside the company. So that is the case with the waltz
company. Waltz company logo representing waltz company image that is simple
and have a vision and mission. The blue color that dominates on the waltz
company logo means a resolver to companies that need help and the light blue
color represents a calming image.
Figure 2.1. Waltz Company

Inside the company logo, there is also a waltz company name. The name of the
waltz company itself has a meaning. Waltz if defined in English is "something that
very easy". Waltz company itself promises easy solution for companies who need
help from waltz company consultant.
2.5 Company Services
Waltz Company leverages its expertise in material experience and expertise to

successfully complete manufacturing initiatives such as:
1. Factory layout and production system
2. System design and production process
3. Product management design
4. Material handling services
5. Project management services
2.6. Structure of Company

The figure below shows the listed names of Board of Director from Waltz
Company. Each person has different responsibilities but does not cover the
opportunity for each department to help other departments in order to make the
company runs well.
Figure 2.2. Structure Organization

These are the specific job description for each person:
1. President of Waltz Company
The President’s job can be said simple, but not that easy as it seems. A
President has a high level of responsibility. President can be responsible
for day-to-day operational tasks to the actions required in a business step.
President’s quality showed when he has a solid team to help the strategy
and market plan and they give employees many opportunities to weigh by
using their point of view. He has to understand her team very well and
does not ignore feedback from his team members.
2. Production and Design Department

Responsibilities of Production and Design Department is conducting R&D
activities and developing conceptual framework for product. Planning and
designing the product and packaging are the main task for Production and
Design Department itself. This department also has objective namely to
cultivate, maintain and increase a company's market share by satisfying a
consumer demand. The production and design department will set
standards and targets for each section of the production process. The
quantity and quality of products coming off a production line will be
closely monitored. In businesses focusing on lean production, quality will
be monitored by all employees at every stage of production, rather than at
the end as is the case for businesses using a quality control approach.
3. Consulting Manager
Consulting manager should conduct the research, surveys and interviews to
gain an understanding of the business. The manager also has to detecting
issues and investigating ways to resolve the problem that appears.
Assessing the pros and cons of possible strategies that have to keep. The
consultant manager also has to makes recommendations for improvement
the problem and presenting findings to client.
4. Finance Department
Finance department is responsible for all financial activities in Company.
The main task of this position is to make arrangements, transactions, create
financial statements of the company. The Finance Department must report
to each member about the current financial situation. The task of finance
departments are to manage the company's finances, perform corporate
financial transactions, make payments to vendors, collect customer billing,
control financial activities/ financial transactions, and create reports on
corporate finance activities.
5. Marketing Department
The Marketing Department plays a vital role in promoting the business and
mission of an organization. It serves as the face of the company,
coordinating and producing all materials representing the business. It is the
Marketing Department's job to reach out to prospects, customers, investors
and the community, and create an overarching image that represents your
company in a positive light—that is, the company’s brand. The marketing
department has overall responsibility for growing revenue, increasing
market share and contributing to company growth and profitability.
CHAPTER III
LITERATURE STUDY
3.1. Engineering Drawing

Engineering drawing is a graphical language used by engineers and other technical
personnel associated with the engineering profession. The purpose of engineering
drawing is to convey graphically the ideas and information necessary for the
construction or analysis of machines, structures, or systems. It helps the engineer
who is designed a part to communicate all needed information with the workers
who will make it. Simply Engineering Drawing is a tools or ways to explaining all
information of a thing from engineer who draw it to workers who want to produce
it.
The picture of engineering drawing must full of information of the thing that want
to produce from head to toe. The picture should draw clearly with explanation of
the size, shape, and dimension. Hopefully the workers can understand clearly and
produce the item without any mistakes.
Engineering Drawing can produce a picture of an item with 2Dimension

projection and 3Dimension projection. The basic engineering drawing is using
hand-drawing to create the picture, and measuring the size and dimension of the
thing manually using scale. Nowadays Engineering Drawing mostly using
computer software that we know as CAD (Computer Aided Design) and many
software has CAD with one specialist such as Solid Works software, Auto CAD
software, Sketch Up Software, etc.
3.1.1. 2 Dimension Projection

2Dimension Projection has 4 type of view, that is front view, top view, side view,
and bottom view. Both American or European use these views.
Top View
Top view gives view from the top of the item. Giving it clearly projection from the
top, workers can know what is the different shape of right and left side also top
and behindside.
Front View
Front view gives view from the front of the items. Hopefully workers can
understand the design from the top view, because front view gives specific
projection of the item shape on the front.
Side View
Side view has left and right side. Same as top and front view, side view has
specific detail of shape of an item based on the left view or right
view. Bottom View
Bottom view gives specific details of shape from the bottom of the item. Also,
same as the other view, hopefully workers can understand better about the items
that designer want to produce.
3.1.2 3 Dimension Projection

3Dimension Projection also known as Exploded Drawing in CAD software menu.
3Dimension gives all view of the item, the workers can imagine the item easier
than
2Dimension view. 3Dimension Projection is usually used for assembly phase,
because it could give the animation of the item that need assembly. If the size or
shape is wrong, 3Dimension Projection could show it specifically until millimeter
unit, so workers can determine the size and the tolerance while producing the item.
Figure below shown the 3Dimension Projection, also the exploded animation
picture.
3.2. Operation Process Chart

Operation process chart is a chart that povides information on the processes
required for each component and the time for each. Operation Process Chart is a
graphic representation that gives an overall view of the flow within facility of an
entire process, including the points at which materials are introduced, the sequence
of inspections, and all operations not involved in material handling. Constructing
an operation process chart is often one of the first activities of a process
improvement effort, because of the following benefits:
Gives everyone a clear understanding of the process

Helps to identify non-value-added operations
Facilitates teamwork and communication
Keeps everyone on the same page Operation process chart shows the
chronological sequence of al operations, inspections, time allowances, and
materials used in a manufacturing or business process, from the arrival of
raw material to the packaging of the finished product.
3.3 Assembly Chart

A schematic model that define how parts go together, the order of assembly,
and the overall structure of the product. This chart is ideal for getting a bird’s eye
view of the process for producing most assembled products. It lists all major
materials and components, subassembly operations, inspections and assembly
operations. This chart is sometimes called gozinto chart. An assembly chart gives
a broad overview of how several parts manufactured separately are to be
assembled to make the final product. It is an analog model of the assembly
process. Circles with a single link denote basic components, circles with several
links denote assembly operations/subassemblies, and squares represent inspection
operations. Assembly charts are used to obtain a general understanding of the
entire process involved in producing products which involve assembly of a
number of parts. They provide an overall macro view of the movement of
components and sub-assemblies in the process of producing a finished
product. They also show the material requirements (i.e. the list of all major
components), sub-assembly operations, quality checks and assembly operations
that are involved in making a mechanical assembly. In these charts, it is a
standard practice to indicate operations by circles and inspections by squares.
3.4 Product Structure and Bill of Material
The product structure provides a hierarchical classification of the items which
form a product. With the product structure, the understanding of the components
which compose a product as well as their attributes, can be represented. The
product structure shows the material, component, parts, subassemblies, and other
items in a hierarchical structure that represents the grouping of items on an
assembly drawing or the grouping of items that come together at a stage in the
manufacturing process.
A representation of the way in which the parts of a product fit together and
interact, organized in levels of detail based on structure. A product structure is
used to manage changes, testing, and problem resolution for complex products
with a large number of interdependent parts and functions.
3.5 Part Specification

An object type does not have any actual parts because it is not instantiated, so the
meta-model must have an entity to pull together all the requirements on actual part
to prepare for the instantiation. Here are some things that need to be recorded at
the type level:
Each part is of a certain type

Part maybe connected in certain ways
Each kind of part may have more than one instance in the instantiated
composite
3.6 Material Specification
The specification is applicable to a raw material or a semi-fabricated material

which are used in the fabrication of a product. Material specification is used as the
inspection specifications. In contrast to the inspection plan, the material
specification is a specification that you can use for all plants, that is easier to
maintain, and that can replace or supplement a plant-specific inspection plan.
CHAPTER IV
DATA COLLECTION AND ANALYSIS
4.1. Product’s Engineering Drawing

In this part, there will be engineering drawing for each product, such as
rectangular oak table (ROT) and casual arm chair (CAC). There are three kinds of
drawing, which are :
Whole Product
Exploded
Part
Each of drawing will have isometric and orthographic view. All of engineering
drawing will be shown on the Attachment.
4.2. Bill of Material

Bill of Materials (BOM) is a final product consisting of a list of items, materials,
or materials needed to assemble, mix or manufacture the finished product. Bill of
material consists of various forms and can be used for various purposes. Bill of
material is made as part of the design process and is used by the manufacturing
engineer to determine the tem to be purchased or produced. Here, there are two
BOM for each product, such as ROT and CAC.
4.2.1. Rectangular Oak Table (ROT)
Below are shown the Bill of Materials from ROT.
Table 4.1. Bill of Material ROT
Level Part Part Name Quantity Make/Buy

Number
0 - ROT 1 Make
1 110 Top Surface Assembly 1 Make
1 140 Pedestal Assembly 1 Make
2 110 Top Surface 1 Make
2 111 Top Surface Slat 11 Make
2 112 Frame Top Surface (B) 2 Make
2 113 Frame Top Surface (C) 2 Make
2 120 Base Surface 1 Make
2 141 Pedestal Pieces (E) 4 Make
2 142 Feet (F) 4 Make
2 143 Pedestal Support (G) 4 Make
2 - Flathead Screw 1”× #8 22 Buy
2 - Flathead Screw 2”× #8 36 Buy
2 - Flathead Screw 2.5”× #12 8 Buy
2 - Carriage Bolts 0.25”×2.5” 8 Buy
Level
ROT (1)
0
Level To p Surface Assembly Pedestal Assembly

1 (1) (1)
Carriag e
Frame Top Frame Top Screw
Level To p Surface Base Screw Pedestal Feet F (4) Pedestal Screw Bolts
Surface Surface C Pieces E (4) 2.5"×#12
Slat (11) Surface (1) 1"×#8 (22) Support (4) 2"×#8 (36) 0.25"×2.5"
2 B(2) (2) (8)
(8)
Figure 4.1. Product Structure ROT
Figure above shown the product structure of Rectangular Oak Table (ROT). ROT is on level 0 as final product. And then,
the ROT has two assembly in level 1 which are top surface assembly and pedestal assembly. The top surface assembly
itself has 5 subassembly in level 2 such as 11 of top surface slat, 2 of frame top surface B, 2 of frame top surface C, 1 of
base surface, and 22 of screw 1”. The pedestal assembly has several subassembly in level 2, such as 4 of pedestal pieces
E, 4 of
feet F, 4 of pedestal support, 36 of screw 2”, 8 of screw 2.5”, and 8 of carriage bolts 0.25”×2.5”.
1.16
4.2.2. Casual Arm Chair (CAC)
Below are shown the Bill of Materials from CAC.
Table 4.2. Bill of Material CAC
BILL OF MATERIALS
Com Prepar
pany: ed by
Prod Casual Date 18-
uct : Armchair Jan-
(CAC) 18
Level Part No. Part Name Qty Make

/Buy
0 - Casual Arm 1 Make
Chair
1 - SA Arm & 2 Make
Leg
1 220 Stretcher 3 Make
1 - Hanger Bolt 6 Buy
1/4" 2 1/2"
1 - Washer 1/4" 6 Buy
1 - Cap Nut 1/4" 6 Buy
1 270 Seat Assembly 1 Make
1 260 Back 1 Make
Assembly
2 - Dowelling 8 Buy
3/8" x 4'
2 - Dowelling 8 Buy
3/8" x 1 1/2"
2 210 Front Leg 2 Make
2 220 Side Stretcher 2 Make
2 230 Arm 2 Make
2 250 Rear Leg 2 Make
2 271 Seat Steel Rod 1 Make
2 272 Canvas Seat 1 Buy
2 261 Back Steel 1 Make
Rood
2 262 Canvas Back 1 Buy
1.17
Casual Arm
Chair (CAC)
SA Arm & Hanger Bolt Washer 1/4" Cap Nut 1/4"

Stretcher (3) 1/4" 2 1/2" Seat Ass (1) Back Ass (1)
Leg (2) (6) (6)
(6)
Dowelli Dowelli Side

ng 3/8" Front Rear Seat Back
ng 3/8" Stretche Arm (2) Leg (2) Steel Canvas Steel Canvas
x 4' (8) x 1 1/2" Leg (2) Seat (1)
r (2) Rod (1) Rood Back (1)
(8)
(1)
Figure 4.2. Product Structure CAC
Figure above shown the product structure of Casual Arm Chair (CAC). CAC is on level 0 as final product. And then,
the CAC has seven assembly in level 1 which are 2 of SA Arm and Leg, 3 of Strecher, 6 of Hanger Bolt, 6 of
Washer,
6 of Cap Nut, 1 of Seat Ass, and 1 of Back Ass. The SA Arm and Leg itself has 6 subassembly in level 2 such as 8 of
Dowelling 3/8”×4’, 8 of Dowelling 3/8”×1 1/2’, 2 of Front Leg, 2 of Side Strecher, 2 of Arm, and 2 of Rear Leg.
The Seat Ass itself has several subassembly in level 2, such as 1 of seat steel rod, 1 of canvas seat, 1 of back steel
rood, and
1 of canvas back.
1.18
4.3. Material and Parts Specification
Specification is the details of the type and level of components to be used. The
material specification is needed to know the total materials needed in each product
and to know the best total materials that should be used to make a good quality
product. Here are several materials and their specifications used to make rectangular
oak table and casual armchair.
Table 4.3 Material Specification of ROT
Materi Mater Specification Number

al ial Thickn Lengt Width of Parts
Name Numb ess h (Inch per
er (Inches (Inch es) Producti
) es) on
Oak 1 ¾ 46 ½ 3½ 11
Oak 2 ¾ 46 ½ 3½ 2
Oak 3 ¾ 38 ½ 3½ 2
Oak 4 ¾ 27 8½ 4
Oak 5 ¾ 22 5½ 4
Plywo 1 ¾ 46 ½ 38 ½ 1
od
Fir 1 2 8½ 2 4
Table above shows the materials specifications for making one product of
Rectangular Oak Table. There are five types of Oak that are used one type of
Plywood and one type of Fir. The table of material specification above contains of the
information regarding the material name, material number, specifications which
include thickness, length, and width (in inches), and the information about the number
of part per production.
1.19
Table 4.4. Material Specification of CAC
Mater Mater Specification Number

ial ial Thickn Lengt Width of Parts
Name Numb ess h (Inche per
er (Inches (Inche s) Producti
) s) on
Brich 1 ¾ 25 1½ 2
Brich 2 ¾ 20 ½ 1½ 3
Brich 3 ¾ 14 ½ 1½ 2
Brich 4 ¾ 19 ½ 2½ 2
Brich 5 ¾ 25 3½ 2
Roun 1 Ф 3/8 9½ 1
d
Steel
Bar
Roun 2 Ф 3/8 17¼ 1
d
Steel
Bar
Table above shows the materials specifications for making one product of Casual
Armchair. There are five types of Birch that are used and two types of Round Steel
Bar. The specifications of each material are listed on the table above.
4.4. Machine Specification and Dimension

Specification is the details of the type and level of components to be used or can be
said specification is the detail and comparison of a kind of thing that is always
associated with a special ability. The machine specification is important to know the
best machine that should be used to make a good quality product. Here are several
machines and their specifications used to make rectangular oak table and casual
armchair.
1. Jointer
The workings of the jointer machine is almost the same or arguably similar to the
electric crank engine. The main use of a jointer machine is to obtain the precision of
the surface and the wooden side. Woods that are joined by a jointer machine will be
square in shape on each side. This machine is used to smoothing 1 or 2 wooden sides
with uneven sides.
Figure 4.3. Jointer Machine
Jointer machine is also used to straighten the wood is bent or 'twisted' so that when
the connection, the wood is really straight on each side. Sometimes this machine is
also called a passenger machine, because it smooths by making a 90 'angle before the
wood is processed further on a single planer machine. The figure above shows the
picture of jointer and table below shows the detail specification of jointer.
1.21
Table 4.5. Jointer Specifications
Motor 2 HP ( 1.500 Watt )

CUTTING CAPACITY
Cutting Capacity 8" (203mm)
Width
Cutting Capacity 1/2" (12.7mm Max)
Depth
Cutting Capacity 1/2" (12.7mm Max)
Rabbeting Capacity
CUTTERHEAD
Cutterhead Speed 4800 RPM 14400
CPM
Cutterhead Number of 4
Knives
TABLE
Table Length : 1800mm
Table Length of Infeed 880mm
Table length of 880mm
Outfeed
Table Width 330mm
Table Height from 795mm
Floor
FENCE
Fence Size 1010mm x 120mm
Fence Tilt in and Out 45
Fence Positive Stops 90|45 in and out
INFORMATION
Dimensions (LxWxH) 1840 x 440 x 260 mm
Weight 208kg
1.22
2. Circular Saw
A circular saw is an electric saw that turns a round flat blade to cut wood, metal, or
plastic depending on the blade selected. Circular saws have a handle with on/off
trigger switch, an arbor nut to hold the blade in place, and guards to protect the
operator from touching the spinning blade. In addition, circular saws have
height/depth and bevel adjustments. Refer to the circular saw's operations manual for
specifics.
Figure 4.4. Circular Saw
The figure above shows the picture of circular saw and table below shows the detail
specification of circular saw.
1.23
Table 4.6. Circular Saw Specifications
Amperage 15.0
Arbor Size 5/8"
Bevel 56°
Bevel Stops 22.5°, 45°
Blade Diameter 7.25
Blade Size 7-1/4"
Case Type Bag
Dust Blower Yes
Height 10.0"
Length 18.0"
Max. Bevel Capacity (°) 56.0
Max. Depth of Cut at 45 1-7/8"
Deg.
Deg.
Deg.
No Load RPM 5,600
1.24
Table 4.7. Circular Saw Specifications (Continued)
Rating 120V
Voltage 120V
Weight 10.2lb
3. Radial Arm Saw
Radial arm saw is a cutting machine consisting of a circular saw mounted on a sliding
horizontal arm. In addition to making length cuts, a radial arm saw may be configured
with a dado blade to create cuts for dado, rabbet or half lap joints. In addition some
radial arm saws allow the blade to be turned parallel to the back fence, allowing a rip
cut to be performed.
Figure 4.5. Radial Arm Saw
1.25
The figure above shows the picture of radial arm saw and table below shows the
detail specification of radial arm saw.
Table 4.8. Radial Arm Saw Specifications
Dimension (mm) 1,110 x 1,476 x 1,710

Weight (kgs) 260
Motor Power (V / Hz / Ph 380 / 50 / 3 / 3
/ kW)
Circular Saw Size (mm / Ø400 / 16
inch)
Circular Saw Bore (mm) Ø30
Circular Saw Speed 2,840
(rpm)
Moving Distance (mm) 1,000
Max. Thickness 110
Workpiece 90º (mm)
Max. Thickness 80
Workpiece 45º (mm)
Table Size (mm) 1,100 x 1,250
Table Height (mm) 780
Blade Tilt (º) 90º ~ 45º
4. Router
A router is a hand tool or power tool that a worker uses to rout (hollow out) an area in
relatively hard material like wood or plastic. Routers are mainly used in
woodworking, especially cabinetry. Routers are typically handheld or fastened
cutting end-up in a router table.
Figure 4.6. Router
The figure above shows the picture of router and table below shows the detail
specification of router.
Table 4.9. Router Specifications
Volt 220V/50Hz
Electricity 930 Watt
Collet 12 mm
Speed Without Load 24000 rpm
Base Diameter 160mm
Weight 6.3 kg
5. Disc Sander
A disc sander is most commonly implemented as a stationary machine that consists of

replaceable circular shaped sandpaper attached to a wheel turned by an electric motor
or compressed air. The usually wooden work piece, (although other materials can be
shaped and worked on such as plastics, metals and other soft materials), is sat on a
front
bench that can be adjusted to various angles. It can be used for rough or fine sanding
depending on the sanding grit used.
Figure 4.7. Disc Sander
The figure above shows the picture of disc sander and table below shows the detail
specification of Disc Sander.
Table 4.10. Disc Sander Specifications
Disc diameter 305mm (12")

Motor (induction) 750w (1hp)
Disc speed 1450rpm
Table size 438mm x 160mm
Table tilt 90 to 45
Dimensions (WxDxH) 438mm x 470mm x
370mm
Weight 27kg
6. Drill Press
Figure 4.8. Drill Press Machine
A drill press is preferable to a hand drill when the location and orientation of the hole
must be controlled accurately. A drill press is composed of a base that support a
column, the column in turn supports a table. Actually the function of drill press
consist of three such as drilling a hole, deburring a hole and reaming a hole. For
drilling a hole, the center of drill should be used. For deburring a hole, the top edge of
hole will be fairy clean, but the bottom of edge will have substantial burrs. Reaming
a hole will required for slip fits or interference fits, a reamer must be used. The
specification of drill press are shown in the figure below.
Table 4.11. Specification of Drill Press Machine
Specification Details
Motor 2 HP A.C. Single Phase 110 V or
220 V
Standard Power down feed
Spindle Speeds 0-1200 RPM
Drills to Center 18-1/8”
Drilling Capacity Steel 1-1/16”
Cast Iron 1-1/4”
Tapping Capacity 3/4"
Morse Taper No.3
Quill Diameter 3”
Column Diameter 4”
Spindle Travel 5-3/8”
Spindle to Table (MAX) 27-1/4”
Spindle to base 46-1/4”
Shipping Weight 675 lbs.
Size Height 69-1/2”
Width 20”
Depth 29”
Table T-slotted 15-7/8” x 17-7/8”
2 slots for ½” t-bolts
Base 16-3/8” x 26-5/8”
2 slots for 1/2" t-bolts
1.30
7. Table Saw
Figure 4.9. Table Saw Machine
A table saw is an essential tool that can be used for an almost unlimited number of
wood working tasks. A tool consist of a circular saw blade, mounted on an arbor that
is driven by an electric motor (either directly by belt or gears). In other words, table
saws are designed to make straight or angled cuts through moderately soft materials
such as wood, plastics or similar materials. The most basic use for a table saw is to
take large sheets of material, usually woods and safely cut it down into smaller pieces
to be used for other projects. The table saw can quickly and safely cut one large sheet
of lumber into several dozen smaller pieces of various shapes and sizes suitable for
many projects. The specification of table saw machine are shown in the figure below.
1.31
Table 4.12 Specification of Table Saw Machine
Height 87 cm
Table Size 85 cm x 72 cm
Weight Approximately 32 kg
Top: 19 kg
Stand: 13 kg
Depth of cut (8/14” blade) 68 mm
Depth of cut (7/14” blade) 55 mm
Rip Width 34 cm
Tilting Not tilt
Power Any power
8. Cut of Saw Machine
Figure 4.10. Cut Saw Machine

In addition to ripping, the cut saws machine can be used in various modes including
cross-cutting and grooving. The specification of cut saw machines are shown in the
figure below.
Table 4.13 Specification of Cut Saw Machine
Maximum cutting height 6 mm
Scoring blade diameter 120 mm
Scoring blade spindle diameter 22 mm
Motor for scoring cutter 1 H.P.
Scoring shaft speed 7200 RPM
Very precise adjustment of Manually
scoring
Machine dimensions (LxBxH) 3300 mm x 3700 mm x 1050 mm
Machine Weight 760 kg
9. Gun Spray
Figure 4.11. Gun Spray Machine
Gun spray is a painting tool that using compressed air from a nozzle to atomize a
liquid into a controlled pattern. The spray nozzle operates by impinging high-velocity
turbulent air on the surface of filaments of films or liquid to collapse and droplets
with a wide range of sizes. Gun spray are usually available as a stationary equipment
for painting automobiles, furniture, and appliances. The specification of gun spray
are shown in the figure below.
Table 4.14. Specification of Gun Spray Machine
Air Pressure (psi) 30-50 psi
Cup Capacity (ml) 600-650 ml
Nozzle Size (mm) 1 mm
Item Weight (kg) 2 kg(s)
Air Consumption (cfm) 9 to 10
Air Inlet (NPT) ¼
Material Metal
Machine and Equipment List Dimension
The table below shows the dimension of each machine and equipment that is used in
producing the Rectangular Oak Table and Casual Arm Chair products. The dimension
is stated in Length x Width in meter units.
Table 4.15. Machine or Equipment Dimension
Machine/Equipment Dimension (Length x Width) m
Jointer 1.84 x 0.44
Circular Saw 1.50 x 0.50
Radial Arm Saw 1.10 x 1.25
Router 1.00x 1.00
Disc Sander 0.43 x 0.47
Drill Press 5.6 x 2
Table Saw 0.85 x 0.72
Bench/Table 0.033 x 0.036
Cut Off Saw 3.3 x 3.7
Spray Booth/Gun Spray 0.8 x 0.8
4.5. Assembly Chart

Assembly chart is a broad overview of how several parts manufactured separately are
to be assembled to make the final product. It is an analog model of the assembly
process. Circles with a single link denote basics components, circles with several
operations.

As can be seen on assembly chart of ROT, subassembly 1 which is top surface
assembly, consist of top surface slat, frame top surface B, frame top surface C, base
surface, and screw 1”×#8. And then, subassembly 2, which is pedestal assembly,
consist of pedestal pieces E, feet F, pedestal support, screw 2”×#8, screw 2.5”×#12,
and carriage bolts 0.25”. Both of subassembly are assembled become final product
ROT. It will be inspected, continue to final coating process, final inspection,
packaging process, and final product finished.

As can be seen on assembly chart of CAC, subssembly 1 which is arm, dowels, front
legs, rear legs, and side stretcher. And then, strecher, washer, hanger, and cap nut will
be assembled with subassembly 1. Continue, subassembly 2 are consist of seat steek
rod and canvas seat. And subassembly 3 consist of back steel rod and canvas back.
All of parts will be assembled become final product, which is CAC.
4.6. Operation Processing Chart (OPC)
OPC is the chronological sequence of all operations, inspections, time allowances,
and materials used in a manufacturing or business process, from the arrival of raw
material to the packaging to the finished product.

The operation processing chart will be started from top surface slat. It will be
assembled with base surface, frame top surface B, and frame top surface C. And then,
the pedestal assembly created by pedestal pieces, pedestal support, and feet. Last, the
top surface assembly and pedestal assembly, will be assembled as final product ROT.

The operation processig chart will be started from assembly the arm and leg (front
and rear legs). Then, it is assembled with straight strecher using 4 dowels and glue. It
is connected with 3 strecher by using washer, hanger and cap nut. Then, its all gaps
are filled with wood filler. Cover the filler contained by sand paper. Continue to final
coating, assemble the seat, back, and final inspection. After the product finished, the
product CAC will be packaged.
CHAPTER V
CONCLUSION
Product and process analysis consist of engineering drawing, OPC, assembly chart,
BOM, & machine specification and dimension; and parts & material specification.
Bill of Materials (BOM) is a final product consisting of a list of items, materials, or
materials needed to assemble, mix or manufacture the finished product. Specification
is the details of the type and level of components to be used. The material
specification is needed to know the total materials needed in each product and to
know the best total materials that should be used to make a good quality product. The
machine specification is important to know the best machine that should be used to
make a good quality product. Assembly chart is a broad overview of how several
parts manufactured separately are to be assembled to make the final product. It is an
analog model of the assembly process. OPC is the chronological sequence of all
operations, inspections, time allowances, and materials used in a manufacturing or
business process, from the arrival of raw material to the packaging to the finished
product.
After this project, there will be continue topic about machine requirement. There will
a deeper analysis about making routing sheet, MPPC, determination of number of
machine and operators, organization structure and determination of the number of
personnel.
REFERENCES
Heragu,Sunderesh S. (2008). Facility Design, Third Edition. USA : CRC Press.
Freivalds,Andris and Niebel, Benjamin. (2009). Niebel’s Methods, Standards, and
Work Design, Twelfth Edition.New York : McGraw-Hill.
APPENDIX
1. Exploded Drawing of Rectangular Oak Table

2. Exploded Drawing of Casual Arm Chair
3. Exploded Drawing of Rectangular Oak Table - Part
4. Exploded Drawing of Casual Arm Chair – Part
5. Rectangular Oak Table 3D
6. Rectangular Oak Table (Front View, Side View, Top View and Bottom View)
7. Casual Arm Chair 3D
8. Casual Arm Chair 3D (Front View, Side View and Top View)
9. 110 Top surface subpart
10. 111 Top surface slat
11. 112 Frame top surface
12. 113 Frame top surface
13. 120 Base surface
14. 140 Pedestal
15. 141 Pedestal Pieces
16. 142 Feet
17. 143 Pedestal Support
18. 210 Front Leg
19. 220 Stretcher
20. 230 Side stretcher
21. 240 Arm
22. 250 Rear leg
23. 260 Back
24. 261 Back Steel Rod
25. 262 Canvas back
26. 270 Seat
27. 271 Seat steel rod
28. 272 Canvas seat
29. Assembly Chart of Rectangular Oak Table
30. Assembly Chart of Casual Arm Chair
31. OPC of Rectangular Oak Table
32. OPC of Casual Arm Chair
Module 2 : Machine Requirement
2/6/2018
PROJECT ASSIGNMENT
Created by,
2. Kelvin (004
INDUSTRIAL ENGINEERING 2015
Phone (021) 8910 9762-6 - Fax (021) 8910 9768 - Email:
TABLE OF CONTENTS
CHAPTER I ......................................................................................................................................... 2.2
INTRODUCTION................................................................................................................................ 2.2
1.1. Background ....................................................................................................................................
2.2
CHAPTER II ........................................................................................................................................ 2.5
LITERATURE STUDY ....................................................................................................................... 2.5
2.1 Routing Sheet ................................................................................................................................. 2.5
2.2 Multi Product/Part Process Chart (MPPC) ..................................................................................... 2.6
2.3 Number of Machine and Operator.................................................................................................. 2.7
CHAPTER III ...................................................................................................................................... 2.9
DATA COLLECTION......................................................................................................................... 2.9
3.1. Bill of Material ............................................................................................................................. 2.9
3.1.1. Rectangular Oak Table (ROT) ................................................................................................... 2.9
3.1.2. Casual Arm Chair (CAC) ......................................................................................................... 2.11
3.2. Assembly Chart ........................................................................................................................... 2.13
3.2.1. Rectangular Oak Table (ROT)................................................................................................. 2.13
3.2.2. Casual Arm Chair (CAC) ........................................................................................................ 2.13
3.3. Operation Processing Chart (OPC) ..............................................................................................
2.13
3.3.1. Rectangular Oak Table (ROT)................................................................................................. 2.13
3.3.2. Casual Arm Chair (CAC) ........................................................................................................ 2.14
3.4. Material and Parts Specification.................................................................................................. 2.14
3.5 Demand, Efficiency, and Working Hours Available .................................................................... 2.16
CHAPTER IV .................................................................................................................................... 2.17
DATA ANALYSIS ............................................................................................................................ 2.17
4.1 Routing Sheet ............................................................................................................................... 2.17
4.1.1 Routing Sheet of Rectangular Oak Table (ROT) ...................................................................... 2.17
4.1.2 Routing Sheet of Casual Arm Chair (CAC) .............................................................................. 2.27
4.2. Multi-Product Process Chart (MPPC) ......................................................................................... 2.38
4.3. Number of Machines and Operators ........................................................................................... 2.39
CHAPTER V...................................................................................................................................... 2.50
CONCLUSION .................................................................................................................................. 2.50
REFERENCES................................................................................................................................... 2.51
APPENDIX: MPPC ........................................................................................................................... 2.52
2.1
CHAPTER I
INTRODUCTION
1.1.Background
This report is continuation of the previous report about facilities design. On the
previous report which is product and process analysis, it has discussed regarding the
operation process chart, engineering drawing, and assembly chart, bill of materials,
materials and parts specification and also machine specifications. This report is the
second assignment to advance the study about facilities design. The main content of
this report discussed about machine requirement. To analyze that things, it is needed
several data which are routing sheet, Multi Product Process Chart, determination the
number of machine and operators, determination the number of personnel,
organizational structure, and job description for each department.
To get the data for this report needs several explanation. One of that is routing sheet.
Routing sheet is the steps covered in producing certain components and details that
need to be from things that are related. The purpose in making routing sheet is
calculating the number of machines required and to count the number of parts that
must be prepared in an attempt to obtain a desired product.
To advance this study about facilities design, this report will be focused in Multi
Product Process Chart. MPPC is an analyzing technique in resembling of work map
and analyzing the flow of materials. The data taken from Operation Process Chart
itself. But, only on MPPC depiction of a process operation is separated in several part
which are rough lumber, fabrication and assembling. The function in making MPPC
are calculating the number of machine based on requirement for making part or
component, determine the number of machine for each unit and operators.
The other topics will be discuss are organizational structure and job description. After
determine the MPPC and flow process chart, the company especially HRD easy to
determine the organizational structure, number of personnels or operators. Then,
assigned them based on the job description and requirement for all production
process.
1.2 Objectives
The objectives of this report are:
To know the flow process for each raw material.
Determine the number of machine needed.
As guideline in determine the production process.
As guideline in determine the production layout.
As a tools in revising the production method.
By knowing the processing time for each activities specified the product
utilization.
To show each of specific steps in making rectangular oak table and casual
armchair.
To practice in making the Multi Product Process Chart and Routing Sheet.
To know the relationship between product and each component.
Determine the number of personnel or operator needed in company.
1.3 Steps
There are several steps to complete this report, which are:
Collect the data from the previous report.
Make template for the new report.
Divide the report for job to take care of each member in group.
Make the organizational Structure and Job Description.
Make the Multi Product Process Chart (MPPC).
Determine and Calculate the Routing Sheet for each part.
Determine number of operator, machine, and personnel.
Complete the report required.
Do the consultation with the lecturer.
Revise based on consultation.
1.4 Tools and Equipment

There are some tools and equipment that support completing this report:
Data from the previous report
Computer
Internet
Facilities Design Book by Heragu and Tompkins.
CHAPTER II
LITERATURE STUDY
2.1 Routing Sheet
A route sheet serves a checklist and a timeline so that deadlines can be met and it
assists floor staff and management. On analysis, it can expose problems and reveal
areas of efficiency so that processes can be improved on an ongoing basis, based on
objectives and without interrupting production. It is therefore an essential component
in the manufacturing process.
Route sheet specifies the operations required for a part as well as the sequence of the
machines visited for these operations. It may also provide the setup time for each
machine, processing time and labor time. It shows how a part is to be produced,
which machine are needed, the tools to use, estimated setup times for the machines
and production in terms for the machines and production in terms of the number of
units expected per hour from each machine. One routing sheet is required for each
part in the assembly.
A route sheet is required for each individual fabricated part of the product (for make
parts). If the finished product is to be manufactured has 30 different parts and you
buy 10 from outside the company and make 20 parts in-house, you will need 20 route
sheets. The route sheet lists the operations requires to makes that part in the proper
sequence.
The route sheet would accompany the material from operation to operation telling the
operators what to do. The route sheet will the plant personnel about the part number,
part name, quantity to produce (left blank until needed), operation number, operation
description, machine number, machine name, tooling needed, and time standard.
The sequence of operation as shown on the route sheet affects the proper layout of the
equipment on the production floor. You the material to flow smoothly through the
plant from the raw material stores to the first operation, to the second operation
whose machine is right next to the first operation. This will ensure that the part
travels as short a distance as possible.
Process-oriented layouts are where you group all like machine together and all parts
to them, whereas product-oriented layouts place machine where they are needed to
eliminate excessive moving. Skipping over machines and backtracking will result
from process layouts and must be discouraged because it adds costs without adding to
the value. When many parts are fabricated in one group of machines (called a process
layout), jumping around may be necessary, but you want to minimize this jumping,
skipping, and backtracking. There are two ways to change the sequence in order to
make the flow through the plant smoother:
Change the route sheet (paper change) if possible so that sequences of operation
agree with the other parts or the existing plant layout.
Change the physical layout of the machines so that the machines are in the
correct sequence.
Formulas used in the process of making routing sheet are:
2.2 Multi Product/Part Process Chart (MPPC)

Multi product process chart (MPPC) is a diagram that shows the order for each
component that will be produced. MPPC also useful for steps of each production on
the certain process to be obtained the information about the similarity of process
from each product to other. Based on MPPC can know the backtracking and the track
not appropriate with the order process.
The information that found from MPPC is the total machine needed. There are
certainties that valid in MPPC, if the number after coma divided by the number
before coma is more than 0.1 so must be round up and if the total machine less than 1
should be round up to 1.
Usually the MPPC is useful to be guideline of production process. Another function
of MPPC are to calculate the number of machine needed, to needs of produce each
component, to determine the number of machine each unit and number of operator.
The purpose of MPPC is:
To determine the number of machines needed,
To show the production linkages between components of a product,
As a guideline in carrying out the production process,
As a work tool that provides information that is useful in improving the
system.
2.3 Number of Machine and Operator
To determine the number of machine needed to produce the product each day, the
author must know how many finished goods are needed per day, each machine runs
what parts, and the time standard for each operation.
Where,
NM = number of machine
τ = operation time machine per day (hour)
t = operation time (hour) p = production rate (unit/day)
η = machine efficiency
With Backward Analysis and each process there is scrap, so total unit that must be
produced:
Where,
Sl = % scrap from first process
Nil = total input for first process
Nol = total output for first process
The advantages of determine the number of machine that needed to production

process:
Make efficient use of capital equipment purchase budget
Make efficient use of maintenance and operating budget
Increase machine utilization
Make efficient use of available space
Where,
N = number of types of operations
Oi = aggregate number of operations of type i required on all the pseudo/real products
manufactured per day
Ti = standard time for an average operation Oi
H = total production time available per day
η = assumed production efficiency of the plant
CHAPTER III DATA
COLLECTION
3.1. Bill of Material
Bill of Materials (BOM) is a final product consisting of a list of items, materials, or
materials needed to assemble, mix or manufacture the finished product. Bill of
material consists of various forms and can be used for various purposes. Bill of
material is made as part of the design process and is used by the manufacturing
engineer to determine the tem to be purchased or produced. Here, there are two BOM
for each product, such as ROT and CAC.
Below are shown the Bill of Materials from ROT.
Table 3.1. Bill of Material ROT
Level Part Part Name Quantity Make/Buy
Number
0 - ROT 1 Make
Assembly
1 140 Pedestal Assembly 1 Make
2 111 Top Surface Slat 11 Make
2 112 Frame Top Surface 2 Make
(B)
2 113 Frame Top Surface 2 Make
(C)
2 120 Base Surface 1 Make
2 141 Pedestal Pieces (E) 4 Make
2 142 Feet (F) 4 Make
2 143 Pedestal Support (G) 4 Make
2 - Flathead Screw 1”× 22 Buy
#8
2 - Flathead Screw 2”× 36 Buy
#8
2 - Flathead Screw 2.5”× 8 Buy
#12
2 - Carriage Bolts 8 Buy
0.25”×2.5”
Level
ROT (1)
0
Level To p Surface Assembly Pedestal Assembly

1 (1) (1)
Carriag e
Frame Top Frame Top Screw
Level To p Surface Base Screw Pedestal Feet F (4) Pedestal Screw Bolts
Surface Surface C Pieces E (4) 2.5"×#12
Slat (11) Surface (1) 1"×#8 (22) Support (4) 2"×#8 (36) 0.25"×2.5"
2 B(2) (2) (8)
(8)
Figure 3.1. Product Structure ROT
Figure above shown the product structure of Rectangular Oak Table (ROT). ROT is on level 0 as final product. And
then, the ROT has two assembly in level 1 which are top surface assembly and pedestal assembly. The top surface
assembly itself has 5 subassembly in level 2 such as 11 of top surface slat, 2 of frame top surface B, 2 of frame top
surface C, 1 of base surface, and 22 of screw 1”. The pedestal assembly has several subassembly in level 2, such as 4
of pedestal pieces E, 4 of feet F, 4 of pedestal support, 36 of screw 2”, 8 of screw 2.5”, and 8 of carriage bolts
0.25”×2.5”.
2.10
Below are shown the Bill of Materials from CAC.
Table 3.2. Bill of Material CAC
BILL OF MATERIALS
Comp Prepare
any: d by
Produ Casual Armchair Date 18-
ct : (CAC) Jan-18
Level Part No. Part Name Qty Make/

Buy
0 - Casual Arm 1 Make
Chair
1 - SA Arm & Leg 2 Make
1 220 Stretcher 3 Make
1 - Hanger Bolt 1/4" 6 Buy
2 1/2"
1 - Washer 1/4" 6 Buy
1 - Cap Nut 1/4" 6 Buy
1 270 Seat Assembly 1 Make
1 260 Back Assembly 1 Make
2 - Dowelling 3/8" x 8 Buy
4'
2 - Dowelling 3/8" x 8 Buy
1 1/2"
2 210 Front Leg 2 Make
2 220 Side Stretcher 2 Make
2 230 Arm 2 Make
2 250 Rear Leg 2 Make
2 271 Seat Steel Rod 1 Make
2 272 Canvas Seat 1 Buy
2 261 Back Steel Rood 1 Make
2 262 Canvas Back 1 Buy
2.11
Casual Arm
Chair (CAC)
SA Arm & Hanger Bolt Washer 1/4" Cap Nut 1/4"

Stretcher (3) 1/4" 2 1/2" Seat Ass (1) Back Ass (1)
Leg (2) (6) (6)
(6)
Dowelli Dowelli Side

ng 3/8" Front Rear Seat Back
ng 3/8" Stretche Arm (2) Steel Canvas Steel Canvas
x 1 1/2" Leg (2) Leg (2)
x 4' (8) r (2) Rod (1) Seat (1) Rood Back (1)
(8)
(1)
Figure 3.2. Product Structure CAC
Figure above shown the product structure of Casual Arm Chair (CAC). CAC is on level 0 as final product. And then,
the CAC has seven assembly in level 1 which are 2 of SA Arm and Leg, 3 of Strecher, 6 of Hanger Bolt, 6 of
Washer, 6 of Cap Nut, 1 of Seat Ass, and 1 of Back Ass. The SA Arm and Leg itself has 6 subassembly in level 2
such as 8 of Dowelling 3/8”×4’, 8 of Dowelling 3/8”×1 1/2’, 2 of Front Leg, 2 of Side Strecher, 2 of Arm, and 2 of
Rear Leg. The Seat Ass itself has several subassembly in level 2, such as 1 of seat steel rod, 1 of canvas seat, 1 of
back steel rood, and 1 of canvas back.
2.12
3.2. Assembly Chart
Assembly chart is a broad overview of how several parts manufactured separately are
to be assembled to make the final product. It is an analog model of the assembly
process. Circles with a single link denote basics components, circles with several
operations.
As can be seen on assembly chart of ROT, subassembly 1 which is top surface
assembly, consist of top surface slat, frame top surface B, frame top surface C, base
surface, and screw 1”×#8. And then, subassembly 2, which is pedestal assembly,
consist of pedestal pieces E, feet F, pedestal support, screw 2”×#8, screw 2.5”×#12,
and carriage bolts 0.25”. Both of subassembly are assembled become final product
ROT. It will be inspected, continue to final coating process, final inspection,
packaging process, and final product finished.
As can be seen on assembly chart of CAC, subssembly 1 which is arm, dowels, front
legs, rear legs, and side stretcher. And then, strecher, washer, hanger, and cap nut will
be assembled with subassembly 1. Continue, subassembly 2 are consist of seat steek
rod and canvas seat. And subassembly 3 consist of back steel rod and canvas back.
All of parts will be assembled become final product, which is CAC.
3.3. Operation Processing Chart (OPC)

OPC is the chronological sequence of all operations, inspections, time allowances,
and materials used in a manufacturing or business process, from the arrival of raw
material to the packaging to the finished product.
The operation processing chart will be started from top surface slat. It will be
assembled with base surface, frame top surface B, and frame top surface C. And then,
the pedestal assembly created by pedestal pieces, pedestal support, and feet. Last, the
top surface assembly and pedestal assembly, will be assembled as final product ROT.
2.13
The operation processig chart will be started from assembly the arm and leg (front
and rear legs). Then, it is assembled with straight strecher using 4 dowels and glue. It
is connected with 3 strecher by using washer, hanger and cap nut. Then, its all gaps
are filled with wood filler. Cover the filler contained by sand paper. Continue to final
coating, assemble the seat, back, and final inspection. After the product finished, the
product CAC will be packaged.
3.4. Material and Parts Specification

Specification is the details of the type and level of components to be used. The
material specification is needed to know the total materials needed in each product
and to know the best total materials that should be used to make a good quality
product. Here are several materials and their specifications used to make rectangular
oak table and casual armchair.
Table 3.3 Material Specification of ROT

Materia Materi Specification Number
l Name al Thicknes Length Width of Parts
Numbe s (Inche (Inche per
r (Inches) s) s) Productio
n
Oak 1 ¾ 46 ½ 3½ 11
Oak 2 ¾ 46 ½ 3½ 2
Oak 3 ¾ 38 ½ 3½ 2
Oak 4 ¾ 27 8½ 4
Oak 5 ¾ 22 5½ 4
Plywoo 1 ¾ 46 ½ 38 ½ 1
d
Fir 1 2 8½ 2 4
Table above shows the materials specifications for making one product of
Rectangular Oak Table. There are five types of Oak that are used one type of
Plywood and one type of Fir. The table of material specification above contains of the
information regarding the material name, material number, specifications which
include thickness, length, and width (in inches), and the information about the
number of part per production.
Table 3.4. Material Specification of CAC
Materi Materi Specification Number
al al Thicknes Length Width of Parts
Name Numbe s (Inches (Inches per
r (Inches) ) ) Productio
n
Brich 1 ¾ 25 1½ 2
Brich 2 ¾ 20 ½ 1½ 3
Brich 3 ¾ 14 ½ 1½ 2
Brich 4 ¾ 19 ½ 2½ 2
Brich 5 ¾ 25 3½ 2
Round 1 Ф 3/8 9½ 1
Steel
Bar
Round 2 Ф 3/8 17¼ 1
Steel
Bar
Table above shows the materials specifications for making one product of Casual
Armchair. There are five types of Birch that are used and two types of Round Steel
Bar. The specifications of each material are listed on the table above.
3.5 Demand, Efficiency, and Working Hours Available
Below are shown the demand, efficiency, and working hours available used for
analysis data on the next Chapter IV Data Analysis.
Table 3.5. Demand, Efficiency, and Working Hours

Product Demand (Units Efficiency Working Hours
per Week) Available
ROT 300 85% 480
CAC 620 minutes/day
CHAPTER IV
DATA ANALYSIS
4.1 Routing Sheet
Routing Sheet is a series of process to be performed to achieve the final product until the product is to be delivered. The
routing sheet data will be useful for making MPPC. The routing sheet of Rectangular Oak Table (ROT) and Casual Arm
Chair (CAC) are shown in below.
4.1.1 Routing Sheet of Rectangular Oak Table (ROT)
Table 4.1. 111 Top Surface Slat (11)

Product
Capacity
Op. Machi Time Requirement Number of
Process Name Srap%
No ne (min) O M/C
Theoritic Actual In
ut
Mark using square for 238.467 3577.01
1 10 240 204 1.16895982
whole raw material 8 7
Cut to the length circ. 2. 1090.909 927.272 1 3577.01 3541.24 3.85756740
2
46.5" saw 2 09 73 % 7 69 6
disc 3541.24 321.931 5.20771599
3 Sand all surfaces 3 800 680
sand 69 5 8
Based on the table above, the company needs 238.4678 raw materials to make 3577.017 top surface slat. Based on
238.4678 raw materials, actually the company can produce 3577.017 top surface slat. But, since there are some machines
that possibly will caused scraps, so the number of top surface slat that can be made perfectly are 321.9315 units. Overall,
the number of machines to make perfect top surface slat are 321.9315 five machines for each operation.
2.17
Table 4.2. 112 Frame Top Surface B (2)
Product
Process Time Capacity Number
Op. No Machine Srap% Requirement
Name (min) of M/C
Theoritic Actual In Out
Mark
using
square
11 11 218.1818 185.4545 42.4949 637.4244 0.2291
for whole
raw
material
Cut to
the
12 circ. saw 2.4 1000 850 2% 637.4244 624.6759 0.7499
length
46.5"
Cut for
the
13 jointer 1.8 1333.3333 1133.3333 1% 624.6759 618.4291 0.5511
joining
edges
Sand the
14 disc sand 2.5 960 816 618.4291 309.2146 0.7578
edges
Based on the table above, the company needs 42.4949 raw materials to make 637.4244 frame top surface. Based on
the 42.4949 raw materials, actually the company can produce 637.4244 frame top surface. But, since there are some
machines that possibly will caused scraps, so the number of frame top surface that can be made perfectly are
309.2146 units. Overall, the number of machines to make perfect frame top surface are 309.2146 one machines for
each operation.
Table 4.3. 113 Frame Top Surface C (2)
Proce Capacity Product Requirement
Op. Time Number
ss Machine Srap%
No (min) Theoritic Actual In Out of M/C
Name
Mark
using
square
1 for 1 35.41 637.4 0.20
200 170
5 whole 2 24 244 83
raw
materi
al
Cut to
2
1 the circ. 1 637.4 631.0 0.74
. 1000 850
6 length saw % 244 501 99
4
38.5"
Cut
for the 1
1 join 1333.3 1133.3 2 631.0 618.4 0.55
joinin .
7 ter 333 333 % 501 291 68
g 8
edges
Sand disc 2
1 923.07 784.61 618.4 309.2 0.78
the san .
8 69 53 291 146 81
edges d 6
Based on the table above, the company needs 35.4124 raw materials to make 637.4244 frame top surface. Based on
the 35.4124 raw materials, actually the company can produce 637.4244 frame top surface. But, since there are some
machines that possibly will caused scraps, so the number of frame top surface that can be made perfectly are
309.2146 units. Overall, the number of machines to make perfect frame top surface are 309.2146 one machines for
each operation.
Table 4.4. 120 Base Surface
Product
Op. Process Time Capacity Number
Machine Srap% Requirement
No Name (min) of M/C
Mark
using
4 square for 3 800 680 325.2165 325.2165 0.4782
whole raw
material
Cut to the
5 width jointer 0.48 5000 4250 2% 325.2165 318.7122 0.0765
38.5"
Cut to the
6 length circ. saw 1.5 1600 1360 2% 318.7122 312.3380 0.2343
46.5"
Based on the table above, the company needs 325.2165 raw materials to make 325.2165 base surface. Based on the
325.2165 raw materials, actually the company can produce 325.2165 base surface. But, since there are some
machines that possibly will caused scraps, so the number of base surface that can be made perfectly are 312.3380
units. Overall, the number of machines to make perfect base surface are 312.3380 one machines for each operation.
Table 4.5. 141 Pedestal Piece (4)
Product
Process Time Capacity Number of
Name (min) M/C
Mark
using
square
22 for 4 600 510 328.4680 1313.8722 0.6440
whole
raw
material
Cut to
the
23 circ. saw 1.6 1500 1275 1% 1313.8722 1300.7335 1.0304
length
27"
Mark
for the
24 2.5 960 816 1300.7335 1300.7335 1.5940
pilot
screw
Drill 2"
screw drill
25 2.4 1000 850 1% 1300.7335 1287.7261 1.5302
for 5 press
holes
Sand all
26 disc sand 3.3 727.2727 618.1818 1287.7261 321.9315 2.0830
surfaces
Based on the table above, the company needs 328.4680 raw materials to make 1313.8722 pedestal pieces. Based on the
328.4680 raw materials, actually the company can produce 1313.8722 pedestal pieces. But, since there are some machines
that possibly will caused scraps, so the number of frame top surface that can be made perfectly are 321.9315 units. Overall,
the number of machines to make perfect frame top surface are 312.9315 two machines for each operation.
Table 4.6. 142 Feet (4)
Product
Process Time Capacity Number
Name (min) of M/C
Marking
using
square
35 4 600 510 318.6797 1274.7188 0.6248
for whole
raw
material
Cut to the
36 length circ. saw 1.4 1714.2857 1457.1429 1% 1274.7188 1261.9716 0.8748
22"
Mark for
37 the pilot 2.2 1090.9090 927.2727 1261.9716 1261.9716 1.3609
screw
Drill 2"
38 screw for drill press 2.1 1142.8571 971.4285 1% 1261.9716 1249.3519 1.2990
4 holes
Sand all disc
39 2.8 857.1428 728.5714 1249.3519 312.3380 1.7147
surfaces sand
Based on the table above, the company needs 318.6797 raw materials to make 1274.7188 frame top surface. Based
on the 318.6797 raw materials, actually the company can produce 1274.7188 frame top surface. But, since there are
some machines that possibly will caused scraps, so the number of frame top surface that can be made perfectly are
312.3380 units. Overall, the number of machines to make perfect frame top surface are 312.3380 two machines for
each operation.
Table 4.7. 143 Pedestal Support
Op. Process Time Capacity Product Requirement Number
Machine Srap%
No Name (min) Theoritic Actual In Out of M/C
Marking
using
square
30 for 4 600 510 318.6797 1274.7188 0.6248
whole
raw
material
Cut to
the
31 circ. saw 1.4 1714.2857 1457.1429 1% 1274.7188 1261.9716 0.8748
length
8"
Mar for
32 the pilot 2 1200 1020 1261.9716 1261.9716 1.2372
screw
Drill
1/4" drill
33 3 800 680 1% 1261.9716 312.3380 1.8558
bolt press
holes
Based on the table above, the company needs 318.6797 raw materials to make 1274.7188 pedestal support. Based on
the 318.6797 raw materials, actually the company can produce 1274.7188 pedestal support. But, since there are some
machines that possibly will caused scraps, so the number of pedestal support that can be made perfectly are 312.3380
units. Overall, the number of machines to make perfect pedestal support are 312.3380 two machines for each
operation.
Table 4.8. Assembly Top Surface (110)
Time Capacity Product Requirement N umber of
Op. No Process Name Machine Srap%
(min) Theoritic Actual In Out M/C
Apply glue & attach

A-1 jointer 15 160 136 2% 321.9315 315.4929 2.3671
all 11 top surface
Apply glue on top of

7 circ. saw 3.6 666.666667 566.66667 1% 315.4929 312.3380 0.5568
base surface
Join the base surface

A-2 1 2400 2040 312.3380 312.3380 0.1531
with top surface
Drill 1" by #8 screw,

8 drill press 12 200 170 1% 312.3380 309.2146 1.8373
7.75" from each end
9 Put all screws 8 300 255 309.2146 309.2146 1.2126
10 Trim off all ends table saw 5 480 408 309.2146 309.2146
Join all frames using
A-3 4.8 500 425 309.2146 309.2146 0.7276
glue
Fill all the holes and
19 gaps with wood 5.6 428.571429 364.28571 309.2146 309.2146 0.8488
filler
20 Sand all surfaces 4 600 510 309.2146 309.2146 0.6063
Apply two coat of
21 gun spray 1.6 1500 1275 309.2146 309.2146 0.2425
polyurethane
Based on the table above, the company needs 321.9315 to apply glue and attach all 11 top surface. The glue applied on top
of base surface with 315.4929 units. Then, the base surface and top surface are assembled for 312.3380 units for each
surface and the scrap is 2 % with the total output are 315.4929. After that, 309.2146 units will put all the screws and trim
off all ends. The all frames will be assembled. There will be around 309.2146 units after assembled that can be made
perfectly.
Table 4.9. Assembly Pedestal (140)
Op. Time Capacity Product Requirement Number of
Process Name Machine Srap%
No (min) Theoritic Actual In Out M/C
Apply glue and attach 4

A-4 jointer 0.8 3000 2550 2% 321.9315 315.4929 0.1262
pedestal pieces
27 Hold and clamp circ. saw 1.4 1714.28571 1457.1429 1% 315.4929 312.3380 0.2165
28 Fasten with 2" screws 6 400 340 312.3380 312.3380 0.9186
29 Put off the clamp 0.6 4000 3400 312.3380 312.3380 0.0919
Attach all the pedestal
A-5 4 600 510 312.3380 312.3380 0.6124
supports using glue
34 Fasten using 2.5" bolts 3.6 666.666667 566.66667 312.3380 312.3380 0.5512
Attach all the feet spports
A-6 8 300 255 312.3380 312.3380 1.2249
using glue
40 Fasten with 2" screws 3 800 680 1% 312.3380 309.2146 0.4547
Fill all the holes and gaps
41 3.2 750 637.5 309.2146 309.2146 0.4850
with wood filler
42 Sand the dry filler 4 600 510 309.2146 309.2146 0.6063
Apply two coat of
43 gun spray 2 1200 1020 309.2146 309.2146 0.3032
polyurethane
Based on the table above, the company needs 321.9315 to apply glue and attach all 11 top surface and the scrap is 2
% with the total output are 315.4929. The hold and clamp are assembled with 315.4929 units. Then, the units are
fasten with 2” crews for 312.3380 units. But, there will be around 309.2146 units after assembled that can be made
perfectly.
Table 4.10. Assembly Final Product (ROT)
Tim Product
O Capacity Numb
Process Machi e Srap Requirement
p. er of
Name ne (mi %
No Theoritic Actual In Out M/C
n)
Inspecti
I-1
on of 2666.666 2266.66 309.21 306.12
A- 0.9 1% 0.1364
110 and 67 67 46 24
7
140
Final gun 1333.333 1133.33 306.12 306.12
44 1.8 0.2701
coating spray 33 33 24 24
Final
circ. 1714.285 1457.14 306.12
I-2 inspecti 1.4 2% 300 0.2101
saw 71 29 24
on
Packagi
45 0.8 3000 2550 300 300 0.1176
ng
Based on the table above, it can be seen that company inspected 309.2146 pairs of 110 and 140. The operation
estimated caused 1 % of scrap so there will be 306.1224 perfect assembled-parts. Then, the 306.1224 units are final
coating between parts of 110 and 140. After that, 306.1224 units of final inspection. This process also take 2% of
scraps, so there will be 300 units left of perfect tables. Then the 300 units of table are packaged to be delivered to the
customer.
4.1.2 Routing Sheet of Casual Arm Chair (CAC)
Table 4.11. 110 Front Leg (2)
Tim Production
Capacity Scra Numbe
Operatio e Requirement
Process Name Machine p r of
n No. (min
) Theoriti (%) M/C
c Actual In Out
Mark Using Square for whole raw 923.076 784.615 271.505 1357.52
8 2.6 0.3460
material 9 4 9 94
2790.69 2372.09 1357.52 1343.95
9 Cut to the width 1.5" Jointer 0.86 1% 0.5723
77 30 94 41
Circ. 6666.66 5666.66 1343.95 1330.51
10 Cut to the length 25" 0.36 1% 0.2372
Saw 67 67 41 46
Mark of 0.75" from edge and pilot 1330.51 1330.51
11 0.24 10000 8500 0.1565
holes 46 46
1330.51 1317.20
12 Remove of 0.75" rounded edge Router 0.4 6000 5100 1% 0.2609
46 94
Drill 1317.20 1304.03
13 Drill the holes 0.4 6000 5100 1% 0.2583
Press 94 73
Disc. 3636.36 3090.90 1304.03 1304.03
14 Sand All surface Sand 0.66 36 91 73 73 0.4219
Gun 1304.03 1304.03
15 Apply two coat of polyurethane Spray 0.4 6000 5100 73 73 0.2557
Based on the table above, the company needs 271.5059 raw materials to make 1304,0373 front legs. Based on the
271.5059 raw materials, actually the company can produce 1357.5294 front legs where each raw material of front leg
can be made 5 front legs. But, since there are some machines that possibly will caused scraps, so the number of front
legs that can be made perfectly are 1304.0373 units. Overall, the number of machines to make 1304.0373 perfect
front legs are one machines for each operation.
Table 4.12. 220 Stretcher (3)
Operation Process Time Capacity Scrap Prod. Requirement Number

Machine
No. Name (min) Theoretic Actual (%) In Out of M/C
Mark using
square for
30 3 800 680 276.6140 1936.2979 0.4068
whole raw
material
Cut to the
31 jointer 0.9 2666.6667 2266.6667 1% 1936.2979 1916.9349 0.8542
width 1.5"
Cut to the
32 circ. saw 0.4 6000 5100 1% 1916.9349 1897.7655 0.3759
length 20.5"
Drill 0.25"
33 drill press 0.6 4000 3400 0 1897.7655 1897.7655 0.5582
holes
Sand all
34 disc sand 0.84 2857.1429 2428.5714 0 1897.7655 1897.7655 0.7814
surfaces
Apply two
35 coat of gun spray 0.45 5333.3333 4533.3333 1897.7655 1897.7655 0.4186
polyurethane
Based on the table above, the company needs 276.6140 raw materials to make 1897.7655 strecthers. Based on the
276.6140 raw materials, actually the company can produce 1936.2979 strecthers. But, since there are some machines
that possibly will caused scraps, so the number of strecthers that can be made perfectly are 1897.7655 units. Overall,
the number of machines to make 1897.7655 perfect stretchers are one machines for each operation.
Table 4.13. 230 Side Stetcher (2)
Machine
Mark
using
23 square for 3 800 680 146.3566 1317.2094 0.2152
whole raw
material
Cut to the
24
width 1.5"
jointer 0.9 2666.6667 2266.6667 1% 1317.2094 1304.0373 0.5811
Cut to the
25 length circ. saw 0.4 6000 5100 1% 1304.0373 1290.9970 0.2557
14.5"
Drill
26 0.25" drill press 0.6 4000 3400 0 1290.9970 1290.9970 0.3797
holes
Sand all
27
surfaces
disc sand 0.8 3000 2550 1290.9970 1290.9970 0.5063
Based on the table above, the company needs 146.3566 raw materials to make 1290.9970 side strecthers. Based on
the 146.3566 raw materials, actually the company can produce 1317.2094 side strecthers. But, since there are some
machines that possibly will caused scraps, so the number of side strecthers that can be made perfectly are 1290.9970
units. Overall, the number of machines to make 1290.9970 perfect side stretchers are one machines for each
operation.
Table 4.14. 240 Arm (2)
Machine of M/C
No. Name (min) Theoretic Actual (%) In Out
Marking
using
1 square for 2 1200 1020 692.6877 1385.3754 0.6791
whole raw
material
Cut to the
2 jointer 0.68 3529.4118 3000 2% 1385.3754 1357.6679 0.4618
width 2.5"
Cut to the
3 length circ. saw 0.55 4363.6364 3709.0909 1% 1357.6679 1344.0913 0.3660
19.5"
Mark of
4 0.75" of 0.44 5454.5455 4636.3636 1344.0913 1344.0913 0.2899
Edges
Remove of
0.75"
5 rounded Router 1.1 2181.8182 1854.5455 2% 1344.0913 1317.2094 0.7248
edges for
Notches
Drill 3/8"
holes on
6 Rounded Drill press 0.88 2727.2727 2318.1818 1% 1317.2094 1304.0373 0.5682
Edges
Sand all
7 disc. Sand 0.92 2608.6957 2217.3913 1304.0373 1304.0373 0.5881
surfaces
Based on the table above, the company needs 692.6877 raw materials to make 1304.0373 arms. Based on the 692.6877 raw
materials, actually the company can produce 1385.3734 arms. But, since there are some machines that possibly will caused
scraps, so the number of arms that can be made perfectly are 1304.0373 units. Overall, the number of machines to make
1304.0373 perfect arms are one machines for each operation.
Table 4.15. 250 Rear leg (2)

Machine
Mark
using
16 square for 1.8 1333.3333 1133.3333 678.7647 1357.5294 0.5989
whole raw
material
Cut to the
17 jointer 0.8 3000 2550 1% 1357.5294 1343.9541 0.5324
width 3.5"
Cut to the
18 circ. saw 0.36 6666.6667 5666.6667 1% 1343.9541 1330.5146 0.2372
length 25"
Mark of
0.75"
19 from edge 0.38 6315.7895 5368.4211 0% 1330.5146 1330.5146 0.2478
and pilot
holes
Remove
of 0.75"
20 router 0.4 6000 5100 1 1330.5146 1317.2094 0.2609
rounded
edge
Drill the
21 drill press 0.8 3000 2550 1 1317.2094 1304.0373 0.5166
holes
Sand all
22 disc sand 0.72 3333.3333 2833.3333 1304.0373 1304.0373 0.4602
surfaces
Based on the table above, the company needs 678.7647 raw materials to make 1304.0373 rear legs. Based on the 678.7647
raw materials, actually the company can produce 1357.5294 rear legs. But, since there are some machines that possibly
will caused scraps, so the number of rear legs that can be made perfectly are 1304.0373 units. Overall, the number of
machines to make 1304.0373 perfect rear legs are one machines for each operation.
Table 4.16. 260 Back (1)
Ti Capacity Sc Prod. Requirement
Proce Num
m ra
Operati ss Mac ber
e Theor Act p
on No. Nam hine In Out of
e
(m etic ual (%
M/C
in) )
Mark
the
bars 210.86 1265.1 0.49
42
to
4.8 500 425
28 770 61
lengt
h 9.5"
Cut
steel cut
bar to 127 1265.1 1252.5 0.99
43 off 1.6 1500 1%
Lengt 5 770 253 23
saw
h 9.5"
Attac
h
canva
s 626.26 626.26 0.73
44 2.4 1000 850
sling 26 26 68
to
Bars
Based on the table above, the company needs 210.8628 raw materials to make 1252.5253 back steel rods for making
626.2626 back seats. Based on the 210.8628 raw materials, actually the company can produce 1265.1770 back steel
rods. But, since there are some machines that possibly will caused scraps, so the number of back steel rods that can
be made perfectly are 1252.5253 units. Overall, the number of machines to make 1252.5253 perfect back steel rods
to become 626 back seats are one machines for each operation.
Table 4.16. 270 Seat (1)
Machine
No. Name min) Theoretic Actual (%) In Out of M/C
Mark the
bars to
39 ength 0.8 3000 2550 425.9855 1277.9566 0.1671
17.25"
Cut steel
bar to
40 Length cut off saw 0.1 24000 20400 1 1277.9566 1265.1770 0.0626
17.25"
Attach
canvas
41 sling to 0.72 3333.3333 2833.3333 632.5885 632.5885 0.2233
Bars
Based on the table above, the company needs 425.9855 raw materials to make 1265.1770 seat steel rods for making
632.5885 seats. Based on the 425.9855 raw materials, actually the company can produce 1277.9566 seat steel rods.
But, since there are some machines that possibly will caused scraps, so the number of seat steel rods that can be made
perfectly are 1265.1770 units. Overall, the number of machines to make 1265.1770 perfect seat steel rods to become
632.5885 seats are one machines for each operation.
Table 4.17. Sub Assembly Arm and Leg (2)
Operation Capacity Prod. Requirement Number
Process Name Machine Time Scrap
No. min) Theoretic Actual (%) In Out of M/C
Attach 4 dowels
(1.5") into edges 0.72 3333.3333 2833.3333 1304.0373 1304.0373 0.4602
A-1 of arm using
glue
Assemble front
A-2 and rear legs to circ. saw 2.8 857.1429 728.5714 1 1304.0373 1290.9970 1.7899
arm
Assemble side
stretcher using 4 2 1200 1020 2 1290.9970 1265.1770 1.2657
A-3 dowels (4") &
glue
Inspect and fill
I-1
O-28
all gaps with 1.2 2000 1700 1265.1770 1265.1770 0.7442
wood filler
Apply two coat 0.4837
29 of polyutethane gun spray 0.78 3076.9231 2615.3846 1265.1770 1265.1770
Based on the table above, the company needs 1304.0373 arms to be assembled with 4 dowels for each arm. Then, the front
and rear legs are assembled with arms for 1304.0373 units for each leg. But, there will be around 1290.9970 units after
assembled that can be made perfectly because there is 1% possibility that the operation caused scraps. The 1290.9970 units
of arm, and both legs are assembled with 1290.9970 side stretchers by using 4 dowels for each unit and glue. This process
of assembling can caused 2 % scraps, so the output of it are 1265.1770 units. Until the end of operation to make Sub
Assembly Arm and Leg, there are 1265.1770 units of it.
Table 4.18. Assembly CAC

Machine
Connect 3
stretchers to
2 SA Arm
and Leg
A-4 using 3.2 750.0000 637.5000 632.5885 632.5885 0.9923
washer,
hanger and
cap nut
Fill all gaps
36 with wood 0.88 2727.2727 2318.1818 632.5885 632.5885 0.2729
filler
Sand the
37 filler 0.56 4285.7143 3642.8571 632.5885 632.5885 0.1737
contained
Final
38
coating
gun spray 0.9 2666.6667 2266.6667 632.5885 632.5885 0.2791
Assemble
A-5
the seat
2.4 1000.0000 850.0000 1 632.5885 626.2626 0.7442
Assemble
A-6
the back
1.8 1333.3333 1133.3333 1 626.2626 620 0.5526
Final
I-2
inspection
1 2400 2040 620 620 0.3039
O-45 Packaging 0.8 3000 2550 620 620 0.2431
Based on the table above, it can be seen that company connected 632.5885 pairs of Sub Assembly Arm and Leg with
1897.7655 stretchers (there will be 1 stretcher left to be saved) by using washer, hanger, and cap nut. Then, the 632.5885
units are filled with wood filler to fulfill all gaps, covered by sand paper, and coated by gun spray. When it is assembled
with 632.5885 seats, the operation estimated caused 1 % of scrap so there will be 626.2626 perfect assembled-parts after
the seat assembly process. After that, 626.2626 units of assembled parts are assembled with 626.2626 units of back. This
process also take 1% of scraps, so there will be 620 units left of perfect chairs. Then the 620 units of chairs are inspected
and packaged to be delivered to the customers.
Table 4.19. Flow Shop
FLOW SHOP
Raw Material
Part Name Material Req Rounded TOTAL
Size
CAC
210 Front Leg
271.5059 272
(A)
Birch 220 Stretcher
276.6140 277 696
12’ x 2” x 1” (B)
230 Side
146.3566 147
Stretcher (C)
Birch
240 Arm (D) 692.6877 693 693
3 ½’ x 3” x 1”
Birch
250 Rear Leg
4 ¼ ’ x 4” x 678.7647 679 679
(E)
1”
261 Back
210.8628 211
Round steel Steel Rood (I)
637
bar ᴓ⅜ x 5’
271 Seat Steel
425.9855 426
Rod (H)
Table 4.20. Job Shop
JOB SHOP
Raw Material
Part Name Material Req TOTAL Rounded
Size
CAC
210 Front
271.5059
Leg (A)
Birch 220 Stretcher
276.6140 694.4765 695
12’ x 2” x 1” (B)
230 Side
146.3566
Stretcher (C)
Birch
3 ½’ x 3” x 240 Arm (D) 692.6877 692.6877 693
1”
Birch
250 Rear Leg
4 ¼ ’ x 4” x 678.7647 678.7647 679
(E)
1”
261 Back
Steel Rood 210.8628
Round steel
(I) 636.8484 637
bar ᴓ⅜ x 5’
271 Seat
425.9855
Steel Rod (H)
2.37
Table 4.21. Production Req
Part Name Production Req

CAC
210 Front Leg (A) 1304.0373
220 Stretcher (B) 1897.7655
230 Side Stretcher
1290.9970
(C)
240 Arm (D) 1304.0373
250 Rear Leg (E) 1304.0373
261 Back Steel Rood
1252.5253
(I)
271 Seat Steel Rod
1265.1770
(H)
4.2. Multi-Product Process Chart (MPPC)

MPPC is a flow process chart containing several products. By creating MPPC, it could
be known the backtracking and flow pattern that is not fit with the sequence of the
process. Another function of MPPC is to determine the number of machine required
theoretically and actually, and the number of operators needed for the production process.
On the Appendix, there will be the multi-product process chart for both product such as
ROT and CAC. There will be analysis from part until finished
product.
4.3. Number of Machines and Operators
The number or total machines and operators can be calculated based on the Route Sheet
and Multi Part Process Chart (MPPC). The data will assume that one machine will
operate by one operator. The number of machines and operators are shown in the table
below.
Table 4.24. Number of Machines and Operators
Process Layout
Total
Total Actual Total
Produc t Theoretic Machin Operato r
Department Machine e
Marking,
Assembling, &
Gluing 17.0416 18 18
Jointer 1.3107 2 2
Circ.Saw 8.7984 9 9
Drill Press 6.5225 7 7
Disc.Sand &
Fillling 13.0981 14 14
Table Saw 0.7579 1 1
Gun Spray 0.8158 1 1
Inspection 0.1364 1 1
ROT Packaging 0.1176 1 1
Marking,
Assembling, &
Gluing 7.1582 8 8
Jointer 3.0018 4 4
Router 1.2466 2 2
Attaching 1.4203 2 2
Circ.Saw 3.2619 4 4
Disc.Sand &
Fillling 3.9487 4 4
Cut Off Saw 1.0549 2 2
CAC Packaging 0.2431 1 1
TOTAL
MACHINE 73.9565 87 87
From the table above, the process layout consist of two such as total theoretic machine
and total actual machine. The total machine can be calculated based on ROT and MPPC.
The total theoretic machine of marking, assembling, and gluing are 17.0416 because this
2.39
department play an important role. Then, the total actual machine round up become 18
machines. Actually, the total theoretic machine are come from the total of component
ROT, sub-assembly ROT, the total component of CAC, and sub-assembly of CAC. The
total theoretic machine for all department are 73.9565. The total actual machine are
taken from the round up the theoretic machine, then the total actual machine are 87
machines. Since one machine is assume handle by one operator, so the total operators
are also 87 operators.
4.4. Organization Structure and Number of Personnel

Every company generally has an organizational structure. Preparation of organizational
structure is the first step in starting the implementation of organizational activities, in
other words the preparation of organizational structure is a planned step in a company to
carry out the functions of planning, organizing, directing, and supervision.
The organizational structure explains how work tasks will be divided, grouped and
formally coordinated. The organizational structure shows the framework and
arrangement of the embodiment of a fixed pattern of relationships between functions,
sections or positions as well as those that show different tasks, powers and
responsibilities within an organization. The organizational framework is called
organizational design and the specific form of the organizational framework is called the
organizational structure.
Therefore, the importance of an organizational structure will assist managers in the
outcome of decisions in organizational design as a way of identifying from human
resource management and all the functions that exist for the completion of the
company's work with guidelines of vision, mission and organizational goals.
PRESIDENT
DIRECTOR
WALTZ COMPANY
VICE
PRESIDENT
WALTZ COMPANY
GENERAL GENERAL GENERAL GENERAL

MANAGER MANAGER MANAGER MANAGER
Human Finance and Marketing and
Manufacturin g Purchase Sales
Resources
Figure 4.1 Board of Director of Waltz Company
From the diagram above it shows the level of authority in Waltz Company. The highest
level course held by the President Director of Waltz Company.
The President Director may function more like a strategist, with other senior general
manager responsible for implementing his plans. The president director's job can be said
simple, but not that easy as it seems. The president director has a high level of
responsibility. The president director can be responsible for day-to-day operational tasks
to the actions required in a business step.
The top level of Board of director also held by some of General Manager from critical
main departments namely Manufacturing Department, Human Resources, Finance and
Purchase Department and Marketing and Sales Department.
General Manager is a function of high position after President Director which has a
duty for leading and directing the employee below their department. General Manager
also has to maintain all of the performance and the effectiveness of staffs and coordinate
all matters handled by each department.
GENERAL MANAGER
MANUFACTURING
DEPARTMENT
MANAGER MANAGER
Engineering Production
Department Department
Head of
Research Head of Design Head of Quality Head of
Development Development Control Supply Chain
WALTZ COMPANY WALTZ COMPANY WALTZ COMPANY WALTZ COMPANY
STAFF STAFF STAFF STAFF
Figure 4.2 Organization Structure of Manufacturing Department
Manufacturing Department is one of the important departments for the apparel

manufacturing company. Manufacturing Department has one General Manager that has
the greatest authority in Manufacturing Department and has a duty for leading and
directing the employee below manufacturing department.
Manufacturing department supervise several division under their department which are
Research development and Design Development, quality control and supply chain
division. There are 2 Managers in this department which are Engineering Department
and Production Department. Engineering department has two divisions which are
research development and design development. And below that division, there is several
staff below that division.
Research and Development Division function is have to make stuff and fond of
solutions that don't just work, but work elegantly, finding a solution to a technical
problem and making the Research solutions into buildable, sellable products. A good
R&D department needs input from customers (either directly or through Marketing) to
understand what the real problems are.
Quality Control Division function is to make sure that what comes out of Production
actually works. In company that manufactures stuff, quality control will devise tests that
every product (or a sample from a production batch) has to pass before it is shipped. In
a software company, QC usually works with the developers to find bugs (although many
companies are letting their customers take on the QC task).
Head of Supply
Chain
Procurement Logistics Management
STAFF Warehouse Inventory Transportation STAFF
STAFF STAFF STAFF
Figure 4.3 Organization Structure of Supply Chain Division
Supply chain division has their own structure. And there are several divisions again
under this division. The divisions are procurement, logistics and management. The
Procurement Department manages about the strategic sourcing such as like KAP
vendors, Cost volume driven, quality assurance, core accommodities and etc. and also
about tactical purchasing such as like release order KAPs , spot orders and etc.
meanwhile The Logistics Department managing something like warehouse, inventory,
transportation and environment. And the last Management Supply Chain Department
function are make a strategy, demand and forecasting, think about technology
efficiencies and process review.
GENERAL MANAGER
Human Resouces Department
Personnel and Administration Training and Development
STAFF STAFF
Figure 4.4 Organization Structure of Human Resources Department
In applied science, HRD commonly referred to as "Personnel". HRD in management is

also called "Human Capitol" or "Human Resources Management". The function of
Human Resources Department is to deal with various problems in the scope of
employees, employees, laborers, managers and other workers to support the activities of
the organization or company to achieve destinations that have been determined.
Human resource management can also be interpreted as an ongoing procedure that aims
to supply an organization or company with the right people to be placed in the right
position and position when the organization needs it.
In Waltz Company, Human Resources Department has two divisions which are
personnel and administration that manage about the employee recruitment, Selection and
evaluation work performances of employees. And training development division that has
function to adjusts the training and development of employee skills when they are need.
GENERAL MANAGER
Finance and Purchase

Department
Financial Administration Purchasing
STAFF STAFF
Figure 4.5 Organization Structure of Finance and Purchase Department
Finance and purchase department has two divisions under it namely financial
administration and purchasing division. Financial Administration employee is
responsible for all financial activities, the main task of this position is to make
arrangements, transactions, make financial report company. The position of Finance
Staff should report to the position of head of financial administration. In this position are
needed discipline, honesty, high accuracy and responsibility because if there is an error
will be very fatal to the company because it involves the company's finances.
Purchasing Department functions such as purchasing goods at the lowest possible
price by maintaining the quality of goods, Fostering good relationships with vendors,
Maintaining effectiveness and Developing high competent personnel and also coordinate
with all departments within the company. Purchasing system is a method used by
companies to buy products and / or services. A purchasing system manages the overall
procurement process, from demand, purchases, product receipts, to payments.
Purchasing systems are a key component of inventory management in monitoring the
availability of goods and helping companies determine what to buy, how much to buy,
and when to buy.
GENERAL MANAGER
Marketing and Sales

Department
Marketing Sales
STAFF STAFF
Figure 4.6 Organization Structure of Marketing and Sales Department
Sales and Marketing Department has a function to carry out all the planning,
assignment and supervision of sales activities within a company. The marketing and
sales department has a significant positive effect on the relationship between market-
oriented behavior and performance. The Marketing Department plays a vital role in
promoting the business and mission of an organization. It serves as the face of the
company, coordinating and producing all materials representing the business. It is the
Marketing Department's job to reach out to prospects, customers, investors and the
community, and create an overarching image that represents your company in a positive
light—that is, the company’s brand. The marketing department has overall responsibility
for growing revenue, increasing market share and contributing to company growth and
profitability.
Table 4.31 Total Personnel President Director
Position Personnel
President Director 1
Vice President Director 1
Total 2
Table 4.32 Total Personnel Manufacturing
General Manager 1
Manufacturing
Department
Engineering Department 1
Manager
Head of Research 1
Research Development Staff 2
Head of Design 1
Design Development Staff 2
Production Department 1
Manager
Head of Quality Control 1

Quality Control Staff 2
Head of Supply Chain 1
Supervisor Procurement 1
Procurement Staff 2
Supervisor Logistic 1
Warehouse Staff
3
Inventory Staff 2
Transportation Staff 2
Supervisor Management 1
Management SC Staff 2
Production Lines Manager 1
Production Lines Staff 2
Supervisor of Production 1
Operator of Production
Lines 65
Total
96
2.47
Table 4.33 Total Personnel Human Resource Department
General Manager 1
Human Resources
Department
Personnel and 1
Administration Manager
Personnel and Admin Staff 2
Training and Development 1
Manager
Training Staff
Total and Development 2
7
Table 4.34 Total Personnel Finance and Purchase Department

General Manager 1
Finance and
Purchase
Department
Financial Administration 1
Manager
Staff
Purchasing ager Man 1
Purchasing Staff 2
Total 7
Table 4.35 Total Personnel Marketing and Sales Department
General Manager 1
Marketing & Sales
Department
Marketing Staff 2
Sales Staff 2
Total 5
2.48
Table 4.36 Total Personnel
Position Personnell
Head Security 1
Security Staff 3
Receptionist 2
Doctor 1
Nurse 1
Head of Canteen 1
Chef 2
Waiter/Waitress 2
Head of Cleaning Service 1
Cleaning Service Canteen 1
Cleaning Service Office 3
Cleaning Service Toilet Man 2
Cleaning Service Toilet 2
Total 22
Total Employees 139
Based on table of total personnel, Waltz Company needs total around 139 personnel
to run the company. There is 1 President Director and 4 General Manager which are
General Manager of Manufacturing Department, General Manager of Human
Resource Department, General Manager of Finance and Purchase Department, and
General Manager of Marketing and Sales. Each general manager will have one
secretary or assistant to support their work and have several managers. And each
manager will have a several staffs under their department or division. This number of
employees are not fixed, the company can change the number of employees based on
their needed.
2.49
CHAPTER V
CONCLUSION
Routing Sheet is a series of process to be performed to achieve the final product until
the product is to be delivered. The routing sheet data will be useful for making
MPPC. MPPC is a flow process chart containing several products. By creating MPPC,
it could be known the backtracking and flow pattern that is not fit with the sequence of
the process. The number or total machines and operators can be calculated based on
the Route Sheet and Multi Part Process Chart (MPPC).
Every company generally has an organizational structure. Preparation of
organizational structure is the first step in starting the implementation of
organizational activities, in other words the preparation of organizational structure is
a planned step in a company to carry out the functions of planning, organizing,
directing, and supervision. Waltz Company needs total around 139 personnel to run
the company.
REFERENCES
Freivalds,Andris and Niebel, Benjamin. (2009). Niebel’s Methods,
Standards,
andWork Design, Twelfth Edition.New York : McGraw-Hill.
APPENDIX: MPPC
2.52
Module 3 : Space Requirement
2/20/2018
PROJECT ASSIGNMENT
Created by,
2. Kelvin (0042
Phone (021) 8910 9762-6 - Fax (021) 8910 9768 - Email:
TABLE OF CONTENTS
CHAPTER I ................................................................................................................... 3.3
INTRODUCTION ......................................................................................................... 3.3
1.1. Background ..................................................................................................... 3.3
1.3. Steps .................................................................................................................... 3.4
1.4. Tools and Equipment .......................................................................................... 3.4
CHAPTER II .................................................................................................................. 3.5
LITERATURE STUDY................................................................................................. 3.5
2.1. Space Requirements ............................................................................................ 3.5
2.2. Workstation Specification ................................................................................... 3.5
2.3. The Employee-Facility Interface......................................................................... 3.7
2.3.1. Employee Parking ............................................................................................ 3.7
2.3.2. Storage of Employees’ Personal Belongings ................................................... 3.8
2.3.3. Restrooms......................................................................................................... 3.8
2.3.5. Health Services................................................................................................. 3.9
2.4. Office Facility Planning .................................................................................... 3.10
2.5. Storage Planning ............................................................................................... 3.11
2.6. Warehouse Operation........................................................................................ 3.12
CHAPTER III .............................................................................................................. 3.15
DATA COLLECTION................................................................................................. 3.15
3.1. Multi Product Process Chart (MPPC) ............................................................... 3.15
3.2. Number of Machines and Operators ................................................................. 3.15
3.3. Machine Dimension .......................................................................................... 3.16
3.4. Number of Personnel ........................................................................................ 3.16
CHAPTER IV .............................................................................................................. 3.20
DATA ANALYSIS ...................................................................................................... 3.20
4.1 Space Requirement for Office........................................................................... 3.20
4.2. Space Requirement for Storage......................................................................... 3.30
4.3 Space Requirement for Other Supporting Facilities .......................................... 3.49
4.3.1. Parking Area............................................................................................... 3.49
4.3.2. Locker Room.............................................................................................. 3.53
4.3.3. Restrooms................................................................................................... 3.54
4.3.4. Food services.............................................................................................. 3.54
3.1
4.3.5. Health care ................................................................................................. 3.54
4.3.6 Musholla...................................................................................................... 3.55
4.3.7 Shipping and Receiving Area...................................................................... 3.55
4.4 Space Requirement for Production Floor........................................................... 3.56
4.5 Space Requirement for Warehouse and Its Specification .................................. 3.58
4.6. Summary of Space Requirements ..................................................................... 3.68
4.7 Green Area ......................................................................................................... 3.68
CHAPTER V................................................................................................................ 3.69
CONCLUSION ............................................................................................................ 3.69
REFERENCES............................................................................................................. 3.70
CHAPTER I
INTRODUCTION
1.1.Background
One of the critical element that can not be easily put aside in developing a layout are the
requirement and availability of space. Space requirements are made with the aim to find
out how big the area of land required by groups of activities are planned in order to be
able to function and work properly, so it created sustainability of activities in the area of
work and production floor. As a company that produce goods made of wood, of course
need to know how much physical space will be required. By understanding the flow
between machines or the interaction departments, as a consultant is able to determine
and predict the space requirement to locate machine and others thing related to business
activity. A facility plant layout can not be made effectively if the supporting data or
information related to the factors that affect the plant layout is not truly complete yet.
Designers often overlook regarding the information of materials, machines, and number
of personnel in designing the facility plant layout, especially in determine the space
requirement of each department in Wood Manufacturing Company. The layout of
production facilities that are less regularly can lead to long distance transfer of materials
which may result in the length of time the production process, as well as the rising costs
of transfer of materials. By designing an adequate production facilities considering the
space requirements of each element will carry on increasing the efficiency of use of
space, time, and cost of material removal or displacement of material.
This report is written as the third assignment in Facility Design subject, analyzing the
previous report furthermore regarding on space requirement. Some details of the space
requirement for analyzing would be provided in this report, such as space requirement
for production floor, storage, warehouse, office, and supporting
facilities
1.2. Objectives
The objectives of this report are:
To determine the space requirement of each element in production floor, storage,
warehouse, office, and supporting facilities
To design the layout of each element in storage, warehouse, office and supporting
facilities
1.3. Steps
There are several steps to complete this report, which are:
Acquire the data from previous report
Calculate space requirement for production floor
Calculate space requirement for storage
Calculate space requirement for warehouse
Calculate space requirement for office
Calculate space requirement for supporting facilities
Finalize the report
Consult the report with the lecturer
Revise the report based on the advise and suggestion given by the lecture
1.4. Tools and Equipment
There are some tools and equipment that support completing this report:
Microsoft Visio is used to compose the layout of each department
Microsoft Excel is used to create measurement table • Solid Work is used to create
3D Engineering Drawing
CHAPTER II
LITERATURE STUDY
2.1. Space Requirements

In determining space requirements for warehousing activities, inventory levels, storage
units, storage methods and strategies, equipment requirements, building constraints, and
personnel requirements must be considered. In manufacturing and office environments,
space requirements should be determined first, for individual workstations, and then for
departmental requirements should be determined based on the collection of workstations
in the department.
Modern manufacturing approaches are changing drastically the space requirements in
production, storage areas, and offices. Specifically, space requirements are being
reduced because products are delivered to the points of use in smaller lot and unit load of
sizes, decentralized storage areas are located at the points of use, less inventories are
carried, more efficient layout arrangements are used, companies are downsizing, offices
are shared and telecommuting is used, and more products are outsourced to other
manufacturers locally or in off-shore locations.
2.2. Workstation Specification

A workstation, like all facilities, includes space for for equipment, materials, and
personnel. The equipment space for a workstation consists of space for equipment,
machine travel, machine maintenance, and plant services.
Equipment space requirement should be readily available from data machinery data
sheets. For machines already in operation, machinery data
sheets should be available from either the maintenance department’s equipment history
records or the accounting department’s equipment inventory records. For new machines,
machinery data sheets should be available from the equipment supplier. If machinery
data sheets are not available, then a physical should be performed.
Floor area requirements for each machine, including machine travel, can be determined
by multiplying total width by total depth. Add the maintenance and plant service area
requirements to the floor area requirement of the machine. The sum of machinery areas
for all machines within a workstation gives the machinery area requirement for the
workstation.
The materials areas for a workstation consist of space for receiving and storing inbound
materials, holding in-process materials, storing outbound materials and shipping, storing
and shipping waste and scrap, and holding tools, fixtures, jigs, dies, and maintenance
materials.
To determine the area requirements for receiving and storing materials, in-process
materials, and storing and shipping materials, the dimensions of the unit loads to be
handled and the flow of material through the machine must be known. Sufficient space
should be allowed for the number of inbound and outbound unit loads typically stored at
the machine. Additional space may be needed to allow for in-process materials to be
placed into the machine, for materials such as bar stock to extend beyond the machine,
and for the removal of material from the machine. Space for the removal of waste and
scrap from the machine and storage prior to removal from the workstation must be
provided.
The personnel area for a workstation consists of space for the operator work area,
material handling, and operator ingress and egress. Space requirements for the operator
and for material handling depend on the method used to perform the operation. The
method should be determined using a motion study of the task and an ergonomics study
of the operator.
In addition to the space required for the operator work area and for material handling,
space must be allowed for operator ingress and egress. A minimum of a 30 inch aisle is
needed for operator travel past stationary objects. If the operator walks between a
stationary object and an operating machine then a minimum if 36 inch aisle is required.
If the operator walks between two operating machines, then a minimum if a 42 inch aisle
is needed.
Table 2.1 specifies aisle widths for various types of flow. If the anticipated flow over an
aisle indicates that only on rare occasions will flow be taking place at the same time in
opposite directions, then the aisle width should for main aisles may be obtained from
Table 2.1. However, if the anticipated flow in an aisle indicates that two-way flow will
occur frequently, then the aisle width should equal the sum of the aisle width required for
the types of flow in each direction.
Table 2.1 Recommended Aisle Widths for Various Types of Flow
2.3. The Employee-Facility Interface

An interface between an employee’s work and nonwork activities must be provided. The
interface functions as a storage area for personal property of the employee during work
hours, personal property typically
includes automobiles and employees’ personal belongings, such as coats, clothes, purses,
and lunches.
2.3.1. Employee Parking
Planning employee parking areas is very similar to planning stores or warehouse areas.
The procedure to be followed is determining the number of automobiles to be parked by
type of automobile, the space required for each automobile, the available space for
parking, alternative parking layous for alternative parking patterns, and selecting the
layout that best utilizes space and maximizes employee convenience.
The size of a parking space for an automobile, which is expressed as the stall width ×
stall depth, can vary from 5.5 ×12 feet to 9.5 ×19 feet, depending on the type of
automobile and the amount of clearance to be provided. The total area required for a
parked automobile depends on the size of the parking space, the parking angle, the aisle
width.
A parking stall width of 7.5 feet for compact automobiles and
8.5 feet for standard-sized automobiles is recommended. In Table 2.2, there are two car
groups, which are small cars and standard cars.
Table 2.2 Module Width for Each Car Groups as a Function of Single- and
Double-Loaded Module Options
2.3.2. Storage of Employees’ Personal Belongings

Employees would like a room to change into and out of work clothes, a place to store
their personal belongings including lunch and paperwork. Separate locker rooms for men
and women are required. The lockers may be located in a corridor adjacent to the
employee entrance if clothes changing does not take place. More commonly, locker
rooms are provided for each sex even if clothes changing are not required. Each
employee should be assigned a locker. For planning purposes, 6 ft2 should be allocated
for each person using the locker room. Locker rooms are often located along an outside
wall adjacent to the employee entrance. Thsi provides excellent ventilation and
employee convenience while not interfering with the flow of work within the facility.
2.3.3. Restrooms
A restroom should be located within 200 feet of every permanent workstation. Separate
restrooms should be provided for each sex. The recommended minimum number of
toilets for the number of employees working within a facility is given in Table 2.3. In
restrooms for males, urinal may be substituted for a toilet, provided that the number of
toilet is not reduced to less than twothirds the minimum recommended, noted in Table
2.3. for space planning purposes, 12.5 ft2 (2.5′× 5′) or 15 ft2 (3′× 5′) should be allowed
for each toilet, and 6 ft2 for each urinal. Toilets and urinals must be designed to
accommodate wheelchairs for handicapped employees as well.
Table 2.3 Plumbing Fixtures Requirements for Number of Employees
For planning purposes, 6 ft2 should be allowed for each sink. A space allowance of 15 ft 2
should be used for the entrance. The above space requirements, combined with necessary
aisles/clearances, can be used to obtain approximate floor space requirements for
restrooms. To provide a clearance between the wall and a row of fixtures, the aisle width
recommended in ranges from 3′6" to 4′0" (for aisles up to 16 feet long), and from 4′0" to
6′0" (for longer aisles), if the toilet doors open in.
2.3.4. Food Services
Food service facilities should be planned by considering the number of employees who
eat in the facilities during peak activity time. While kitchen facilities should be planned
by considering the total number of meals to be served. Space requirements for cafetarias
should be based on on the maximum number of of employees to eat in the cafetaria at
any one time. Table 2.4 gives general area requirements guidelines. The space allocated
within the ranges given in Table 2.4 should be determined by the type of tables to be
utilized. Popular table sizes are 36-, 42-, and 48-inchsquare tables; rectangular tables 30
inches wide and 6, 8, and 10 feet long; and round tables 30, 36, and 42 inches in
diameter. Square tables require more aisle space than rectangular tables but result in
more attractive cafetarias.
2.3.5. Health Services
The facility planner should check the firm’s operating procedure to determine what types
of services are to be offered and what health services staff is to be housed within the
facility. At the very least, a small first aid room should be included. The minimal
requirements for a first aid room are an approved first aid kit, a bed, and two chairs. A
minimum of 100 ft2 is required. If a nurse is to be employed, the forst aid room should
have two beds and should be expanded to 250 ft2. Health services should be located such
that examination rooms are adjacent to first aid rooms and close to the most hazardous
tasks.
2.4. Office Facility Planning
Offices are among the most challenging facilities to plan. One reason for this is each
office employee has an opinion on how space should be planned. An open office is one
in which the office area is free form temporary or permanent partition walls. The space is
open, and no floor to ceiling walls exist. A closed office structure is a structure where
floor to ceiling temporary or permanent partition walls break up the office facility into
smaller rooms. The motivation for open offices is to increase flexibility for changes in
office operations and to easily accommodate expansion. Additional benefits of open
offices include:
Improved communications
Improved supervision
Better access to common files and equipment
Greater ease of illumination, heating, cooling and ventilation
Lower maintenance costs
Reduced space requirements due to space flexibility
Some objections frequently cited concerning open offices are
Lack of privacy
Lack of status recognition
Difficulty in controlling noise
Easy access for interruptions and interference
Closed offices are recommended when the work is confidential, when noise from
various sources cannot be masked and when the tasks to be performed require
undisturbed concentration. Most office structures are a combination of open and
closed. Although traditional office layouts consist of private, semi private and
general closed offices, more contemporary offices are a combination of closed
private and semi private and general open offices.
Planning for new office facilities requires decisions beyond just the determination
of square footage requirements. Nevertheless, the specification of square footage
requirements is an essential step in the planning of office facilities. The following
data are suggested in
President’s office: 250 - 400 ft2
Vice President’s office: 150-250 ft2
Executive Office: 100-150 ft2
Partitioned open space – supervisor or manager: 80 – 110 ft2
Open space – clerical or secretary: 60 – 110 ft2
Conference room: 15 ft2 per person (theater style) and 20 – 30 ft2 per person
(conference seating)
Mailroom: 8 to 9 feet wide; length depends on the amount of usage
Reception area: 125 – 200 ft2( receptionist and 2-4 people) and 200 – 300 ft2 (
receptionist and 6 – 8 people)
File room: 7 ft2 per file with a 3-4 foot aisle width
2.5. Storage Planning
Storage materials in a planned and orderly manner that does not endanger employee
safety. Ensure stacks, tiers, and piles are stable and stacked to aid safe handling and
loading. Store all materials on all pallets to discourage rodent infestation. Use slings to
hoist bagged material, lumber, bricks, masonry blocks, and similar loosely stacked
materials only if the slings are fully secured against falling by straps, sideboards, nets, or
suitable devices.
Storage materials indoors requires attention to access, fire prevention and protection,
floor loading, and overhead hazards. Building under construction require special
precautuions. In terms of access, store materials so they do not interfere with access
ways and the aisles must be wide enough to accommodate forklifts or firefighting
equipment. For the fire prevention and protection matter, store noncompatible materials
that may create a fire hazard at least 25 feet apart or separate them with a barrier having
at least an hour five rating. Fire doors, maintain a 24-inch clearance around the travel
path of fire doors. Sprinklers, maintain at least 18-inch clearance between stired
materials and sprinkler heads. Heating appliances, maintain at least 3-foot clearance
between stored materials and unit heaters, radiant space heaters, duct furnaces, and flues
or clearances shown on the approval agency label. Fire protection, emergency fore
equipment must be readily accessible and in good working order. In concern of floor
loading, conspiciously post load limits un all storage areas, exceot for floor or slabs on
grade. Building under construction, store materials inside buildings under construction at
least 6 feet away from any hoistwasy
or inside floor openings, and 10 feet away from an exterior wall that does not extend
ebove the top of material stored.
Stack bagged materials by stepping back the layers and cross-keying the bags at least
every 10 bags high, except when restrained by walls or partitions of adequate strength.
Stack lumber on level and solidly supported sills so that the stacks are stable. Do not pile
the number more than 16 feet high.
Closed tanks and containers, only use the one that has been approved and labeled to
store, handle, and dispense flammable and combustible liquids. Original container, store
and use flammable combustible liquids in the original Departmet of Transportation
(DOT) shipping containers.
However, store only up to a day use in the work area, up to a maximum of 25 gallons of
a Class 1A liquid or a maximum of 120 gallons of any other class of liquid. When
dispensing and using smaller quantities of flammable and combustible liquids, dispense
them into properly labeled, approved safety containers. Safety can, an approved
container holding no more than 5 gallons with a spring-closing lid, spout cover, and
designed to safely relieve internal pressure when subjected to fire or heat exposure.
Drum or barrel, an approved container holding more than 5 gallons but no more than 60
gallons. Portable tanks, an approved and closed storage vessel holding more than 60 but
no more than 660 gallons and not intended to be fixed installation.
2.6. Warehouse Operation
The warehouse plays a critical role in supporting a company’s supply chain success. The
mission of warehouse is to effectively ship products in any configuration to the next step
in the supply chain without
damaging or alerting the product’s basic form. If the warehouse cannot
process order quickly, effectively, and accurately, than the company’s supply chain
optimization effort will suffer. All warehouse opportunities, including order picking,
cross docking, productivity, space utilization and value added services, allow the
warehouse to process and ship orders more effectively.
Problems can occur in planning receiving and shipping facilities if the carriers that
interface with receiving and shipping activities are not properly considered. Positioning
of the carries and their characteristics are important to receiving and shipping operation.
The steps required to determine and calculate the total space requirement for receiving
and shipping areas are;
Determine what is to be received and shipped Determine the information on the what,
how much and when of items received or shipped. The part list and the market analysis
information for all products must be analyzed to determine reasonable unit loads and
order quantities. Determine at a minimum, the types of carriers; the overall length,
width, and height; and the height to the carrier’s dock should be specified.
Determine the number and type of docks Waiting line analysis may be used to determine
the number of docks that will provide the required service if arrivals and/or services are
Poisson distributed and the arrival and service distribution do not vary significantly over
time. Use Table 2.6 to know the space requirement for Dock.
Table 2.6 Space Requirement for Dock
Determine the space requirements for the receiving and shipping area within thE facility.
Receiving and shipping department area requirement within a facility may include space
allocation for personnel convenience/office, receiving hold area, trash disposal and
recycling bins, pallet and packaging material storage/palletizing equipment,
the trucker’s lounge, buffer of staging areas and material handling equipment
maneuvering. To determine the minimum allowance for receiving and shipping areas use
Table 2.7 below.
Table 2.7 Minimum Maneuvering Allowance for Receiving and Shipping Areas
3.14
CHAPTER III
DATA COLLECTION
3.1. Multi Product Process Chart (MPPC)

MPPC is a flow process chart containing several products. On the next page, there will be
the multi-product process chart for both product such as ROT and CAC. There will be
analysis from part until finished product.
3.2. Number of Machines and Operators
The number or total machines and operators can be calculated based on the Route Sheet
and Multi Part Process Chart (MPPC). The data will assume that one machine will
operate by one operator. The number of machines and operators are shown in the table
below.
Table 3.1. Number of Machines and Operators
Process Layout
Total Total
Theoretic Actual Total
Product Department Machine Machine Operator
Marking,
Assembling, &
Gluing 17.0416 18 18
Jointer 1.3107 2 2
Circ.Saw 8.7984 9 9
Disc.Sand & Fillling 13.0981 14 14
Table Saw 0.7579 1 1
ROT Packaging 0.1176 1 1
Marking,
Assembling, &
Gluing 7.1582 8 8
Jointer 3.0018 4 4
Router 1.2466 2 2
Attaching 1.4203 2 2
Circ.Saw 3.2619 4 4
Disc.Sand & Fillling 3.9487 4 4
Cut Off Saw 1.0549 2 2
CAC Packaging 0.2431 1 1
TOTAL MACHINE 73.9565 87 87
3.15
3.3. Machine Dimension
The table below shows the dimension of each machine and equipment that is used in
producing the Rectangular Oak Table and Casual Arm Chair products. The dimension is
stated in Length x Width in meter units.
Table 3.2. Machine or Equipment Dimension
Machine/Equipment Dimension (Length x Width) m
Jointer 1.84 x 0.44
Circular Saw 1.50 x 0.50
Radial Arm Saw 1.10 x 1.25
Router 1.00x 1.00
Disc Sander 0.43 x 0.47
Drill Press 5.6 x 2
Table Saw 0.85 x 0.72
Bench/Table 0.033 x 0.036
Spray Booth/Gun Spray 0.8 x 0.8
3.4. Number of Personnel

The number of personnel in the Waltz Company is around 139 personnel. The
table in the following shows the detail information about the total of employees that exist
in the Waltz Company. This number of employees are not fixed, the company can
change the number of employees based on their needed.
Table 3.3 Total Personnel President Director
Position Personnel
President Director 1
Vice President Director 1
Total 2
Table 3.4 Total Personnel Manufacturing
General Manager 1
Manufacturing
Department
Engineering Department 1
Manager
Head of Research 1
Research Development Staff 2
Head of Design Development 1
Design Development Staff 2
Production Department 1
Manager
Head of Quality Control 1

Quality Control Staff 2
Head of Supply Chain 1
Supervisor Procurement 1
Procurement Staff 2
Supervisor Logistic 1
Warehouse Staff
3
Inventory Staff 2
Transportation Staff 2
Supervisor Management 1
Management SC Staff 2
Production Lines Manager 1
Production Lines Staff 2
Supervisor of Production 1
Operator of Production Lines
65
Total
96
3.17
Table 3.5 Total Personnel Human Resource Department
General Manager 1
Human Resources
Department
Personnel and 1
Administration Manager
Personnel and Admin Staff 2
Training and Development 1
Manager
Training Staff
Total and Development 2
7
Table 3.6 Total Personnel Finance and Purchase Department

General Manager 1
Finance and
Purchase
Department
Manager
Staff
Purchasing ager Man 1
Purchasing Staff 2
Total 7
Table 3.7 Total Personnel Marketing and Sales Department
General Manager 1
Marketing & Sales
Department
Marketing Staff 2
Sales Staff 2
Total 5
3.18
Table 3.8 Total Personnel
Position Personnell
Head Security 1
Security Staff 3
Receptionist 2
Doctor 1
Nurse 1
Head of Canteen 1
Chef 2
Waiter/Waitress 2
Head of Cleaning Service 1
Cleaning Service Canteen 1
Cleaning Service Office 3
Cleaning Service Toilet Man 2
Cleaning Service Toilet 2
Total 22
Total Employees 139
3.19
CHAPTER IV
DATA ANALYSIS
4.1 Space Requirement for Office

Space standards were established to create uniformity and effieciency in the work
environment. The standards encourage designers and stakeholders to think in terms of
adaptability for future reconfigurations. Inherently, the standars also discourage designs
that dedicate space to infrequent or “luxury” uses.
4.1.1. Office Room

Setting up the right office space is crucial and can make a large difference in the success
of the business. It is important to discover what the business needs in a space and get it
right. Doing so can ensure efficient workflow and concentration for the employees. To
make the office rooms planning, the total number of personnel is needed to know. The
number of personnel for each department is already mentioned in report 2.
4.1.1.1. President Director Room
President director has a largest room in the company. President Director’s room can be
allocated an enclosed office but it is not mandatory and it is an allowance not an
entitlement. The area of this room should be calculated by all of item required in each
room.
Table 4.1 President Director Room Calculation
Length/
diameter width Area Allowance Total Area
Item Qty (ft) (ft) 2 (300%) 2
(ft ) (ft )
Desk 1 6.50 3.50 22.75
Chair 1 2.25 2.25 5.0625
Sofa (single) 1 2.25 2.25 5.0625
Sofa ( triple ) 1 6.50 2.25 14.625
Table 1 3.50 3.00 10.5
Trash bin 1 ᴓ0.79 0.489
Drawer 1 3.00 2.50 7.50
3.20
Book shelf 1 5 3.00 15
Storage Unit 1 4 2.50 10
Total 90.98 272.96 363.95
The table above shows the total space in President Director’s Room. The total area is
90.98 ft2. The total area is multiply with the allowance, which is 300% (assumed) and
the result must be sum with the original or first total area to get the total all of area.
The square footage requirement for president director’s office is amount 250-400 ft2.
And the total area of president director’s room in Waltz Company is 363.95 ft2. Thus,
the president director’s room in Waltz Company is meet the standards or can be said by
the area requirement.
4.1.1.2 General Manager Room
General Manager is a function of high position after President Director which has a duty
for leading and directing the employee below their department. General Manager Room
is smaller than president director’s room. The area of this room should be calculated by
all of item required in each room.
Table 4.2 General Manager Room
Length/
width Area Allowance Total Area
Item Qty diameter (ft) (ft^2) (300%) (ft^2)
(ft)
Desk 1 4.5 3 13.5
Chair 1 2.25 2.25 5.0625
Sofa (Single) 1 2.25 2.25 5.0625
Sofa (Double) 1 4.5 2.25 10.125
Table 1 3 2.25 6.75
Trash Bin 1 ᴓ0.79 0.4899
Book shelf 1 4 2.5 10.0
Total 50.98 152.94 203.92
The table above show the total space in General Manager Room. The total area is 50.98
ft2. . The total area is multiply with the allowance, which is 300% and the result must be
sum with the original or first total area to get the total all of area.
The square footage requirement for general manager’s office is amount 150-250 ft2.
And the total area of general manager’s room in Waltz Company is 203.92 ft2. Thus,
the general manager’s room in Waltz Company is meet the standards or can be said by
the area requirement
In Waltz Company, There are 4 general managers, which Manufacturing Department,
Human Resources, Finance and Purchase Department and Marketing and Sales
Department and each of general managers have the same size of area.
4.1.1.3 Secretary Office Space
Secretary has a job that is not far from the company executive. Secretary has a function
in a company or organization to help the executive to complete his work in running the
company. A secretary has a job function that is very varied and diverse. The secretary's
work space needed to be adjacent to the executive room that housed the secretary itself.
Table 4.3 Secretary Room
Length/
Width Area Allowance Total Area
Item Qty diameter 2
(ft ) (ft) (300%) (ft2)
(ft)
Desk 1 4.50 3 13.5
Chair 1 2.25 2.25 5.0625
Drawer 1 2 1.50 3
Trash bin 1 ᴓ0.79 0.489919

Total 22.05 66.15 88.20
The table above shows the total space for the secretary. The total area is 22.05 ft2. After
that the total area multiplies with the assumed allowance (300%). And then, the result of
multiplication should be sum with the original total area. There are square footage
requirements of secretary space are 50-100 ft2. The total area of secretary is 88.20 ft2.
Thus, the secretary area is accepted by the area requirement.
4.4.1.4. Manager Room

Manager is a function of position after General Manager which has a duty for leading
and directing the employee below their division. For instance like a manufacturing
department of Waltz Company that leading by the general manager of manufacturing
department, have two division which are engineering department and production
department that leading by the manager for each division. The manager room space
requirement is 80 –
120 ft2.
Table 4.4 Manager Room
Manager's Room
Length/
diameter Width Area Allowance Total Area
Item Qty (ft) (ft) (300%) 2
(ft )
(ft )
Desk 1 4.50 3 13.5
Chair 1 2.25 2.25 5.0625
Chair 2 1 1.85 1.85 3.4225
Trash bin 1 ᴓ0.69 0.373739
Book shelf 1 4 2 8
Total 30.3582 91.0762 109.55095
The table above shows the total space for the manager room. The total area is 30.35 ft2.
After that the total area multiplies with the assumed allowance (300%). And then, the
result of multiplication should be sum with the original total area. There are square
footage requirements of secretary space are 80 – 120 ft 2. The total area of manager
room is 109.55 ft2. Thus, the manager area is accepted by the area requirement. There
are 7 managers in this company and they have the same area of room.
4.4.1.5. Manufacturing Department Room
In the Manufacturing Department, there are 2 managers which are engineering division
manager and production division manager.
For engineering division, there are 7 employees consist of 1 engineering division
manager. Below that there is 1 head of research development that have 2 staff and 1
head of design development that have 2 staff.
For production department, there are 15 employees consist of 1 production division
manager, 1 head of quality control that have 2 staff, supply chain division that have 10
staffs and 1 of head supply chain.
This room will build in cubicles system and connected with manager’s room. The total
employee that will be in cubicles is 20 staffs. The requirement for cubicles is 65 ft2 and
because there are 20 persons in this room, the calculation of the area will be
20×65×allowance. After that, sum the first result with the original total area.
Table 4.5 Manufacturing Room
Length/
width Area Allowance Total Area
Item Qty diameter 2
(ft ) (ft) (300%) (ft2)
(ft)
Desk 20 4 2.50 200
Chair 20 1.64 1.64 53.79
Board 1 3.28 0.16 0.5248
Trash bin 20 ᴓ0.69 7.47
Book shelf 1 4 2.5 10.0
Gallon 1 2 2 4
(Dispenser)
Sofa (Double) 1 4.5 2.25 10.125
Gucci (Vas) 1 1.5 1.5 2.25
Total 288.15 864.46 1152.615
The calculation of manufacturing room is (20×65×300%) + (20×65) = 5200 ft2. The

table above show the total area for manufacturing room is 1152.61 ft2. Therefore, the
manufacturing room can be used. This room use cubicles layout system. The cubicles
use L shape of cubicle table.
4.4.1.6 Finance and Purchase Department Room
The Finance and Purchase Department controlled and leaded by the general manager of
this department and there are 2 managers in this department which are financial
administration manager and purchasing manager.
Financial administration division has 3 employees consist of 1 manager and 2 staffs and
otherwise with the purchasing division has 1 manager and 2 staffs.
The finance and purchase department room is consisting of the room that same with
manufacturing department has a cubicles layout and connected with manager’s room.
The total employee that will be in cubicles is 4 staffs. The requirement for cubicles is 65
ft2 and because there are 4 persons in this room, the calculation of the area will
be
4×65×allowance. After that, sum the first result with the original total area.
Table 4.6 Finance and Administration Room
Len
W Ar Allowa Total
Item gth/ nce
idt ea Area
2
dia h ( ft (300 (ft2)
Desk 4 2.5 40
Chair 1.64 1.64 32.275
Board 3.28 0.16 0.5248
Trash ᴓ0.69 0.3737
Book 3.94 1.31 5.1614
Flower 1. 1.5 2.25
Gallon 2 2 4
(Dispe
Sofa 4. 2.25 10.125
Total 94.70 284.11 378.81
The calculation of finance and purchase room is (4×65×300%) + (4×65) = 1040 ft2. The
table above show the total area for finance and purchase room is 378.81 ft2. Therefore,
the finance and purchase room can be used. This room use cubicles layout system. The
cubicles use L shape of cubicle table.
4.4.1.7 Human Resources Department Room
Human Resources Department controlled and leaded by the general manager of this
department and there are 2 managers in this department which are Personnel and
Administration Manager and Training and Development Manager.
Personnel and Administration division has 3 employees consist of 1 manager and 2
staffs and otherwise with Training and Development division has 1 manager and 2
staffs. Human Resources Department room is consisting of the room that
same with manufacturing department and finance and purchase department has a
cubicles layout and connected with manager’s room. The total employee that will be in
cubicles is 4 staffs. The requirement for cubicles is 65 ft2 and because there are 4
persons in this room, the calculation of the area will be 4×65×allowance. After that,
sum the first result with the original total area.
Table 4.7 Human Resources Department Room
Len
W Ar Allowa Total
Item gth/ nce
idt ea Area
2
dia h ( ft (300 (ft2)
Desk 4 2.5 40
Chair 1.64 1.64 32.275
Board 3.28 0.16 0.5248
Trash ᴓ0.69 0.3737
Book 3.94 1.31 5.1614
Flower 1. 1.5 2.25
Gallon 2 2 4
(Dispe
Sofa 4. 2.25 10.125
Total 94.70 284.11 378.81
The calculation of Human Resources Department Room is (4×65×300%) + (4×65) =

1040 ft2. The table above show the total area Human Resources Department room is
378.81 ft2. Therefore, the Human Resources Department Room can be used. This room
use cubicles layout system. The cubicles use L shape of cubicle table.
4.4.1.8 Marketing & Sales Department
Marketing & Sales Department controlled and leaded by the general manager of this
department and 4 employees that consist of 2 employees from marketing and 2
employees from sales.
Marketing and Sales Department room is quite different with the Manufacturing room,
Finance and Purchase room and Human Resources Department room because in the
marketing and sales department the general manager room connected with the room for
marketing and sales staff. Meanwhile, in the others departments the room for staff is
connected with manager and for general manager room is separated with the
departments room. In marketing and sales department, the total employee that will be in
cubicles is 4 staffs. The requirement for cubicles is 65 ft2 and because there are 4
persons in this room, the calculation of the area will be 4×65×allowance. After that, sum
the first result with the original total area.
Table 4.8 Marketing & Sales Department
Len
W Ar Allowa Total
Item gth/ idt ea nce Area
dia 2
h ( ft (300 (ft2)
Desk 4 2.5 40
Chair 1.64 1.64 32.275
Board 3.28 0.16 0.5248
Trash ᴓ0.69 0.3737
Book 3.94 1.31 5.1614
Flower 1. 1.5 2.25
Gallon 2 2 4
(Dispe
Sofa 4. 2.25 10.125
Total 94.70 284.11 378.81
The calculation of Marketing & Sales Department Room is (4×65×300%) + (4×65) =

1040 ft2. The table above show the total area Marketing & Sales Department room is
378.81 ft2. Therefore, the Marketing & Sales Department Room can be used. This room
use cubicles layout system. The cubicles use L shape of cubicle table.
4.1.2 Office Facilities
The company must protect the safety and health of everyone in the workplace. For
instance, Facilities like toilets that are accessible for employees and visitors, an area to
wash, and clean drinking water. Consider lighting, ventilation and temperature for the
employees in their working environment can be said also facilities that company should
be provide. In Waltz Company, there are also some office facilities. Here some facilities
in office which are lobby, meeting room, janitor room, pantry, and restroom.
4.1.2.1. Lobby
Lobby is the first real world impression of the company for prospective customers and
employees. Lobby is the one of the important facility of the office. Lobby is the first
place to welcome visitors from the other company, customers, and anyone who has to do
something in the office. In the lobby, there is receptionist area with the waiting room in
there. Receptionist are has the footage requirement which is for 2-3 people receptionist
should be given around 100 – 200 ft for the receptionist area. Waltz Company only uses
2 people to become receptionists. Thus, the total space required for lobby is 175 ft.
4.1.2.2. Meeting Room
For the business, the staff meetings, client pop-ins and scheduled appointments are
common. Having the space to hold such occasions is important for a lot of reasons. A
functional meeting room is accommodating a group of people works best. With a
conference space, with 1 big screen with projector, so everyone can be seen and heard
clearly. Meeting room also has one long table or wide enough and 20 chairs to
accommodate everyone in attendance as well as to eliminate blocking of sight lines.
This meeting room has 30 ft. length and 23.5 ft. width. Thus, the total area for the
meeting room is 705 ft2.
4.1.2.3. Pantry
Pantry is the room in the office where beverages, food and sometimes dishes, household
cleaning chemicals, linens or provisions are stored. Usually in the office, there is pantry
for each floor that purposed for the employee to get their need for instance likes drink
easily. The requirement space for pantry is 100 ft2. And it should be located 500 feet of
every permanent work station or at least 1 pantry each floor.
4.1.2.4 Janitor Room
Janitor is the person who has a responsible to maintain the cleanness of the building. But
in some cases, they will also carry out maintenance and security duties janitor room is
the room that used to keep or save the cleaning stuff such as like a broom, mops, buckets
and etc. usually janitor rooms is located beside the pantry room. This room provided for
cleaning service officer.
The janitor room requirement is 100 ft2, and same with the pantry, janitor room also
usually located in every floor in the office and located next to pantry room.
4.1.2.5. Restroom
The restroom for the office staffs is also needed in the office. For making the toilet there
is some requirements needed. Because in Waltz Company there are 52 staffs that
working in the office (not in the plant or warehouse) and 52 staffs consist of 24 female
employees and 28 male employees. So the number of female toilet in the office is 2
lavatories with
2 wastafel and mirror. And for the male toilet, there are 3 lavatories with 2 wastafel and
mirror. The total area for one lavatory is 15ft2. Wastafel area is 4ft2. Thus the total area
for restroom is (15x5) + (4x4) = 91ft2. Each floor in the company have a restroom.
Table 4.9 Summary of Office Space Requirement
No Department Area (ft2)
1 President Director 363.95
Room
2 General Manager 203.92
3 Secretary Room 88.2
4 Manager Room 109.55
5 Manufacturing Room 1152.615
6 Finance and Purchase 986.78
Room
7 Human Resource 986.78
Room
8 Marketing and Sales 986.78
Room
9 Lobby 175
10 Meeting Room 705
11 Pantry 100
12 Janitor 100
13 Restroom 91
Total 6050
3.29
4.2. Space Requirement for Storage
To make the ROT and CAC, there are two kind of material needed such as direct
material (DM) and indirect material (IDM). The material will be stored in the
storage area, and in this section, there will be calculation towards the space
required for storage. The lead time of placing order is 2 weeks (10 days). Below
are shown the calculation of space storage required.
Table 4.9 Direct Material Specifications

Material Material Dimension (In)
No Material
Code L W T/Ø
1 O1 Oak 60' x 3 1/2" x 3/4 " 720 3 1/2 ¾
2 PLY Plywood 4' x 4' x 3/4" 48 48 ¾

3 O2 Oak 10' x 8 1/2" x 3/4 " 120 8 1/2 ¾
4 O3 Oak 8' x 5 1/2" x 3/4" 96 5 1/2 3/4
5 F Fir 3’ ×2”×2” 36 2 2
6 B1 Birch 12' x 2" x 1" 144 2 1
7 B2 Birch 3 1/2' x 3" x 1" 42 3 1
8 B3 Birch 4 1/4' x 4" x 1" 51 4 1
9 RSB Round Steel Bar Ø3/8" x 5' 60 - Ø3/8
From the table above shown that there are 9 kinds direct material that will be
stored in the storage. The direct material O1, PLY, O2, O3, and F will be used to
make the ROT. The direct material B1, B2, B3, and RSB will be used to make
the CAC.
And then the Table 4.3 below shows 20 kinds of indirect materials that will be
used for CAC and ROT and the size of the materials. The dimension of the
indirect material is already known except for the Carton ROC, Carton CAC,
sand paper, label, white glue, resin glue, wood filler, and clear polyurethane
finish. For the Carton CAC and Carton ROT, the dimension must be
calculated first for the
packaging of the product.
3.30
Table 4.10 Indirect Material Specifications
Material Material Dimension (In)
No Material
Code L W/Ø T
1 FHS1 Flathead screw 1" x #8 0.164 0.164 1
2 FHS2 Flathead screw 2" x #8 0.164 0.164 2
3 FHS3 Flathead screw 2 1/2" x #12 2/9 0.216 2 1/2
4 CB Carriage Bolts 1/4" x 2 1/2" 1/4 ¼ 2 1/2
5 W Washer 1/4" 1/4 ¼ 0.062
6 N Nut 1/4" 1/4 ¼ 0.219
7 D1 Dowelling Ø3/8" x 3" 3/8 3/8 3
8 D2 Dowelling Ø3/8" x 1 1/2" 3/8 3/8 1 1/2
9 HB Hanger Bolt 1/4" x 2 1/2" 1/4 ¼ 2 1/2
10 CN Cap nut 1/4" 1/4 ¼ 0.4
11 CROT Carton ROT 90 31.5 1
12 CCAC Carton CAC 47 32.5 1
13 CB Canvas Back 23 1/2 9 3/8
14 CS Canvas Seat 23 1/2 17 3/8
15 SP Sand Paper (R+C) 15 10 0.1
16 LAB Label (R+C) 10 6 0.01
17 WG White Glue 10 10 15
18 AR Aliphatic Resin/ Resin Glue 10 10 15
19 WF Wood filler (ROT + CAC) 10 10 15
20 CPF Clear Polyurethane Finish (R+C) 10 10 15
21 PRR Plastic Roll ROT 20 4 4
22 PRC Plastic Roll CAC 20 4 4
3.31
Table 4.11 Direct Material Requirements
Finished Product Dimension Material Dimension

(In) (In)
Req Req
No Code Part Name
(unit/week) (unit/LT)
L W T/Ø L W T/Ø
1 111 Top Surface Slat 46 ½ 3½ ¾ 238.46 476.92
Frame Top Surface

2 112 46 ½ 3½ ¾ 42.49 84.98
(B) 720 3½ ¾
Frame Top Surface

3 113 38 ½ 3½ ¾ 35.41 70.82
(C)
4 120 Base Surface 46 1/2 38½ ¾ 48 48 ¾ 325.21 650.42

5 141 Pedestal Pieces 27 8½ ¾ 120 8½ ¾ 328.46 656.92
6 142 Feet 22 5½ ¾ 96 5½ ¾ 318.67 637.34
7 143 Pedestal Support 8 1/2 2 2 36 2 2 318.67 637.34
8 210 Front Leg 25 1½ ¾ 271.5 543
9 220 Stretcher 20 1/2 1½ ¾ 144 2 1 276.61 553.22
10 230 Side Stretcher 14 1/2 1½ ¾ 146.35 292.7
11 240 Arm 19 1/2 2½ ¾ 3 1/2 3 1 692.68 1385.36
12 250 Rear Leg 25 3½ ¾ 4 1/4 4 1 678.76 1357.52
13 261 Back Steel Rod 9 1/2 - Ø 3/8 60 - Ø 3/8 210.86 421.72
14 271 Seat Steel Rod 17 1/4 - Ø 3/8 60 - Ø 3/8 425.98 851.96
3.32
The requirement of the direct material per week already calculated in previous report.
The next step is to calculate the required material per lead time. The demands of the
materials are multiplied by the leads time of the materials which are 2 weeks to get the
required material per lead time. From the table above, the required material per week for
Top Surface Flat is 238.46. And then for the required material per lead time is 476.92, it
comes from 238.46 multiplied by 2 weeks (the lead time).
Some of the indirect materials requirements are already known, and for the other indirect
materials that still unknown, the amount will be assumed. The requirements of the
indirect material per product are already stated in the next table, for example one ROT
needs 22 flathead screw 1” x #8. And then the material required per lead time is
calculated by the material per product times by lead time (2 weeks) and the demand of
final product ROT (300 products). So, the requirement of flathead screw 1” x #8 for
every 2 weeks is 13,200
pieces (22 x 2 x 300).
3.33
Table 4.12 Indirect Material Requirements
Material BoxDimension
Dimension (In) (In)
Material Req Material Req Material Req A ctual Req Details

No Material Material L W/Ø T (units/product) (units/LT) (Box/LT) (Box/LT) L W T/Ø (pcs/box)
Flathead screw
1 FHS1 1"x #8 1/6 1/6 1 22 13200 2.64 3 20 5 5 5000
Flathead screw
2 FHS2 2"x #8 1/6 1/6 2 36 21600 4.32 5 20 5 5 5000
Flathead screw 2
3 FHS3 1/2" x #12 2/9 2/9 2 1/2 8 4800 0.96 1 20 5 5 5000
Carriage Bolts
4 CB 1/4" x 2 1/2" 1/4 1/4 2 1/2 8 4800 1.6 2 20 5 5 3000
5 W Washer 1/4" 1/4 1/4 0.062 14 25760 5.152 6 20 5 5 5000

6 N Nut 1/4" 1/4 1/4 0.219 8 4800 0.96 1 20 5 5 5000
Dowelling
7 D1 Ø3/8"x 4" 3/8 3/8 3 8 9920 9.92 10 20 5 5 1000
Dowelling
8 D2 Ø3/8"x 1 1/2" 3/8 3/8 1 1/2 8 9920 3.306666667 4 20 5 5 3000
Hanger Bolt
9 HB 1/4"x 2 1/2" 1/4 1/4 2 1/2 6 7440 1.86 2 20 5 5 4000
10 CN Cap nut 1/4" 1/4 1/4 0.4 6 7440 1.488 2 20 5 5 5000
3.34
Table 4.12 Indirect Material Requirements (continued)
11 CROT Carton ROT 90 31 1/2 1 1 600
12 CCAC Carton CAC 47 32 1/2 1 1 1240
13 CB Canvas Back 23 1/2 9 3/8 1 1240 17.71428571 18 24 18 15 70
14 CS Canvas Seat 23 1/2 17 3/8 1 1240 35.42857143 36 24 18 15 35
Sand Paper
15 SP (R+C) 15 10 0.1 0.5 920 3.68 4 16 11 30 250
16 LAB Label (R+C) 10 6 0.01 1 1840 0.92 1 16 11 30 2000
17 WG White Glue 10 10 15 0.025 31
liphatic Resin/
18 AR Resin Glue 10 10 15 0.05 30
20 liter/tin. 1 tin for 20 ROT or 40 CAC
Wood filler
19 WF ROT+ CAC) 10 10 15 0.075 138
Clear
Polyurethane
20 CPF Finish (R+C) 10 10 15 0.075 138
Plastic Roll
21 PRR ROT 20 4 4 2 1200 80 80 20 20 15 15
Plastic Roll
22 PRC CAC 20 4 4 1 1240 82.67 83 20 20 15 15
3.35
The Indirect Material will be put inside the box and then the box will be stack inside the
rack. Some of the indirect material aren’t placed inside the box like Carton CAC, Carton
ROT, White Glue, Resin Glue, Wood Fillers, and Clear Polyurethane Finish. For the
indirect materials that will not be placed inside the box, they will just store inside the
rack. For the white glue, wood filler and the other material that have the formed of tin,
will be place at the lowest level of the shelf because those material is quite heavy.
There are 4 different kinds of box to store the materials. For the flathead screw 1” x #8,
it will store inside the box with dimension 20 x 5 x 5 inches and the capacity is 5000
pieces. So, it will need 3 boxes to store flathead screw 1” x #8 (13,200 divided by
5000). The illustration of the boxes that are used for the indirect material can be seen
from the figures below.
Figure 4.1 Box 20” x 5” x 5”
Figure 4.2 Box 24” x 18” x 15”
3.36
Box 20” x 5” x 5” is used to store the small indirect material like flat head screw,
carriage bolt, dowelling, hanger bolt, and washer. The number of the box used is 36
boxes. These boxes will be put at the top level shelf because they are not heavy compare
to the other indirect material. And then all these boxes will be put just in one rack. Box
24” x 18” x
15” is used to store canvas seat and canvas back. The total box needed is 54 boxes.
And then, Box 16” x 11” x 30” is used to store sand paper and label. The total box
needed is 5 boxes. Box 20” x 20” x 15” is used to store plastic roll ROT and CAC. The
total box needed is 163 boxes.
Figure 4.3 Box 16” x 11” x 30”
Figure 4.4 Box 20” x 20” x 15”

3.38
Table 4.13 Aggregation of Direct Material
Material Dimensions(Inches) Total

Material Part Actual Actual
No MaterialCode Part Name Req.(Units/LT)
Name Code Req(Units/LT) Req.
(Units/LT)
L W T/Ø
Top Surface
111 476.92 477
Slat
Oak 60' x
Frame Top
1 O1 3 1/2" x 720 3 1/2 3/4 112 84.98 85 633
Surface (B)
3/4 "
Frame Top
113 70.82 71
Surface (C)
Plywood
2 PLY 4' x 4' x 48 48 3/4 120 Base Surface 650.42 651 651
3/4"
Oak 10' x
3 O2 8 1/2" x 120 8 1/2 3/4 141 Pedestal Piece 656.92 657 657
3/4 "
Oak 8' x 5
4 O3 1/2" x 96 5 1/2 3/4 142 Feet 637.34 638 638
3/8"
Fir Pedestal
5 F 36 2 2 143 637.34 638 638
3'×2"×2" Support
210 Front Leg 543 543
Birch 12'
6 B1 x 2" x 1" 144 2 1 220 Stretcher 553.22 554 1390
230 Side Stretcher 292.7 293
Birch 3
7 B2 1/2' x 3" x 42 3 1 240 Arm 1385.36 1386 1386
1"
Birch 4
8 B3 1/4' x 4" x 51 4 1 250 Rear Leg 1357.52 1358 1358
1"
3.39
Back
Round 261 421.72 422
Steel
Steel
Rod
9 RSB Bar 60 - Ø3/8 1274
Ø3/8"x Seat
5' 271 Steel 851.96 852
Rod
Table 4.13 Aggregation of Direct Material (Continued)
The table above shows the total required material needed per lead times (2 weeks). The table also shows the dimension of the
material. For Oak 60' x 3 1/2" x 3/4 ", it needs 633 raw materials to make top surface slat, frame top surface (B), and frame
top surface (C) for every 2 weeks.
3.40
Table 4.14 Storage Space Requirement Calculation for Direct Material
Round
Rack Dimension (Ft)
up
Actual
Vertical Horizontal No. Of No of Rack Number of
No MaterialCode MaterialName Req.
Stacks Stacks Item Shelf
(units/LT)
L W H
Oak 60' x 3 1/2"

1 O1 x 3/4 " 633 51 12 612 60 4 3.5 1.034314 2 2/3
Plywood 4' x 4'x

2 PLY 651 51 14 714 60 4 3.5 0.911765 1 1/3
3/4"
Total Shelf 1
Area (Ft Square) 240
Allowance 300% 720
Oak 10' x 8 1/2"

3 O2 657 51 4 204 12 4 3.5 3.220588 4 1 1/3
x 3/4 "
Oak 8' x 5 1/2"x

4 O3 638 107 7 749 12 4 3.5 0.851802 1 1/3
3/4"
5 F Fir 3'×2"×2" 638 107 4 428 12 4 3.5 1.490654 2 2/3
3.41
6 B1 Birch 12' x 2"x 1390 37 23 851 12 4 3.5 1.633373 2 2/3
1"
Table 4.14 Storage Space Requirement Calculation for Direct Material (Continued)
Birch
3 1/2' 13 3 4 166 1 3. 0.8324
7 B2 4 1 1/3
x3" x 86 7 5 5 2 5 32
1"
Birch
4 1/4' 13 3 2 1 3. 1.6683
8 B3 814 4 2 2/3
x4" x 58 7 2 2 5 05
1"
Roun
d
1 2
RS Steel 12 271 1 3. 0.0468
9 0 5 4 1 1/3
B Bar 74 78 2 5 76
7 4
Ø3/8"
x 5'
5
Total Shelf
1/3
25
Area (Ft square)
6
76
Allowance 300 %
8
19
Total Area (Ft2)
84
3.42
From table above, there are 2 kinds of shelf to store the direct materials. The first shelf
has the size 60.3 x 4 x 7.6 feet and the total shelf needed is 1 shelf. The shelf is used to
store O1 and PLY, and the shelf will have 2 levels. For the direct material O1, it will
store at the first level shelf and for the material PLY will be store at the second level.
The illustration of the shelf can be seen below.
Figure 4.5 Direct Material Shelf 60.3’ x 4’ x 7.6’
The shelf is consist of 2 rack with the dimension of 60.3’ x 4’ x 3.5’ per rack. The rack
can store 612 units of material O1. The maximum of the horizontal stack is 12, come
from the area of the rack, 240 Ft square (60’ times by 4’) divided by area of the
material, 17.5
Ft square (60’ times by 0.29’). The maximum of the vertical stack are 51, come from the
thickness of the rack, 3.5 feet divided by the thickness of the material, ¾ inches (0.0625
feet) equals 56. But for the vertical stack is reduced become 51 to make it easier when
the
material needs to be taken out. The requirement of O1 is 633 units.
3.43
The second shelf has the size 12.3’ x 4’ x 11.25’ and the total shelf needed is 5 shelf. The shelf is used to store all the direct
material except for O1 and PLY, and the shelf will have 3 levels. The shelf is consist of 3 rack with the dimension of 12’ x 4’ x
3.5’ per rack. The illustration of the shelf can be seen below.
2 2. 2
The total area is 256 ft . The allowances is 768 ft So the total storage area for the direct materials is 1,984 ft .
3.44
Table 4.15 Storage Space Requirement Calculation for Indirect Material
Actual Vertical No. Rack Horizontal No. Of Rack

Req. Stack Horizon of Dimension Stack in 1 (max hor.
No Material Material (Box/LT) (max 7) Stack Item (ft) Rack Stack=20) No of Shelf
Flathead
1 FHS1 screw 1"x #8 3 3 1 3 8 3 3
Flathead
2 FHS2 screw 2"x #8 5 5 1 5 8 3 3
Flathead
screw 2 1/2"
3 FHS3 x #12 1 1 1 1 8 3 3
Carriage
Bolts 1/4" x
4 CB 2 1/2" 2 2 1 2 8 3 3
5 W Washer 1/4" 6 6 1 6 8 3 3
6 N Nut 1/4" 1 1 1 1 8 3 3
Dowelling
7 D1 Ø3/8"x 4" 10 5 2 10 8 3 3
Dowelling
Ø3/8"x 1
8 D2 1/2" 4 4 1 4 8 3 3
Hanger Bolt
9 HB 1/4"x 2 1/2" 2 2 1 2 8 3 3
10 CN Cap nut 1/4" 2 2 1 2 8 3 3 11 1 0.333333333
3.45
Table 4.15 Storage Space Requirement Calculation for Indirect Material (continued)
k Dimension (ft)
No Material Material ual Req. (Box/LT) tical Stack izon Stack of Item L W /Ø No Rack Round Up No of Shelf
11 CROT Carton ROT 600 30 1 30 8 3 3 20 20 .666666667
12 CCAC Carton CAC 1240 30 2 60 8 3 3 .6666667 21 7
13 CB Canvas Back 18 2 5 10 8 3 3 1.8 2 .666666667
14 CS Canvas Seat 36 2 5 10 8 3 3 3.6 4 .333333333
15 SP Sand Paper (R+C) 4 2 5 10 8 3 3 0.4 1 .333333333
16 LAB Label (R+C) 1 1 1 1 8 3 3 1 1 .333333333
17 WG White Glue 31 2 25 50 8 3 3 0.62 1 .333333333
18 AR Aliphatic Resin/ Resin Glue 30 2 25 50 8 3 3 0.6 1 .333333333
19 WF Wood filler (ROT+ CAC) 138 2 25 50 8 3 3 2.76 3 1
Clear Polyurethane Finish

20 CPF (R+C) 138 2 25 50 8 3 3 2.76 3 1
21 PRR Plastic Roll ROT 80 2 5 10 8 3 3 8 8 .666666667
22 PRC Plastic Roll CAC 83 2 5 10 8 3 3 8.3 9 3

Total Shelf 25
Area (Ft Square) 600
Allowance 300% 1800
Total Area (Ft Square) 2400
3.46
It can be known from Table 4.8 that the total shelf that is used for the indirect
material is 24 shelves. The shelf has the size of 8.3 x 3 x 9.75 feet. The shelf is used
to store the boxes that are used to store the indirect material. The shelf has 3 level
racks with the dimension of 8’ x 3’ x 3’. For all the boxes with dimension 20” x 5” x
5”, will be placed just in 1 rack. The same kind of indirect material will be stack in 1
vertical stack. So for example material FHS1 will need 3 boxes in total. These boxes
will be stacked up, so it’s only need 1 horizontal stack. The maximum vertical stack
is 7 stacks because the thickness of the rack is 3 feet (36 inches), and the thickness
of the box is
5 inches, so 36 inches divided by 5 inches equal to 7.
Another example is material D1 will need 10 boxes. Because the maximum vertical
stack is 7, so material D1 will need 2 horizontal stack. The maximum total of the
horizontal stack in 1 rack is 19 because the length of the rack is 8 feet (96 inches)
and the width of the box is 5 inches, so 96 inches divided by 5 inches equal to 19.
The total of horizontal stack needed to store all the boxes 20” x 5” x 5” is 11 stacks,
so it can be store in just 1 rack. So, the total shelf used for them is 0.333 or 1 over
third of the shelf because 1 shelf has 3 level racks.
For the other indirect material they won’t be store together with different kind of
material. So 1 rack only can store the same kind of indirect material. For the material
CROT, it needs 560 units for every 2 weeks. And the total rack needed is 17 rack, or
5.67 shelves.
So the area needed for indirect material is 576 Ft square (8 x 3 x 24 shelves). The
allowance 300% is 1728 Ft square, so the total storage area for the indirect material
is
2304 Ft square. The illustration of the shelf for indirect material can be seen from the
Figure 4.8 below.
3.47
After calculated all the area for the direct materials and indirect materials, the next
step is to calculate the area for the unloading area. The company will have 3 docks
for the unloading area. The 60 foot truck is the largest truck that will be come to the
storage, so the dock width must be 12 feet. The total dock face needed for 3 docks is
36 feet. The material handling equipment that will be used in the storage is Narrow-
aisle truck, so the minimum maneuvering allowance is 10 feet. The dock boards will
be extended
6 feet into the building, so the maneuvering distance is 16 feet (10’ + 6’). The total
2
area for the maneuvering is 576 ft (36’ docks face x 16’ maneuvering distance).
Table 4.16 Storage Area
Facility Area (ft2) Allowance 300% Total Area (ft2)

Direct Material Shelf 480 1440 1984
Indirect Material Shelf 576 1728 2400
Maneuvering Area + Docks 768 - 576
Total 4960
So, the storage area is consists of direct material shelf, indirect material shelf and maneuvering plus docks area. The area of the
2
facility is stated at the table above. With allowance 300%, the total area needed for the storage is 4960 ft .
4.3 Space Requirement for Other Supporting Facilities
4.3.1. Parking Area
Parking area divided into three area such as car parking lot, motorcycle parking lot, and truck parking
lot.
4.3.1.1. Car Parking Lot
Car parking lot is useful for the employee who don’t ride the motorcycle. The total employee is 139 persons. Assume that from 139
employee, only 36 percent of the employee who use the car. The employee should not be required to walk more than 300-400-ft from
parking place to the entrance of the facility. The car will divided into two groups such as compact automobiles and standard-sized
automobiles. The layout use 90o double-loaded, because it is more efficient than single-loaded. The parking lot will consist of four row. A
parking layout consisting
3.49
of two-way traffic between five rows of 90o standard-sized automobiles and two rows of 90o compact automobiles would require a parking
lot width of
5(18.5) + 2(28) +1(16) = 92.5 + 56 + 16 = 164.5ft
This configuration will be utilized, since it is not too wide to be placed in a lot 180 ft. wide. Then, the available parking lot is 164.5 feet
wide. Leaving 24ft for two-way cross-aisle traffic at the front of the lot and 14ft for one-way cross-aisle traffic at the rear of the lot, the 90o
standard- sized automobile rows can accommodate;
Standard-sized automobiles = [(139 – (24+14)] / 8.5 = 12 automobiles
Leaving 22ft for two-way cross-aisle traffic at the front of the lot and 12ft for one-way cross-aisle traffic at the rear of the lot, the 90o
compact automobile rows can accommodate:
Compact automobiles = [(139 – (24+14)] / 7.5 = 14 automobiles
Hence, the total possible number of car that can parking in the parking lot are 2(12) + 2(14) = 52 automobiles, which is closer with the
required number.
The estimation of parking space for compact and standard calculation with the 90o are shown in below;
Parking space for compact= 17.7 x 8.7ft + 14 x 8.7/2 = 153.99 + 60.9 = 214.89 ft2
Parking space for standard = 19 x 9.8ft + 18 x 9.8/2 = 186.2 + 88.2 = 274.4 ft2.
The requirement of car parking area is 200ft. Waltz company provide the area for car parking is 200ft x 180 ft. Thus, the total area is 36000
ft2. Based on the calculation, the layout of the car parking lot are shown in the figure below.
Figure 4.8 Car Parking Lot
4.3.1.2. Motorcycle Parking Lot

Motorcycle parking lot is create in order to the employees and operators who ride a motorcycle. The most people who use motorcycle is
operator. Assume that 64 % of employee are use the motorcycle. The estimated number of person who use motorcycle is = 64 and the
number of guest is 36 persons. Thus, the total estimated number are 100 persons. The area requirement for motorcycle is 19.375 ft 2. Then,
the total area for the motorcycle parking lot is [(100 x 19.375) x 300 %] + (100 x 19.375) = 7750 ft2. The area size of motorcycle parking
lot is 130ft x 60ft = 7800 ft2. Thus, the size is accepted since the value is closer to the area requirement. The layout of motorcycle parking
lot is shown in the figure below.
Figure 4.9 Motorcycle Parking Lot
4.3.1.3. Truck Parking Lot

The truck parking lot is use the estimation with the layout of the lot used 90 docks, the length of truck is 60’, the dock width is 12’ and the
apron depth is 63’. Based on the estimation, the total space requirement for truck parking lot is 123ft x 100ft = 12300 ft2, and the capacity
of parking area is can accommodate four trucks. The layout of truck parking lot with the scale 1:10 is shown in the figure below.
Figure 4.10 Truck Parking Layout
4.3.2. Locker Room

Locker rooms should be provide between entrance and work area. Locker room are designed for the operator to save their personal
belongings. The locker room will divided into two such as for male and female. 6 ft2 allocated to each person using the locker room. The
type of locker is double tier with 3 wide, 5ft high and 12 inches deep. Since the total employees are 139 persons, then the total locker are
needed around
139/6 = 24 lockers. Thus, the total area required for locker room are [(24 x 6 ft2) x 300 %] + (24 x 6 ft2) = 576 ft2.
4.3.3. Restrooms
The Waltz company have 65 operators with the ratio is 1:2 for female and male. The number of toilets required is determined the number of
employees at the production floor. Then, the total toilets for male at least three toilets and for female are two toilets. Since the standard
requirement with 65 employees should at least have 4 toilets, the company will make 5 toilets, 3 toilets for male and 2 toilets for female.
The restrooms consist of pocket door, toilet and corner sink with the dimension 5ft x 3ft, and 6 ft2 for each urinal. The restroom has total
area =
25ft x 15ft = 375 ft2.
4.3.4. Food services

The total employee are 139 persons. The designed for food services are consist of seating area (enclosed space and semi-enclosed space),
kitchen, counter area, a refrigerator, a store room, a decorated entrance foyer. The type of tables that use in the cafeteria is square tables
with the size 2.5ft x 2.5ft and the number of seats are 2-4 persons. Then, 6.25-ft2 square tables are to be utilized. The requirement square
footage allowance per person is 12 ft2. Therefore, a 1668-ft2 cafeteria should be planned. A vending machine area is to be used in
conjunction with the cafeteria, then an area of 200 ft2 should be allocated for vending machine. Thus, the total space requirement become
1868-ft2. A serving line may serve 70 employees in the first second of each meal shift. Therefore, two serving line of 300 ft 2 should be
planned. The total area requirement for the kitchen is 900 ft2 because the total of meals around 100 – 200 served. Therefore, a total area for
full-service food service facility is 3368 ft2.
4.3.5. Health care
It is very difficult to predict every employee’s health. Health care is create in order to give the maintenance or improvement of health each
employee. The health care internally provide a reception area, waiting room, two treatment rooms, and staff rest area. The company
should
hire more employee such as doctor and nurse for health care area. For each additional nurse to be employed, 250 ft2 should be added to the
space requirements. The layout design for health care is 32.8084ft x 16.4042ft. The total area of health care is 788.19 ft 2.
4.3.6 Musholla
Since the most religion in Indonesia is Muslim, then the company should create the musholla for the employee. The size of musholla is
19.685ft x 19.685ft. The mushola will created with cabinet, wudhu place and area for worship. The area of worship for male and female
will be separated with the balance ratio. The area for male is 9.8425ft and female is 9.8425. The area needed for one person is 7.75 ft2. The
total area for musholla is 387.5 ft2. The musholla can accommodate 50 peoples, 25 peoples for male and 25 peoples for female.
4.3.7 Shipping and Receiving Area

In order to determine the shipping and receiving area, there are several steps, such as determine what is to be received and shipped,
determine number and type of docks, and determine the space requirements for the receiving ad shipping area within the facility.
Maneuvering area 2000
Staging Area 5000
Truckers lounge 500
Office 500
Total 8000 ft2
4.4 Space Requirement for Production Floor
In the production system, there are 11 departments that working together in the production floor to produce the rectangular oak table (ROT)
and casual armchair (CAC). The required space for production floor must be calculated by knowing the required space for all machines in
each department. As it is known in the route sheet and MPPC, here is the required space for each department.
Table 4.17 Space Requirement for Production Floor

Dimension
Allowance Total Area Total
Number of Area Total Space
Department Machine (300%) (m^2)/ Space
Machines Length Width (m^2) (m^2)
(m^2) Machine (ft^2)
Marking, Assembling,
Bench (3) 26 1.20 1.00 3.60 10.80 14.40 374.40 4030.01
& Gluing
Jointer Jointer 6 1.84 0.44 0.81 2.43 3.24 19.43 209.15
Attaching Bench 2 1.20 1.00 1.20 3.60 4.80 9.60 103.33
Circ.Saw Circ.Saw 13 1.50 0.50 0.75 2.25 3.00 39.00 419.79
Drill Press Drill Press 10 5.60 2.00 11.20 33.60 44.80 448.00 4822.23
Router Router 2 1.00 1.00 1.00 3.00 4.00 8.00 86.11
Disc.Sand
Disc.Sand & Fillling 18 1.20 1.00 1.20 3.60 4.80 86.40 930.00
& Bench
Table Saw Table Saw 1 0.85 0.72 0.61 1.84 2.45 2.45 26.35
Cut off
Cut off Saw 2 3.70 3.30 12.21 36.63 48.84 97.68 1051.42
Saw
Table 4.18 Space Requirement for Production Floor (Continued)
Dimension
Total Area Total Total
Number of Area
Department Machine Allowance (300%) (m^2) (m^2)/ Space Space
Machines Length Width (m^2)
Machine (m^2) (ft^2)
Inspection Bench 1 1.2 1 1.2 3.6 4.8 4.8 51.67

Packaging Bench 1 1.2 1 1.2 3.6 4.8 4.8 51.67
Maintenance
Room - 2 3 2 6 18 24 48 516.67
Tools Room - 2 2 2 4 12 16 32 344.45
TOTAL REQUIRED SPACE
(ft^2) 12725.51
Based on the table above, it can be seen that the company use 300% allowance in order to ease the access of operators in the production
floor by considering the space for the whole process of material handling and also the number of operators itself. In the production floor,
there are also tools room and maintenance room to provide the process of setup for machines. Overall, the company needs 12725.51 ft 2 to
make the production floor. The calculation in the table above can be known by using these formula, with several example for calculation.
Area
��‫݁ݎܽ = ܮ݊݁݃ݐ‬ℎ ‫ݐ݀𝑖𝑊 ݔ‬ℎ
��݂‫݋‬
ͷ.͸ ݉ ‫ݎ݂݁ܽ = ݉ ʹ ݔ‬
ͳͳ.ʹ��݈݈
݉2 𝑃‫= ݎ݁ݏݏ‬
𝐷‫ݎ‬
�
Allowance (300%) �݈݈‫ݓ = ��݁ݎܽ ݔ‬
ܽ݊݁ܿ ‫ ݋‬%
��݈݈݂݂‫݋ݓܽ݊ܿ݁ ݁݋‬
ܿ ݊ ܽ 𝐷‫݈݈��ݎ‬
𝑃‫ͳͳ = ݎ݁ݏݏ‬.ʹ ݉2 ‫ͲͲ͵ ݔ‬% =
͵͵.͸ ݉2
T
o
t
a
l
A
r
e
a
p
e
r
M
a
c
h
i
n
e
ܶܿܽ‫݋ ݈ܽݐ ��ݎܽ݁ ݁݌ݎ ܯ‬ℎ𝑖݊݁
= ��‫ݓ‬
ܽ݊݁ܿ ‫ ��݈݋‬+ ܽ‫݁ݎ‬
݂ܶ‫݋‬ ݂ܽ݁‫��ݎ‬ ݈ܽ�݈݈ 𝐷‫ݎ݁ݏݏ ܯܽܿ𝑃 ݈݈��ݎ‬ℎ𝑖݊݁ =

݈݂ܽ‫݋ݐ‬
ͳͳ.ʹ ݉2 + ͵͵.͸ ݉2 = ͶͶ.8 ݉2
T
o
t
a
l
3.58
space of material handling and operators
S
p accessibility. There are 10 machines of Drill
a Press. Where the Drill Press Department needs
c
e 448 m2 or 4822.23 ft2.
ܽ ‫ ݋ ݈ܽݐ‬ሺ𝐷݁o‫݌ݐ‬. ሻ
ܶ݁ܿ‫ܵ݌‬ 4.5 Space Requirement for
Warehouse and Its
Specification
݁ ܽ‫݋ݐ݈ܽ ��݁ݎ‬ℎ𝑖݊݁
= ܶ‫݌ݎ ܽܿܯ‬ When the products already become finished
goods, then it will be stored into warehouse
before shipped. The shipping process will take
ܿ‫݋ ܽܯ‬
݂ ‫ݔ ܰ ܾ݁݉ݑݎ‬ℎ𝑖݊݁
5 working days or 1 week as the lead time.
Where in one week, the demand of products are
ܶ ݁ܿܽ‫݋ݐ݂݈ܽ ݌‬
݁ ܿ ܽܵ ݈ܽ�݈݈ 300 units of Rectangular Oak Table and 620
units of Casual Arm Chair. Each product will
݂ 𝐷‫𝑃 ݈݈��ݎ‬
݂‫݋‬
be packaged into a box, and it will be stored in
‫ݎ݁ݏݏ‬D݁𝐷‫݌ݐ‬. = ͶͶ.8 a shelf to be more organized. Thus, in order to
know the space requirement for warehouse,
݉2 ‫ = Ͳͳ ݔ‬ͶͶ8 ݉2 =
first the size of each product’s box and then the
Ͷ8ʹʹ.ʹ͵ 2݂ ‫ݐ‬ shelf must be determined.
As the example of
calculation above, it The dimension of Rectangular Oak Table can
can be seen for be determined by knowing the longest
example in the Drill dimension of length, width, and height of the
Press Department. It product. The longest length and width of table
2
needs space 11.2 m is the dimension of top surface slat with each
to put one Drill side thickness 0.75”. Thus,
Press machine. As
the allowance is
three times than the
area, so each
machine of Drill
Press need space
44.8 m2 include the
3.59
the length and width of table surface are 48” (46.5”+2 x 0.75”) and 40” (38.5”+
0.75” x 2), and the height of table is 30.5”. In order to create a the ROT box, then
the dimension of the box will follow the dimension of table with additional small
space 2”. So, the dimension of the ROT box will be like on the table below.
Table 4.19 Dimension of Rectangular Oak Table Box
Dimension of ROT Box Inch ft

Length 48” + 2” 50” 4.17’
Width 40” + 2” 42” 3.50’
Height 30.5” + 2” 32.5” 2.71’
Based on the table above, so the dimension of the ROT box is 4.17’ x 3.50’ x 2.71’
or 1.27 m x 1.07 m x 0.83 m. The box can be seen on the figure below.
Figure 4.12 ROT Box Dimension

Figure 4.13 ROT Unboxing
Then, each shelf can containts 50 boxes, where each row containts 10 boxes. The
space of each row can be seen on the table below.
Table 4.20 Dimension of Each Row of ROT Shelf
Dimension of Each Row Inch

Length 50" x 10 + 1"x 11 511"
Width 42" + 1" 43"
Height 32.5" + 1" 33.5"
Based on the table above, the height of one shelf will be around 5 times of each
row’s height with the thickness of shelf and its feet. The shelf can be seen on the
figure below.
Table 4.21 Dimension of ROT Shelf
Dimension of ROT Shelf Real Shelf (Inch) Real Shelf (ft)

Length 511" 511" 42.58’
Width 43" 43" 3.58’
Height 167.5" 175" 14.58’
Figure 4.14 Dimension of ROT Shelf
Figure 4.15 ROT Shelf (Aluminium Diamond Plate)

In other side, the dimension of Casual Arm Chair can be determined by knowing
the longest dimension of length, width, and height of the product. The longest
length, width, and height of chair are 25.5” x 19.5” x 31.5”. In order to create a
the CAC box, then the dimension of the box will follow the dimension of chair
with additional small space 2”. So, the dimension of the CAC box will be like on
the table below.
Table 4.22 Dimension of Casual Arm Chair Box
Dimension of CAC Box Inch Ft

Length 25.5" + 2" 27.5" 2.29’
Width 19.5" + 2" 21.5" 1.79’
Height 31.5"+ 2" 33.5" 2.79’
Based on the table above, so the dimension of the CAC box is 27.5” x 21.5” x
33.5”
or 0.69 m x 0.54 m x 0.85 m. The box can be seen on the figure below.
Figure 4.16 CAC Box Dimension

Figure 4.17 CAC Unboxing
Then, each shelf can containts 100 boxes, where each row containts 20 boxes. The
space of each row can be seen on the table below.
Table 4.23.Dimension of Each Row of CAC Shelf
Dimension of Each Row Inch

Length 27.5" x 20 + 1"x 21 571"
Width 21.5" + 1" 22.5"
Height 33.5" + 1" 34.5"
Based on the table above, the height of one shelf will be around 5 times of each
row’s height with the thickness of shelf and its feet. The shelf can be seen on the
figure below.
Table 4.24 Dimension of CAC Shelf
Dimension of CAC Shelf Real Shelf (Inch) Real Shelf (ft)

Length 571" 571" 47.58’
Width 22.5" 22.5" 1.87’
Height 172.5" 180" 15.00’
Figure 4.18 Dimension of CAC Shelf
Figure 4.19 CAC Shelf (Aluminium Brushed Radial)

After the size of each shelf already determined, then the number of required shelf
for ROT and CAC can be found. After that, the total area for ROT shelfs and CAC
shelfs can be determined in order to know the space of warehouse.
3.65
Table 4.25 Shelf Area Calculation of Warehouse
Lead Packaging dimension (ft) Shelf Dimension (ft) Round Area
Product Demand time (1 Shelf Shelf No. Of
Up (ft2)
Name (unit/week) week) L W H L W H Capacity Level shelf
ROT 300 300 4.1667 3.5000 2.7083 42.58 3.58 14.58 50 3 6 6 915.53
CAC 620 620 2.2917 1.7917 2.7917 47.58 1.87 15.00 100 3 6.2 7 624.53
TOTAL 1540.06
Based on the table above, it can be seen that in order to meet the weekly demand, there are 6 shelf for ROT and 7 shelf for CAC. The
number of shelf can be obtained by dividing the demand/unit with shelf capacity. For example, in order to find the number of shelf needed
for ROT, then the demand of ROT which is 300 units/week divided by 50 as the capacity for each shelf. So, the number of ROT shelf will
be 6 units, the calculation for CAC also same with ROT. The required space for all shelfs in the warehouse is 1,540.06 ft 2, where 915.53 ft2
belong to ROT shelfs and 624.53 ft2 belong to CAC shelf. In the warehouse, there will be some space for unloading area. In order to know
the space for unloading area, first the type of truck must be determined. The company will use 60 foot truck because it is the largest truck
that can bring more products. Thus, the company will choose the dock with 14 ft width and 60 ft apron depth. There are 3 docks in the
warehouse, so the total dock face is 42 feet (14 feet x 3). The finished goods will be unloaded and loaded by using narrow-aisle truck. The
manuevering has minimum allowance 10 feet with 6 feet from the dock boards that extend into the building, so the manuevering distance is
16 feet. Then, the
total area of manuevering is 672 ft2 (42 feet x 16 feet).
3.66
Table 4.26 Total Warehouse Area
Facility Area (ft2) Allowance (300%) Total Area (ft2)
ROT Shelf 915.53 2746.603027 3662.14
CAC Shelf 624.53 1873.578761 2498.11
Manuevering 672 2016 2688.00
TOTAL 8848.24
Based on the table above, it can be seen that the company needs 8848.24 ft 2 for
warehouse area with 2688.00 ft2 for manuevering, 2498.11 ft2 for CAC shelfs, and
3662.14 ft2 for ROT shelfs.
3.67
4.6. Summary of Space Requirements
The total space requirements will be calculated from the total area of production
floor, storage, warehouse, office, car parking lot, motor cycle parking lot, truck
parking lot, food services, locker room, health care, restroom, and musholla. The
total factory area are shown in the figure below.
Table 4.27 Summary of space requirements
No Facilities Area(ft2)
1 Production floor 12725.51
2 Storage 4960
3 Warehouse 8848.24
4 Office 4071.85595
5 Car parking lot 36000
6 Motor cycle parking lot 7800
7 Truck parking lot 12300
8 Food services 3368
9 Locker room 576
10 Health care 788.19
11 Restroom 375
12 Musholla 387.5
13 Genset storage 3
Total Factory Area 92203.29
4.7 Green Area

The requirement of green area is 30 percent from the total factory area. Then, the
total green area in Waltz company is
Green area = 30 % x 92203.29 = 276609.87 ft2
The green area of Waltz company is 276609.87 ft2.
CHAPTER V
CONCLUSION
Summary of office space requirement is 6050 ft2. The storage area is consists of
direct material shelf, indirect material shelf and maneuvering plus docks area. The
area of the facility is stated at the table above. With allowance 300%, the total area
needed for the storage is 4960 ft2.
Based on the table above, it can be seen that the company needs 8848.24 ft 2 for
warehouse area with 2688.00 ft2 for manuevering, 2498.11 ft2 for CAC shelfs, and
3662.14 ft2 for ROT shelfs.
REFERENCES
Freivalds,Andris and Niebel, Benjamin. (2009). Niebel’s Methods, Standards,

andWork Design, Twelfth Edition.New York : McGraw-Hill.
Module 4 : Quantitative and
Qualitative Analysis
3/13/2018
PROJECT ASSIGNMENT
Created by,
2. Kelvin (0042
Phone (021) 8910 9762-6 - Fax (021) 8910 9768 - Email:
TABLE OF CONTENTS
CHAPTER I ......................................................................................................... 4.2
INTRODUCTION ............................................................................................... 4.2
1.1.Background ................................................................................................ 4.2
1.2.Objective .................................................................................................... 4.2
1.3. Steps .......................................................................................................... 4.2
1.4.Tool and Equipment ................................................................................... 4.3
CHAPTER II ........................................................................................................ 4.4
LITERATURE STUDY....................................................................................... 4.4
2.1. From To Chart ........................................................................................... 4.4
2.2. Activity Relationship Chart (ARC)........................................................... 4.4
2.3. Activity Relationship Diagram (ARD) ..................................................... 4.6
CHAPTER III ...................................................................................................... 4.8
DATA COLLECTION......................................................................................... 4.8
3.1. Route Sheet ............................................................................................... 4.8
3.2. Density of Material ................................................................................. 4.23
3.3. Dimension of Machine in Production Floor .......................................... .4.23
CHAPTER IV ................................................................................................... .4.24
DATA ANALYSIS ........................................................................................... .4.24
4.1. Calculation of Raw Material Weight ..................................................... .4.24
4.2. Calculation of Part’s Weight ................................................................... 4.25
4.3. Material Flow .......................................................................................... 4.27
4.3.1. Material Flow of ROT.......................................................................... 4.27
4.3.2. CAC ..................................................................................................... 4.33
4.4. Aggregate of the Material Flow .............................................................. 4.37
4.4.1. Aggregate of the Material Flow of Part ............................................... 4.37
4.4.2. Aggregate of the Material Flow of Assembly...................................... 4.41
4.5. From to Chart and Flow Metric .............................................................. 4.44
4.6. Activity Relationship Chart and Diagram (ARC and ARD)................... 4.48
4.6.1. Office.................................................................................................... 4.49
4.6.2. Whole Plant .......................................................................................... 4.53
CHAPTER V...................................................................................................... 4.59
CONCLUSION .................................................................................................. 4.59
REFERENCES................................................................................................... 4.60
4.1
CHAPTER I
INTRODUCTION
1.1.Background
One of the problem that frequently encountered in industrial world is the layout or
arrangement of production facilities and work area. Facility layout designers often
overlook the information regarding the materials and manufacturing process in
designing the facility plant layout, especially the arrangement of the flow of each
department, and material movement.
In report III, space requirement of facility layout has been discussed. Routing
sheet data will be used to calculate from to chart in this report. From to chart is a
quantitative measurement. In addition, another method that will be used to finish
this report is Qualitative measurement, such as Activity relationship chart and
activity relationship diagram are qualitative measurement.
In this report, this company will provide some information about quantitative and
qualitative of production floor and whole company.
1.2.Objective
To determine the movement of material

To plan the flow of material movement
To minimize the total handling cost and maximize the efficiency
To determine the closeness relationship among group’s activity
1.3. Steps
There are several steps to do this report:
Acquire the data from previous report

Take all the data of material that used in the production of ROT and CAC
Calculate the total weight requirement
Aggregate the total weight requirement
Calculate the from to chart 6. Make the ARC for all department that exist in
the company
Make ARD for all the ARC 8. Make ATBD from the ARD
Finalize the report
Revise the report based on the adviser and suggestion given by the lecturer.
1.4.Tool and Equipment

There are several tool and equipments to do this report:
Microsoft Excel is used to create the from to chart calculation.

Microsoft Visio is used to compute Activity relation chart and activity
relation diagram.
CHAPTER II
LITERATURE STUDY
2.1. From To Chart
From to chart is a numeric representation of the traffic flow intensity visually
depicted in the product flow diagram. It allows the facility analyst to focus on
those areas where blocking or queuing are likely to occur. From to chart is a
square matrix but is seldom symmetric.
A from to chart is constructed as follows:
List all departments down the row and across the column following the
over all flow pattern.
Establish a measure of flow for the facility that accurately indicates
equivalent flow volumes. If the items moved are equivalent with respect to
ease of movement, the number of trips may be recorded in the from to
chart. If the items moved vary in size, weight, value, risk of damage, shape
and so on, then some common unit of measure may be established so that
the quantities recorded in the from to chart represent the proper
relationship among the volumes of movement.
Based on the flow of paths for the item to be moved and the established
measure of flow, record the flow volumes in the from to chart.
2.2. Activity Relationship Chart (ARC)

Activity relationship chart is a tabular means of displaying the closeness rating
among all pairs of activities or departments. In ARC there are six closeness rating
which may be assigned to each pair of departments, as well as nine reasons for
those ratings.
Table 2.1. Rating Symbol for ARC
The closeness ratings indicate the importance of locating department pair next to
each other. For example, it is absolutely important that department pair with an A
rating be placed adjacent to each other. Similarity, it is especially important that
department pair with an A rating to be nonadjacent. Also, if a department I has A
relationship with so many others that some of these can not be adjacent, then the
departments are placed as close as possible to department i. this is why it is
important to keep the number of A relationship in a chart within 5% of the total
relationships. The letter codes for the closeness rating s may easily be converted
into numerical values. Some layout software packages allow the user to set
numerical values for closeness rating.
In relationship chart, it is desirable to have ratings occur in increasing frequency

from A through U: 2-5% for A, 3-10% for E, 5-15% for I, 10-25% for O, and 25-
60% for U. The frequency of X ratings depends on the layout problem.
There are some steps to construct activity relationship chart:
List all the departments within the facility and draw a rectangle around
each each one.
Draw a rhombus between each department, until you fully construct the
rhombus as a tree.
Divide each rhombus into two halves; the upper half will contain the rating
letter, while the lower half will contain the rating reason code.
Figure 2.2. Example of Activity Relationship Chart
2.3. Activity Relationship Diagram (ARD)

A relationship diagram is a spatial arrangement of the departments to represent the
relationship data in a graphical way. In activity relationship diagram use a line
code for to make the diagram that will show in table 2.1. This diagram is also
called an adjacency graph. There are two ways of making activity relationship
diagram:
 By making an activity template block diagram ( ATBD)

 By using the combination of standardize lines and color codes. Using
information from the space relationship diagram, determine the relative
positioning of department pairs with A relationship are adjacent, those with
an X relationship are nonadjacent ( preferably in distant locations), those
with E relationship are place as close as possible and so on. The relative
positioning of departments is typically determined by trial and error. The
procedure for graphically making an activity-relationship diagram, based
on the relationships of activity-areas having been charted, is as follows:
 Starting with Activity-area 1, see if it relates to any other activity-area by an
A rating.
 If so, diagram this by starting more or less in the center of a plain piece of
paper. Draw the symbol for Activity-area 1; place the numeral 1 inside it;
about a half inch to the right, draw the symbol for the A-related activity-
area and place its number inside; In metric, space symbols one centimeter
apart and keep approximately two millimeters between lines.
 Continue down the row for Activity-area I, adding the respective symbol
and number to the diagram for any A-rated relationships, placing each at
the same half-inch distance from the symbol for the activity-area with
which it bears an A rating. Continue for the row representing Activity-area
2, then 3, etc… Place these in the diagram, trying to maintain a half-inch
distance between the symbols of each pair of A-related activity-areas.
Don't try to look ahead. Progress down each of the rows until all A's are
diagramed. Don't worry if you have to start a second partial diagram below
the first that is not connected to the first; it will connect up later on.
 Count the number of 4-line relationships and be sure it equals the
frequency count on the relationship chart for the number of A ratings.
 If there are more than six or eight relationships diagramed, the planner
should redraw the diagram trying to get the symbols so located as to honor
the halfinch distance for each set or bundle of four lines. Don't worry if the
lines cross; don't worry if symbols hang off by themselves related only by
one relationship.
CHAPTER III DATA
COLLECTION
3.1. Route Sheet

Below are shown the route sheet of ROT and CAC. Routing sheet is the list of
operations and times required to produce a component. Route sheet specifies the
operations required for a part as well as the sequence of the machines visited for
these operations. Route sheet shows how a part is to be produced, which machine
are needed, the tools to use, estimated setup times for the machines and
production in terms of the number of units expected per hour form each
machine.The route sheet will be used to calculate weight of each raw material
and parts.
Table 3.1. Assembly Final Product (ROT)
Op. Proces Machi Tim Capacity Srap Product Numb
No s ne e % Requirement er of
Name (mi Theoriti Actual In Out M/C
n) c
Inspect 0.9 2666.666 2266.66 1% 309.21 306.12 0.1364
ion of 67 67 46 24
I-1
110
A-7 and
140
Final gun 1.8 1333.333 1133.33 306.12 306.12 0.2701
44 coating spray 33 33 24 24
Final circ. 1.4 1714.285 1457.14 2% 306.12 300 0.2101

I-2 inspect saw 71 29 24
ion
Packag 0.8 3000 2550 300 300 0.1176
45 ing
Assembly Pedestal (140)
O Process Machi Tim Capacity Srap Product Numb
p. Name ne e % Requirement er of
No (mi Theoriti Actual In Out M/C
n) c
A- Apply jointer 0.8 3000 2550 2% 321.93 315.49 0.1262
4 glue and 15 29
attach 4
pedestal
pieces
Table 3.1. Assembly Final Product (ROT) (continued)
Hold circ 1.4 1714.2 1457.14 1 315.49 312.33 0.21

27 and . 8571 29 % 29 80 65
clamp saw
Fasten 6 400 340 312.33 312.33 0.91
28 with 2" 80 80 86
screws
Put off 0.6 4000 3400 312.33 312.33 0.09
29 the 80 80 19
clamp
Attach 4 600 510 312.33 312.33 0.61
all the 80 80 24
pedestal
A-5
supports
using
glue
Fasten 3.6 666.66 566.666 312.33 312.33 0.55
using 6667 67 80 80 12
34
2.5"
bolts
Attach 8 300 255 312.33 312.33 1.22
all the 80 80 49
feet
A-6
spports
using
glue
Fasten 3 800 680 1 312.33 309.21 0.45
40 with 2" % 80 46 47
screws
Fill all 3.2 750 637.5 309.21 309.21 0.48
the 46 46 50
holes
and
41
gaps
with
wood
filler
Sand 4 600 510 309.21 309.21 0.60
42 the dry 46 46 63
filler
Apply gun 2 1200 1020 309.21 309.21 0.30
two coat spra 46 46 32
43 of y
polyuret
hane
4.9
Assembly Top Surface (110)

Proc Ti Product
Capacity Numb
Op. ess Mach me Srap Requirement
er of
No Nam ine (mi Theori Actua l %
In Out M/C
e n) tic
Appl
y
glue
&
A-1 attac jointe 321. 315.49 2.367
15 160 136 2%
h all r 9315 29 1
11
top
surfa
ce
Appl
y
glue
on
7 circ. 666.66 566.66 315. 312.33 0.556
top 3.6 1%
saw 6667 667 4929 80 8
of
base
surfa
ce
Join
the
base
surfa
A-2 312. 312.33 0.153
ce 1 2400 2040
3380 80 1
with
top
surfa
ce
Drill
1" by
#8
screw
8 drill 312. 309.21 1.837
, 12 200 170 1%
press 3380 46 3
7.75"
from
each
end
Put
9 all 309. 309.21 1.212
8 300 255
screw 2146 46 6
s
4.10
Trim
10 off table 309. 309.21 0.757
5 480 408
all saw 2146 46 9
ends
Join
all
A-3 frame 309. 309.21 0.727
4.8 500 425
s using 2146 46 6
glue
Fill all
the
holes
19 and 428.57 364.28 309.21 309. 0.848
5.6
gaps 1429 571 46 2146 8
with
wood
filler
Sand
20 all 309.21 309. 0.606
4 600 510
surfac 46 2146 3
es
Apply
two
gun
21 coat 309.21 309. 0.242
spra 1.6 1500 1275
of 46 2146 5
y
polyur
ethane
143 Pedestal Support

Product
Op Proce Capacity Numb
Mac Time Sra Requirement
. ss er of
hine (min) Theori Actua p%
No Name In Out M/C
tic l
Marki
ng
using
square 1274
318.67 0.624
30 for 4 600 510 .718
97 9
whole 8
raw
materi
al
4.11
Cut to
1261
31 the circ. 1714.2 1457.1 1274.7 0.874
1.4 1% .971
length saw 8571 429 188 8
6
8"
Mar
1261
32 for the 1261.9 1.237
2 1200 1020 .971
pilot 716 2
6
screw
Drill
drill
33 1/4" 1261.9 312. 1.855
pres 3 800 680 1%
bolt 716 3380 8
s
holes
142 Feet (4)
Product
. ss er of
No Name In Out M/C
tic l
Marki
ng
using
square 1274
35 318.67 0.624
for 4 600 510 .718
97 9
whole 8
raw
materi
al
Cut to
1261
36 the circ. 1714.2 1457.1 1274.7 0.874
1.4 1% .971
length saw 8571 429 188 8
6
22"
Mark
1261
37 for the 1090.9 927.27 1261.9 1.360
2.2 .971
pilot 0909 273 716 9
6
screw
Drill
2" drill 1249
38 1142.8 971.42 1261.9 1.299
screw pres 2.1 1% .351
5714 857 716 1
for 4 s 9
holes
Sand
39 all disc 857.14 728.57 1249.3 312. 1.714
2.8
surfac sand 2857 143 519 3380 8
es
4.12
141 Pedestal Piece (4)

Product
. ss er of
hine (min) Theori Actua l p%
No Name In Out M/C
tic
Mark
using
square
1313
22 for 328.46 0.644
4 600 510 .872
whole 805 1
2
raw
materi
al
Cut to
1300
23 the circ. 1313.8 1.030
1.6 1500 1275 1% .733
length saw 722 5
5
27"
Mark
1300
24 for the 1300.7 1.594
2.5 960 816 .733
pilot 335 0
5
screw
Drill
2" drill 1287
25 1300.7 1.530
screw pres 2.4 1000 850 1% .726
335 3
for 5 s 1
holes
Sand
26 all disc 727.27 618.18 1287.7 321. 2.083
3.3
surfac sand 2727 182 261 9315 1
es
120 Base Surface
Product
. ss er of
No Name In Out M/C
tic l
Mark
using
square
325.
for 325.21 0.478
4 3 800 680 2165
whole 655 3
5
raw
materi
al
4.13
Cut to
318.
the joint 325.21 0.076
5 0.48 5000 4250 2% 7122
width er 655 5
2
38.5"
Cut to
the circ. 318.71 312. 0.234
6 1.5 1600 1360 2%
length saw 222 3380 3
46.5"
113 Frame Top Surface C
Product
. ss er of
No Name In Out M/C
tic l
Mark
using
square
637.
15 for 35.412 0.208
12 200 170 4244
whole 469 3
4
raw
materi
al
Cut to
631.
16 the circ. 637.42 0.749
2.4 1000 850 1% 0501
length saw 444 9
9
38.5"
Cut
for the 618.
17 joint 1333.3 1133.3 631.05 0.556
joinin g 1.8 2% 4291
er 3333 333 019 8
edges 9
Sand
18 disc 923.07 784.61 618.42 309. 0.788
the 2.6
sand 6923 538 919 2146 2
edges
112 Frame Top Surface B (2)
Product
. ss er of
No Name In Out M/C
tic l
Mark
using
square
637.
for 218.18 185.45 42.494 0.229
11 11 4244
whole 1818 455 963 1
4
raw
materi
al
4.14
Cut to
624.
12 the circ. 637.42 0.749
2.4 1000 850 2% 6759
length saw 444 9
5
46.5"
Cut
for the 618.
13 joint 1333.3 1133.3 624.67 0.551
joinin g 1.8 1% 4291
er 3333 333 595 2
edges 9
Sand
14 disc 618.42 309. 0.757
the 2.5 960 816
sand 919 2146 9
edges
111 Top Surface Slat (11)
Product
. ss er of
No Name In Out M/C
tic l
Mark
using
square
1 for 238.46 3577 1.169
10 240 204
whole 78 .017 0
raw
materi
al
Cut to
3541
2 the circ. 1090.9 927.27 3577.0 3.857
2.2 1% .246
length saw 0909 273 17 6
9
46.5"
Sand
3 all disc 3541.2 321. 5.207
3 800 680
surfac sand 469 9315 7
es
4.15
Table 3.2. Assembly Final Product (CAC)
210 Front Leg (2)

Ti Production
Sc Nu
m Capacity Requireme
Ope ra mb
e nt
ratio Mac p er
Process Name (
n hine The ( of
m Act
No. oriti % In Out M/
in ual
c ) C
)
Mark Using Square 923. 784. 271. 135
8 2. 0.3
for whole raw 076 615 505 7.52
material 6 460
9 4 9 94
279 237 135 134
9 Cut to the width Joint 0. 1 0.5
0.69 2.09 7.52 3.95
1.5" er 86 % 723
77 30 94 41
666 566 134 133
10 Cut to the length Circ. 0. 1 0.2
6.66 6.66 3.95 0.51
25" Saw 36 % 372
67 67 41 46
133 133
11 Mark of 0.75" from 0. 100 850 0.1
0.51 0.51
edge and pilot holes 24 00 0 565
46 46
133 131
12 Remove of 0.75" Rout 0. 600 510 1 0.2
0.51 7.20
rounded edge er 4 0 0 % 609
46 94
Drill 131 130
13 0. 600 510 1 0.2
Drill the holes Pres 7.20 4.03
4 0 0 % 583
s 94 73
Disc 363 309 130 130
14 0. 0.4
Sand All surface . 6.36 0.90 4.03 4.03
66 219
Sand 36 91 73 73
Gun 130 130
15 Apply two coat of 0. 600 510 0.2
Spra 4.03 4.03
polyurethane 4 0 0 557
y 73 73
220 Stretcher (3)
Ti Prod.
Sc Nu
m Capacity Requireme
Ope ra mb
e nt
ratio Mac p er
Process Name (
n hine The ( of
m Act
No. oret % In Out M/
in ual
ic ) C
)
Mark using square 276. 193
30 0.4
for whole raw 3 800 680 614 6.29
068
material 0 79
266 226 193 191
31 Cut to the width joint 0. 1 0.8
6.66 6.66 6.29 6.93
1.5" er 9 % 542
67 67 79 49
4.16
Table 3.2. Assembly Final Product (CAC) (continued)
Cut to
32 the circ. 1916. 1897. 0.37
0.4 6000 5100 1%
length saw 9349 7655 59
20.5"
Drill
33 drill 1897. 1897. 0.55
0.25" 0.6 4000 3400 0
press 7655 7655 82
holes
Sand
34 all disc 0.8 2857. 2428. 1897. 1897. 0.78
0
surface sand 4 1429 5714 7655 7655 14
s
Apply
two coat
35 gun 0.4 5333. 4533. 1897. 1897. 0.41
of
spray 5 3333 3333 7655 7655 86
polyure
thane
230 Side Stetcher (2)
Ti Scr Prod. Num
Opera Capacity
Process Mac me ap Requirement ber of
tion
Name hine (mi Theor Actua (% M/C
No. In Out
n) etic l )
Mark
using
square
23 for 146.3 1317. 0.21
3 800 680
whole 566 2094 52
raw
materia l
Cut to
24 the jointe 2666. 2266. 1317. 1304. 0.58
0.9 1%
width r 6667 6667 2094 0373 11
1.5"
Cut to
25 the circ. 1304. 1290. 0.25
0.4 6000 5100 1%
length saw 0373 9970 57
14.5"
Drill
26 drill 1290. 1290. 0.37
0.25" 0.6 4000 3400 0
press 9970 9970 97
holes
Sand
27 all disc 1290. 1290. 0.50
0.8 3000 2550
surface sand 9970 9970 63
s
4.17
240 Arm (2)

Proc Ti Scr Prod. Num
Opera Capacity
ess Mac me ap Requirement ber of
tion
Nam hine (mi Theor Actua l (% M/C
No. In Out
e n) etic )
Mark
ing
using
squar
1 e for 692.68 1385.3 0.679
2 1200 1020
77 754 1
whol
e raw
mate
rial
Cut
to
2 the jointe 0.6 3529.4
3000 2%
1385.3 1357.6 0.461
widt r 8 118 754 679 8
h
2.5"
Cut
to the
3 lengt circ. 0.5 4363.6 3709.0
1%
1357.6 1344.0 0.366
h saw 5 364 909 679 913 0
19.5"
Mark
of
4 0.75" 0.4 5454.5 4636.3 1344.0 1344.0 0.289
of 4 455 636 913 913 9
Edge
s
Rem
ove
of
0.75"
5 roun Route
1.1
2181.8 1854.5
2%
1344.0 1317.2 0.724
ded r 182 455 913 094 8
edge
s for
Notc
hes
4.18
Dri
ll
3/8
"
hol
Drill
es 0.8 2727.2 2318.1 1317.2 1304.0
6 on pres 1% 0.5682
8 727 818 094 373
s
Ro
und
ed
Ed
ges
San
d
all disc.
0.9 2608.6 2217.3 1304.0 1304.0
7 surf San 0.5881
2 957 913 373 373
ace d
s
250 Rear leg (2)
Tim Prod. Nu
Oper Capacity Scra Requirement
Process Mach e mbe
ation ine p
Name (mi Theor r of
No. n) etic Actual (%) In Out
M/C
Mark
using
square
16 for 1333.3 1133.3 678.76 1357.5 0.59
1.8
whole 333 333 47 294 89
raw
material
Cut to
17 the jointe 1357.5 1343.9 0.53
width 0.8 3000 2550 1%
r 294 541 24
3.5"
Cut to
18 the circ. 6666.6 5666.6 1343.9 1330.5 0.23
length 0.36 1%
saw 667 667 541 146 72
25"
Mark of
0.75"
19 from 6315.7 5368.4 1330.5 1330.5 0.24
edge 0.38 0%
895 211 146 146 78
and pilot
holes
Remove
20 of 0.75" 1330.5 1317.2 0.26
router 0.4 6000 5100 1
rounded 146 094 09
edge
4.19
Drill
drill 1317.20 1304.03
21 the 0.8 3000 2550 1 0.5166
press 94 73
holes
Sand
all disc 3333.33 2833.33 1304.03 1304.03
22 0.72 0.4602
surfac sand 33 33 73 73
es
260 Back (1)
Tim Prod.
Proce Capacity Scra Numb
Operati Machi e Requirement
ss (mi p er of
on No. ne Theore
Name n) Actual (%) In Out M/C
tic
Mark
the
42 bars 210.862 1265.17
4.8 500 425 0.4961
to 8 70
length
9.5"
Cut
steel
43 cut off 1265.17 1252.52
bar to 1.6 1500 1275 1% 0.9923
saw 70 53
Lengt
h 9.5"
Attac
h
canva
44 s 626.262 626.262
2.4 1000 850 0.7368
sling 6 6
to
Bars
270 Seat (1)

Tim Prod.
Proce Capacity Scra Numb
Operati Machi e Requirement
ss p er of
on No. ne (mi Theore
Name Actual (%) In Out M/C
n) tic
Mark
the
bars
39 to 425.985 1277.95
0.8 3000 2550 0.1671
length 5 66
17.25
"
Cut
steel
bar to
40 Lengt cut off 1277.95 1265.17
0.1 24000 20400 1 0.0626
h saw 66 70
17.25
"
4.20
Attach
canvas 0.7 3333. 2833. 632.5 632.5 0.22
41
sling to 2 3333 3333 885 885 33
Bars
Sub Assembly Arm and Leg (2)

Ti Scr Prod. Num
Opera Capacity
Proces s Mac me ap Requirement ber of
tion
Name hine (mi Theor Actua (% M/C
No. In Out
n) etic l )
Attach
4
dowels
(1.5")
A-1 0.7 3333. 2833. 1304. 1304. 0.46
into
2 3333 3333 0373 0373 02
edges of
arm
using
glue
Assem
ble
front
A-2 circ. 857.1 728.5 1304. 1290. 1.78
and 2.8 1
saw 429 714 0373 9970 99
rear
legs to
arm
Assem
ble side
stretche
A-3 r using 1290. 1265. 1.26
2 1200 1020 2
4 9970 1770 57
dowels
(4") &
glue
Inspect
and fill
I-1 all gaps 1265. 1265. 0.74
O-28 1.2 2000 1700
with 1770 1770 42
wood
filler
Apply
two coat
29 gun 0.7 3076. 2615. 1265. 1265. 0.48
of
spray 8 9231 3846 1770 1770 37
polyute
thane
4.21
Assembly CAC
Ti Scr Prod. Num
Opera Proce Capacity
Mac me ap Requirement ber of
tion ss
hine (mi Theor Actua l (% M/C
No. Name In Out
n) etic )
Conne
ct 3
stretch
ers to
2 SA
Arm
and
A-4 750.00 637.50 632.5 632.5 0.992
Leg 3.2
00 00 885 885 3
using
washe
r,
hanger
and
cap
nut
Fill all
gaps
36 0.8 2727.2 2318.1 632.5 632.5 0.272
with
8 727 818 885 885 9
wood
filler
Sand
the
37 0.5 4285.7 3642.8 632.5 632.5 0.173
filler
6 143 571 885 885 7
contai
ned
Final
38 gun 2666.6 2266.6 632.5 632.5 0.279
coatin 0.9
spray 667 667 885 885 1
g
Assem
A-5 1000.0 850.00 632.5 626.2 0.744
ble the 2.4 1
000 00 885 626 2
seat
Assem
A-6 1333.3 1133.3 626.2 0.552
ble the 1.8 1 620
333 333 626 6
back
Final
I-2 0.303
inspec 1 2400 2040 620 620
9
tion
O-45 Packa 0.243
0.8 3000 2550 620 620
ging 1
4.22
3.2. Density of Material
Below are shown the density of material. It will be used to calculate the
weight of material and part. Here is the table of density of material.
Table 3.3. Density of Material
No Material Density kg/m3
1 Plywood 500 - 650

2 Oak 749
3 Paper 450
4 Birch 670
5 Plastic 8.5
6 Iron 7250
7 Paint 3750
8 Glue 1250
9 Thread 100
10 Mild Steel (screw, Nail, ect) 7.75 - 8.05

11 Fir 530
12 Polyurethane 25 - 55
3.3. Dimension of Machine in Production Floor

In order to determine the space that will be calculated in this discussion, the
table below shows the dimension that needed by of all the machines and
equipment that is used to make the Rectangular Oak Table and Casual Arm
Chair.
Table 3.4. Dimension of Machine in Production Floor
Dimension (Length x
No Machine/Equipment
Width) m
1 Jointer 1.84 x 0.44
2 Circular Saw 1.50 x 0.50
3 Radial Arm Saw 1.10 x 1.25
4 Router 1.00x 1.00
5 Disc Sander 0.43 x 0.47
6 Drill Press 5.6 x 2
7 Table Saw 0.85 x 0.72
8 Bench/Table 0.033 x 0.036

9
10 Spray Booth/Gun Spray 0.8 x 0.8
4.23
CHAPTER IV
DATA ANALYSIS
4.1. Calculation of Raw Material Weight
The Company produces two kinds of product which are Rectangular Oak Table
(ROT) and Casual Arm Chair (CAC). There are 9 kinds of material used as
shown in the table. Each of raw material has their own dimension consist of
Length, Weight and Thickness/Diameter. In order to calculate the total
weight of each raw material, the density of each raw material have to be
known and it has already provided on the case study. Here is the example of
calculation of raw material which is Oak (60’ x 3 ½” x ¾”).
3
Volume = Length x Width x Thickness = 720” x 3.50” x 0.75” = 1890 in
3
Density = Oak (749 kg/m ) convert to Oak (0.0122739 kg/in3)
3 3
Weight = Volume x Density = 1890 in x 0.0122739 kg/in =
23.20kg
Table 4.1. Raw Material Weight
Raw Weight
Material Density Weight
No
Name Thickness Length Width Volume (Kg/Inch3) (kg)
(Inches) (Inches) (Inches) (Inch3)
Oak
1 60’ x 3 0.75 720 3.5 1890 0.0123 23.1977
½” x ¾”
Oak
2 10’ x 8 0.75 120 8.5 765 0.0123 9.3895
½” x ¾”
Oak
3 8’ x 5 0.75 96 5.5 396 0.0123 4.8605
½” x ¾”
Table 4.1. Raw Material Weight (continued)
Plywood
4 4’ x 4’ x 1 48 48 1728 0.0094 16.3105
¾”
Fir 3’ x
5 2 36 2 144 0.0087 1.2507
2" x 2”
Birch
6 12’ x 2” 1.00 144 2 288 0.0110 3.1620
x 1”
Birch
7 3 ½’ x 1.00 42 3 126 0.0110 1.3834
3” x 1”
Birch
8 4 ¼’ x 1.00 51 4 204 0.0110 2.2398
4” x 1”
Round
9 steel bar ᴓ 0.38 60 6.62 0.00960 0.0636
⅜ x 5’
4.2. Calculation of Part’s Weight

The Company produces two kinds of product which are Rectangular Oak Table
(ROT) and Casual Arm Chair (CAC). There are 16 kinds of parts produced as
shown in the table. Each of raw parts has their own dimension consist of
Length, Weight and Thickness/Diameter. In order to calculate the total
weight of each part, the density of each rmaterial have to be known and it
has already provided on the case study. Here is the example of calculation of
part which is Top Surface Slat.
3
Volume = L x W x T =46.5 x 3.5 x 0.75 = 122.06in
3 3
Density = Oak (749 kg/m ) convert to Oak (0.0122739 kg/in )
3 3
Weight = Volume x Density = 122.06in x 0.0122739 kg/in =
1.498 kg
Table 4.2. Part’s Weight
Raw Weight
Material Density Weight
No Thickness Length Width Volume
Name (Kg/Inch3) (kg)
(Inches) (Inches) (Inches) (Inch3)
Top
1 Surface 0.75 46.5 3.5 122.0625 0.0123 1.4982
Slat
Frame
Top
2 0.75 46.5 3.5 122.0625 0.0123 1.4982
Surface B
Frame
Top
3 0.75 38.5 3.5 101.0625 0.0123 1.2404
Surface C
Base
4 0.75 46.5 38.5 1342.6875 0.0094 12.6736
Surface
Pedestal
5 0.75 27 8.5 172.1250 0.0123 2.1126
Pieces
6 Feet 0.75 22 5.5 90.7500 0.0123 1.1139
Pedestal
7 2.00 8.5 2 34.0000 0.0123 0.4173
Support
Front
8 0.75 25 1.5 28.1250 0.0110 0.3088
Leg
9 Sretcher 0.75 20.5 1.5 23.0625 0.0110 0.2532
Side
10 16.3125 0.1791
Strecher 0.75 14.5 1.5 0.0110
11 Arm 0.75 19.5 2.5 36.5625 0.0110 0.4014
12 Real Leg 0.75 25 3.5 65.6250 0.0110 0.7205
Back
13 Steel 0.0101
Rod 0.375 9.5 1.0487 0.0096
Seat
14 Steel 0.0185
Rod 0.375 17.5 1.9318 0.0096
Canvas
15 0.1293
Back 0.375 23.5 9 79.3125 0.0016
Canvas
16 0.2442
Seat 0.375 23.5 17 149.8125 0.0016
4.26
4.3. Material Flow
Based on the previous calculation which are raw material weight and part’s
weight, it would affect the calculation in material flow. Material flow has
already provide in the route sheet which is describe the material flow from the
storage until the finished good, process of material in some machines, and
scrap some procesess that may affect the weight of the material itself.
4.3.1. Material Flow of ROT
Below are shown the material flow of ROT in each process. Here is the example
of material flow calculation of Pedestal Support (O-30)
Product Requirement Output (O-30) = 1274.7188 units

Weight = 1.2507 kg
Product Requirement in kg = Prod. Req. Input x Weight = 1274.7188 units x
1.2507 kg = 398.5600055 kg
Table 4.3. Material Flow of ROT
143 Pedestal Support
Product Requirement
Process
Op. No Machine Srap%
Name
In Out
Marking
using
square
30 for 398.5600055 398.5600055
whole
raw
material
Cut to
the 398.5600055 3.236548732
31 circ. saw 1%
length
8"
Mar for
32 the pilot 3.236548732 3.236548732
screw
4.27
Table 4.3. Material Flow of ROT (continued)
Drill
1/4" drill 3.236548732 0.801045811
33 1%
bolt press
holes
142 Feet (4)
Product Requirement
Process
Name In Out
Marking
using
square
35 for 1548.93134 1548.93134
whole
raw
material
Cut to
the 1548.93134 1405.655191
36 circ. saw 1%
length
22"
Mark
for the 1405.655191 1405.655191
37
pilot
screw
Drill 2"
screw drill 1405.655191 1391.598639
38 1%
for 4 press
holes
Sand all 1391.598639 347.8996599
39 disc sand
surfaces
141 Pedestal Piece (4)

Product Requirement
Process
Name In Out
Mark
using
square
22 for 3084.161746 3084.161746
whole
raw
material
4.28
Cut to
the 3084.161746 2747.988115
23 circ. saw 1%
length
27"
Mark
for the 2747.988115 2747.988115
24
pilot
screw
Drill 2"
screw drill 2747.988115 2720.508234
25 1%
for 5 press
holes
Sand
26 all disc sand 2720.508234 680.1270586
surfaces
120 Base Surface
Process Product Requirement
Name In Out
Mark
using
square
4 for 5304.446361 5304.446361
whole
raw
material
Cut to
the 5304.446361 4039.218488
5 jointer 2%
width
38.5"
Cut to
the 4039.218488 3958.434118
6 circ. saw 2%
length
46.5"
113 Frame Top Surface C
Name In Out
Mark
using
square
15 for 821.4868002 821.4868002
whole
raw
material
4.29
Cut to
the 821.4868002 782.7742347
16 circ. saw 1%
length
38.5"
Cut for
the 782.7742347 767.11875
17 jointer 2%
joining
edges
Sand
18 the disc sand 767.11875 383.559375
edges
112 Frame Top Surface B (2)
Name In Out
Mark
using
square
11 for 985.7841602 985.7841602
whole
raw
material
Cut to
the 985.7841602 935.8788371
12 circ. saw 2%
length
46.5"
Cut for
the 935.8788371 926.5200487
13 jointer 1%
joining
edges
Sand
14 the disc sand 926.5200487 463.2600244
edges
111 Top Surface Slat (11)
Name In Out
Mark
using
square
1 for 5531.897644 5531.897644
whole
raw
material
4.30
Cut to
the 5531.897644 5305.435584
2 circ. saw 1%
length
46.5"
Sand all 5305.435584 482.3123258
3 disc sand
surfaces
Assembly Top Surface (110)
Name In Out
Apply glue
& attach all 482.3123 472.6661
A-1 jointer 2%
11 top
surface
Apply glue
7 on top of circ. saw 1% 3958.4341 3918.8498
base surface
Join the base

A-2 surface with 4391.5159 4391.5159
top surface
Drill 1" by
#8 screw, drill 4391.5159 4347.6007
8 1%
7.75" from press
each end
Put all 4347.6007 4347.6007
9
screws
Trim off all table 4347.6007 4347.6007
10
ends saw
Join all
A-3 frames using 5194.4201 5194.4201
glue
Fill all the
holes and 5194.4201 5194.4201
19
gaps with
wood filler
Sand all 5194.4201 5194.4201
20
surfaces
4.31
Apply two
gun 5194.4201 5194.4201
21 coat of
spray
polyurethane
Assembly Pedestal (140)

Name In Out
Apply glue
and attach 4 680.1271 666.5245
A-4 jointer 2%
pedestal
pieces
Hold and 666.5245 659.8593
27 circ. saw 1%
clamp
Fasten with 659.8593 659.8593

28
2" screws
Put off the 659.8593 659.8593

29
clamp
Attach all the

pedestal 660.6603 660.6603
A-5
supports
using glue
Fasten using 660.6603 660.6603

34
2.5" bolts
Attach all
the feet 1008.5600 1008.5600
A-6
supports
using glue
Fasten with 1008.5600 998.4744

40 1%
2" screws
Fill all the

holes and 998.4744 998.4744
41
gaps with
wood filler
Sand the dry 998.4744 998.4744
42
filler
4.32
Apply two
gun 998.4744 998.4744
43 coat of
spray
polyurethane
Assembly Final Product (ROT)

Name In Out
Inspection
I-1 A-7 of 110 and 1% 6192.8945 6130.9655
140
Final gun 6130.9655 6130.9655
44
coating spray
Final 6130.9655 6008.34622
I-2 circ. saw 2%
inspection
45 Packaging 6008.34622 6008.34622
4.3.2. CAC
Below are shown the material flow of CAC in each process. Here is the example
of material flow calculation of Front Leg (O-8)
Product Requirement Output (O-30) = 1357.52 units

Weight = 3.1620 kgs
Product Requirement in kg = Prod. Req. Input x Weight = 1357.52 units x 3.1620
kgs = 858.5120 kgs
Table 4.4. Material Flow of CAC
210 Front Leg (2)
Production
Scra Requiremen t
Operati Machi
Process Name p
on No. ne
(%)
In Out
Mark Using Square for whole raw 858.51 858.51
8 20 20
material
858.51 415.00
9 Cut to the width 1.5" Jointer 1% 20 34
Circ. 415.00 410.85

10 Cut to the length 25" 1% 34 33
Saw
Mark of 0.75" from edge and pilot 410.85 410.85
11 33 33
holes
410.85 406.74
12 Remove of 0.75" rounded edge Router 1% 33 48
4.33
Table 4.4. Material Flow of CAC (continued)
Drill 3986.09 3946.23
13 Drill the holes 1%
Press 91 81
Disc. 3946.23 3946.23
14 Sand All surface
Sand 81 81
Apply two coat of Gun 3946.23 3946.23
15
polyurethane Spray 81 81
220 Stretcher (3)
Scra Prod.
Operati Machin Requirement
Process Name p
on No. e
(%) In Out
30
8571.70 4756.79
31 Cut to the width 1.5" jointer 1%
75 54
4756.79 4709.22
32 Cut to the length 20.5" circ. saw 1%
54 74
drill 4709.22 4709.22
33 Drill 0.25" holes 0
press 74 74
disc 4709.22 4709.22
34 Sand all surfaces 0
sand 74 74
Apply two coat of gun 4709.22 4709.22
35
polyurethane spray 74 74
230 Side Stetcher (2)
Scra Prod.
Operati Machin p Requirement
Process Name
on No. e
(%) In Out
23
4535.29 2288.81
24 Cut to the width 1.5" jointer 1%
50 81
2288.81 2265.92
25 Cut to the length 14.5" circ. saw 1%
81 99
drill 2265.92 2265.92
26 Drill 0.25" holes 0
press 99 99
disc 2265.92 2265.92
27 Sand all surfaces
sand 99 99
240 Arm (2)
Scra Prod.
Operati Machin Requirement
Process Name p
on No. e
(%) In Out
Marking using square for 9390.93 9390.93
1
4.34
Cut to the width
2 jointer 2% 9390.9334 5341.0934
2.5"
Cut to the length
3 circ. saw 1% 5341.0934 5287.6825
19.5"
Mark of 0.75" of
4 5287.6825 5287.6825
Edges
Remove of 0.75"
5 rounded edges for Router 2% 5287.6825 5181.9288
Notches
Drill 3/8" holes on Drill
6 1% 5181.9288 5130.1095
Rounded Edges press
disc.
7 Sand all surfaces 5130.1095 5130.1095
Sand
250 Rear leg (2)
Operation Scrap Prod. Requirement
Process Name Machine
No. (%) In Out
Mark using square
16 for whole raw 14898.7608 14898.7608
material
Cut to the width
17 jointer 1% 14898.7608 9489.7438
3.5"
Cut to the length
18 circ. saw 1% 9489.7438 9394.8463
25"
Mark of 0.75"
19 from edge and 0% 9394.8463 9394.8463
pilot holes
Remove of 0.75"
20 router 1 9394.8463 9300.8979
rounded edge
drill
21 Drill the holes 1 9300.8979 9207.8889
press
22 Sand all surfaces disc sand 9207.8889 9207.8889
260 Back (1)
No. (%) In Out
Mark the bars to
42 131.3956 131.3956
length 9.5"
Cut steel bar to cut off
43 1% 131.3956 123.5776
Length 9.5" saw
Attach canvas
44 917.0134 917.0134
sling to Bars
4.35
270 Seat (1)

No. (%) In Out
Mark the bars to
39 length 17.25" 265.4456 265.4456
Cut steel bar to cut off

40 1 265.4456 229.9423
Length 17.25" saw
Attach canvas sling
41 1743.7929 1743.7929
to Bars
Sub Assembly Arm and Leg (2)
No. (%) In Out
Attach 4 dowels
A-1 (1.5") into edges of 5130.1095 5130.1095
arm using glue
Assemble front and
A-2 circ. saw 1 18284.2365 18101.3941
rear legs to arm
Assemble side
A-3 stretcher using 4 2 20367.3240 19959.9776
dowels (4") & glue
Inspect and fill all
I-1
gaps with wood 19959.9776 19959.9776
O-28
filler
Apply two coat of
29 polyutethane gun spray 19959.9776 19959.9776
Assembly CAC
No. (%) In Out
Connect 3 stretchers
to 2 SA Arm and
A-4 Leg using washer, 24669.2050 24669.2050
hanger and cap nut
Fill all gaps with
36 24669.2050 24669.2050
wood filler
Sand the filler
37 24669.2050 24669.2050
contained
38 Final coating gun spray 24669.2050 24669.2050
A-5 Assemble the seat 1 26412.9979 26148.8680

Assemble the
A-6 1 27065.8814 26795
back
I-2 Final inspection 26795 26795
O-45 Packaging 26795 26795
4.36
4.4. Aggregate of the Material Flow
Aggregate of the material flow is to divide the flow of material based on from-to
deptpartment. All of material flow and assembly are collected in one flow from-to
department. Below are shown the results.
4.4.1. Aggregate of the Material Flow of Part

Below are shown the aggregate of the material flow of part.
Table 4.5. Aggregate Material Flow of Part
Part Total Weight

No From To Code (kg)
142 Feet 1548.9313

143
Pedestal 398.5600
Support
141
Pedestal 3084.1617
Piece
112
Frame Top 821.4868
Surface C
113
Frame Top 985.7842
Surface B
Assembling, 120 Base 5304.4464

1 Storage Marking, Surface
Gluing 111 Top
Surface 5531.8976
Slat
261 Back 13.4077
Steel Rod
271 Seat 27.0863
Steel Rod
220 874.6640
Stretcher
230 Side 462.7852
Stretcher
210 Front 858.5120
Leg
250 Rear 1520.2817
Leg
240 Arm 958.2585
Total 22390.2635
4.37
Table 4.5. Aggregate Material Flow of Part (continued)
142 Feet 1548.9313

143
Pedestal 398.5600
Support
141
Pedestal 3084.1617
Piece
Assembling, 112
2 Marking, Circular Saw Frame Top 821.4868
Gluing Surface C
113
Frame Top 985.7842
Surface B
111 Top
Surface 5531.8976
Slat
Total 12370.8217
142 Feet 1405.6552

143
Pedestal 3.2365
Support
141
Assembling, Pedestal 2747.9881
3 Circular Saw Marking, Piece
Gluing
210 Front 410.8533
Leg
250 Rear 958.6578
Leg
240 Arm 539.5594
Total 64575.6351
112
Frame Top 782.7742
Surface C
4 Circular Saw Jointer
113
Frame Top 935.8788
Surface B
Total 16842.8001
4.38
120 Base 4039.2185
Surface
220 485.3873
Stretcher
230 Side 233.5529
Stretcher
5 Jointer Circular Saw
210 Front 415.0034
Leg
250 Rear 968.3412
Leg
240 Arm 545.0095
Total 65527.8249
142 Feet 1405.6552

143
Assembling, 3.2365
Pedestal
6 Marking, Drill Press
Support
Gluing
141
Pedestal 2747.9881
Piece
Total 45866.7436
142 Feet 1391.5986

141
Pedestal 2720.5082
Piece
220 480.5334
Stretcher
Disc Sand &
7 Drill Press 230 Side 231.2173
Filling
Stretcher
210 Front 402.6774
Leg
250 Rear 939.5805
Leg
240 Arm 523.4806
Total 65558.0412
120 Base 5304.4464
Surface
220 874.6640
Stretcher
230 Side 462.7852
Assembling,
Stretcher
8 Marking, Jointer
210 Front 858.5120
Gluing
Leg
250 Rear 1520.2817
Leg
240 Arm 958.2585
Total 66652.7754
4.39
112
Frame Top 767.1188
Surface C
Disc Sand &
9 Jointer
Filling 113
Frame Top 926.5200
Surface B
Total 16597.6602
10 Circular Saw Disc Sand & 111 Top 5305.4356
Total 51993.2687
220 480.5334
Stretcher
11 Circular Saw Drill Press
230 Side 231.2173
Stretcher
Total 6975.1574
210 Front 410.8533
Leg
Assembling,
Marking, 250 Rear 958.6578
12 Router
Gluing Leg
240 Arm 539.5594
Total 18708.8915
210 Front 406.7448

Leg
13 Router Drill Press 250 Rear 949.0712
Leg
240 Arm 528.7682
Total 18468.9258
261 Back 13.4077

Assembling,
Steel Rod
14 Marking, Cut off Saw
271 Seat 27.0863
Gluing
Steel Rod
Total 357.0907
Disc Sand & 220 480.5334

15 Gun Spray
Filling Stretcher
210 Front 402.6774
Leg
Total 8655.4655
261 Back 12.6100

Steel Rod
16 Cut off Saw Attaching
271 Seat 23.4635
Steel Rod
Total 353.5198
4.40
4.4.2. Aggregate of the Material Flow of Assembly
Below are shown the aggregate of the material flow of assembly.
Table 4.6. Aggregate Material Flow of Assembly
No From To Part Code Total

Pedestal 666.5245
Circular
1 Jointer Top Surface 472.6661
Saw
Assembly
Total 11164.0678
Pedestal 659.8593
Assembly
Assembling,
Top Surface 3918.8498
2 Circular Saw Marking,
Assembly
Gluing
SA Arm & 1847.0810
Leg
Total 62972.7428
Pedestal 659.8593
Assembling, Assembly
Assembling, Marking, Top Surface 5194.4201
3 Marking,
Gluing Assembly
Gluing
CAC 2668.2518
Total 83520.8058
Pedestal 998.4744
Assembly
Assembling, Marking, Disc. Sand SA Arm & 2036.7324
4
Gluing & Filling Leg
CAC 2517.2658
Total 55671.0434
Pedestal 998.4744
Assembly
Disc. Sand Top Surface 5194.4201
5 Disc. Sand & Filling
& Filling Assembly
CAC 2517.2658
Total 86616.3828
Pedestal 998.4744
Assembly
Top Surface 5194.4201
6 Disc. Sand & Filling Gun Spray Assembly
SA Arm & 2036.7324
Leg
CAC 2517.2658
Total 106576.3603
4.41
Table 4.6. Aggregate Material Flow of Assembly (continued)
Assembling, Marking, Top Surface

7 Drill Press 4391.5159
Gluing Assembly
Total 4391.5159
8 Drill Press 4347.6007
Gluing Assembly
Total 4347.6007
9 Gluing Table Saw 4347.6007
Assembly
Total 4347.6007
10 Table Saw 4347.6007
Gluing Assembly
Total 4347.6007
11 Inspection Gun Spray ROT 6130.9655
CAC 2036.7324
Total 8167.6979
12 Gun Spray Circular Saw ROT 6130.9655
Total 6130.9655
13 Circular Saw Packaging ROT 6008.3462
Total 6008.3462
CAC 2734.2064
14
Packaging Warehouse ROT 6008.3462
Total 8742.5526
Assembling, Marking,
15 Gun Spray CAC 2517.2658
Gluing
Total 2517.2658
16 Inspection CAC 4770.9388
Gluing
Total 4770.9388
17 Inspection Packaging CAC 2734.2064
Total 2734.2064
18 Assembling, Marking, Gluing Circular Saw SA Arm and Leg 523.4806
Total 523.4806
Below are shown the summary of part and asssembly’s material flow from and to
department with the total weight. It will be inputted to from-to chart.
Table 4.7. Summary Aggregate Material Flow
No From To Total Weight (N)

Assembling, Assembling, Marking, 8522.531202
1 Marking, Gluing Gluing
Assembling, 5552.472599
2 Disc. Sand & Milling
Marking, Gluing
Table 4.7. Summary Aggregate Material Flow (continued)
3 Drill Press
Marking, Gluing
4 Table Saw
Marking, Gluing
5 Marking, Gluing Inspection
6 Jointer
Marking, Gluing
7 Router
Marking, Gluing
8 Cut off Saw
Marking, Gluing
9 Circular Saw
Marking, Gluing
10 Circular Saw Assembling, Marking, Gluing 12491.7405
11 Circular Saw Jointer 1718.653072
12 Circular Saw Disc Sand & Milling 5305.435584
13 Circular Saw Drill Press 711.7507506
14 Circular Saw Packaging 6008.34622
15 Cut of Saw Attaching 36.07345317
Disc. Sand & 8710.160292
16 Milling Disc. Sand & Milling
Disc. Sand & 11630.10347

17 Milling Gun Spray
18 Drill Press Assembling, Marking, Gluing 4347.600698
19 Drill Press Disc Sand & Milling 6689.596042

20 Gun Spray Circular Saw 6130.96553
21 Gun Spray Assembling, Marking, Gluing 2517.265817
22 Inspection Gun Spray 8167.697935

23 Inspection Packaging 2734.206382
24 Jointer Circular Saw 7825.703338
25 Jointer Disc Sand & Milling 1693.638799
26 Packaging Warehouse 8742.552602
27 Router Drill Press 1884.584261
28 Storage Assembling, Marking, Gluing 22390.26354
29 Table Saw Assembling, Marking, Gluing 4347.600698
4.43
4.5. From to Chart and Flow Metric
Below are shown the from to department chart. The total weight (in Newton) between two department are inputted into from-to chart.
Table 4.8. From to Chart
Storag Assemblin Attachin Cut off Gun Inspectio Packagin Warehou

From\To Jointer Circ. Saw Router Drill Press Disc. Sand Table saw
e g g saw Spray n g se
22390.263
Storage 54
Assembli 9978.947 12894.302 1909.0705 8548.3957 5552.4725 40.494003 4347.6006 4770.938
ng 8 26 6 12 99 98 8
Attaching
7825.7033 1693.6387
Jointer 38 99
12491.740 1718.65 711.75075 5305.4356 6008.346
Circ. Saw 5 06
Router 1884.5843
Drill 4347.6006 6689.596
Disc. 11630.1
Cut off 36.07345
saw 3
Gun 2517.2658 6130.9655
Spray 17 3
Table saw 4347.6006
98
8167.7 2734.206
Inspection
Packagin 8742.55
g
Warehous
4.44
From to chart is a chart that shows the material flow from one department to
the other department. The From-to-Chart above shows the total weight in
Newton that should be moved from one department to other department.
The value of aggregate weight has been calculated from previous section. For
example the total material flow from department Assembling, Marking, and
Gluing to Disc. Sand & Milling is 55671.04336.
There is no value in the yellow diagonal because the arrival and the
destination of the material is the same. For example, Assembling, Marking,
and Gluing to Assembling, Marking, and Gluing because it come and head
towards the same department. The value that located above the yellow
diagonal is forward movement and the value that located below the yellow
diagonal is backward movement. The value will be calculated per diagonal.
The detail calculation of the total moment shows in the table below.
Table 4.9. Forward and Backward Movement Analysis
Forward Movement Backward Movement
Diagonal Total Diagonal Total

Movement Penalty Movement
Row Movement Row Movement
1 50266.90616 50266.90616 1 2 1718.653072 3437.306144
2 22320.80205 44641.60411 2 2 8167.697935 32670.79174
3 18199.73784 54599.21353 3 2 12491.7405 74950.44299
4 3602.709359 14410.83744 4 2 0 0
5 8548.395712 42741.97856 5 2 10478.56623 104785.6623
6 5552.472599 33314.8356 6 2 36.07345317 432.881438
7 40.49400339 283.4580238 7 2 0 0
8 6008.34622 48066.76976 8 2 2517.265817 40276.25307
9 4347.600698 39128.40628 9 2 4347.600698 78256.81256
10 4770.938786 47709.38786 10 2 0 0
11 0 0 11 2 0 0
12 0 0 12 2 0 0
13 0 0 13 2 0 0
Total 375163.3973 Total 334810.1502
Total
709973.5475
Moment
4.45
For the forward movement, every diagonal will be multiplied by penalty of 1 until
13 according to the diagonal row. For example the movement of diagonal row 1
of the forward movement is 22390.26354 +7825.703338+1884.5843+ 6689.596+
2734.206+ 8742.55 equals to 50266.90616. And then that value will be multiplied
by the penalty of 1 so become 50266.90616. The total of all forward movement
is 375163.3973.
For the backward movement, every diagonal will be multiplied by the diagonal
row (1 until 12) and also the penalty of 2 because of the backward movement
will cost greater than forward movement. For example the movement of
diagonal row of 2 of the backward movement is 8167.697935. And then that
value will be multiplied by the diagonal row which is 2, and the penalty of 2. So
the total movement is 32670.79174. The total of all backward movement is
334810.1502. So, the total moment of the From- to-chart is the summation of
the total forward and total backward movement which is 709973.5475 kgs.
On the next page, shown the flow metric from and to department. Flow metric is
sum of from and to department. The detail of flow metric are shown on the next
page.
Table 4.10. Flow Metric
Cut off Gun Table Inspec Packa Warehou
From Metric Storage Assembling Attaching Jointer Circ. Saw Router Drill Press Disc. Sand saw Spray saw tion ging se
22390.26354
Storage
22390.26 9978.94 25386.04 1909.07 12895.9964 5552.473 40.494 2517.26 8695. 4770.
Assembling 8 1 5817 201 939
36.07345
Attaching
9978.947838 9544.356 1693.639
Jointer
25386.04276 9544.35 711.750751 5305.436 6130.96 6008.
Circ. Saw 6 553 346
1909.07056 1884.58426
Router
12895.99641 711.7508 1884.58 6689.596
Drill Press 4
5552.472599 1693.63 5305.436 6689.59604 11630.1
Disc. Sand 9 0347
40.49400339 36.07345
Cut off saw
8167.
2517.265817 6130.966 11630.1 698
Gun Spray
8695.201395
Table saw
8167.69 2734.
4770.938786 7935 206
Inspection
6008.346 2734. 8742.552
Packaging 206 602
8742.
553
Warehouse
4.47
4.6. Activity Relationship Chart and Diagram (ARC and ARD)
Activity Relationship Chart and Diagram is an activity or activity between each part
that is important or not the proximity of the room.
In a factory organization there must be a relationship between one activity with other
activities that are very important and always close together for the smoothness of its
activities. Therefore created an Activity Relationship, which will be known how
relationship that occurs and must meet in accordance with the tasks and relationships
that support.
The list of all departments of the company and supporting facilities adopted from
the space requirement report. After the list is known the first step is define the
criteria for assigning the closeness relationship and criteria as the reason for the
relationship values in on the relationship chart. The closeness relationship can be
rated as table below.
In general, the Activity Relationship Chart can be defined as follows, which is the
ideal technique for the regularity of regularity between each group of interconnected
activities. ARC and ARD will relate to the organizational structure and counting
tables. The main purpose of ARC is to know the close relationship of each group of
activities in this case the factory organization.
Table 4.11 Closeness Relationship Value
Code Closeness Line

A Absolutely necessary
E Especially important
I Important
O Okay
U Unimportant No line
X Undesirable
4.48
Based on the table of closeness relationship value above, the value can be divided into
several type which are absolute necessary with code A, especially important with
code E, important with code I, Okay with code O, unimportant with code U and code
X for undesirable. The value can be stated as absolute necessary if the room really
need to contiguous one and another. To decide whether relation code to use A, E, I,
O, U, or X there should be a reason or more for placing one of relation code there.
There are 5 reasons that used for placing relation code in Activity Relationship
Chart. Below is table of reasons.
Table 4.12 Reason of Relationship Chart
Code Reason
1 Flow of information and document is high
2 Flow of information and document is low
3 Necessary in the same area
4 Not necessary in the same area
5 Personnel relationship intensity
6 high frequency to use
4.6.1. Office
The activity relationship chart below have a content of 13 facilities in the office, the
data get from the space requirement report. From those 13 facilities, it can be
generated to activity relationship chart. In the activity relationship chart, it shows the
relationship between each facility. The figure below shows the activity relationship
chart.
Figure 4.1 Activity Relationship Chart for Office
4.50
Table 4.13 Activity Relationship Worksheet of Office
No. Room A E I O U X
1 President 2,3 4,10 13 5,6,8 7,9 11,12
2 General Manager 1,3 4,10 13 5,6,7,8 9 11,12
3 Secretary 1,2 - 4 7,8,10, 5,6,9 12
11,13
4 Manager - 1,2,5,6,7, 3 10,11,13 9,12 -
8
5 Manufacturing - 4,11,13 10 1,2,6,12 3,7,8,9 -
Department
6 Finance and Purchase - 4,11,13 10 1,2,5,7,8 3,9 -
Department ,12
7 Human Resources - 4,11,13 8,10 2,3,5, 1,9 -
Department 6,12
8 Marketing and Sales - 4,11,13 7,10 1,2,3 5,9 -
Department 6,12
9 Lobby - - 13 11 1,2,3,4,5,6, -
7,8,10,12
10 Meeting - 1,2 5,6,7,8,13 3,4,11,1 9 -

2
11 Pantry - 5,6,7,8 12 3,4,9 - 1,2
10,13
12 Janitor 13 - 11 5,6,7, 4,9 1,2,3
8,10
13 Restroom 12 5,6,7,8 1,2,9,10 3,4,11 - -
Table above shows the relationship between each room. Most of the entire
relationship is categorized Important which has a code I and followed by Okay which
has the code O. Each relationship has its reason why the relationship between each
room is categorized like that. For example, the relationship between President
room and General Manager room is categorized as absolutely necessary because
information flow high, necessary in the same area and the personnel relationship
intensity. Then these two rooms should be close enough to exchange information,
communication, etc. and there only 5 rooms that does not have good relationship
(undesirable).
4.51
Human
Resources President
Secretary Room
Department Director Room
General
Manager
Manager
Room
Room
Finance and
Purchase
Department
Restroom Meeting Room
Marketing and
Sales
Department
Janitor Pantry
Manufacturing
Department Lobby
Figure 4.2 Activity Relation Diagram of Office by Line
Figure above shows the figure of activity relationship diagram of office. The main
office itself consist of President room, General Manager room, Manager room,
Secretary room, Manufacturing room, Finance and purchase room, Human Resources
room, Marketing and Sales room, Lobby, Meeting room, Pantry, Janitor room and
Restroom.
Activity Relationship Worksheet used to be the input for Activity Relationship

Diagram, the Activity Relationship Diagram made according the data from the
Activity
Relationship Worksheet. The important relationship or A will defined as blue line, E
will defined as red line, I will defined as yellow line, O will defined as purple line,
U will not defined with line and X will defined as purple line. Based on the
closeness rating line, the layout of plant factory are designed based on the figure
above.
After create the Activity Relationship Chart and Diagram, the next step is creating the
Activity Template Block Diagram, that will arrange the rooms with high relationship
nearly each other. The Activity Template Block Diagram also seems like a rough map
of rooms’ arrangement.
Figure 4.3 Activity Relationship Diagram of Office
4.6.2. Whole Plant

After create the ARC of office, the nest step is create the ARC for a plant factory. The
code of closeness relationship with reasons is shown in the table below.
Table 4.14 Reason of Closeness Ratings
Code Reason
1 Good flow information
2 Bad flow information
3 Necessarily in the same area
4 Not necessarily in the same area
5 Material Flow
6 Frequency of use is high
7 Noisy
Based on the closeness ratings, the Activity Relationship Chart of plant factory is
created. The closeness rating of A means absolutely necessary, E means especially
important, I means important, O means Okay, U means Unimportant, and X means
Undesirable. The code are used to show the reason of closeness ratings. The high
closeness rating means the relationship are closed. The important relationship
between production floor, storage, warehouse, shipping and receiving area, and truck
parking lot. The divisions are important each other because it is the material flow.
Therefore the location of this department must close since the relationship are closed.
The Activity Relationship Chart as a tool before making the layout of the plant
factory. The ARC of plant factory are shown in the figure below.
Figure 4.4 Activity Relationship Diagram of Plant Office
Based on the figure above, the Activity Relationship worksheet each department from
production floor until shipping and receiving are shown in the table below.
Table 4.15 Activity Relation Worksheet Plant Factory
No Room A E I O U X
1 Production 2,5 4,9,11 7,8,12,13 3,6,10 8 9
Floor
2 Warehouse 11,13 - - - 2,3,4,5,6,7,8,9,11 -
3 Office - 4 6,9,10 1,7,13 2,5,8,11,12 -
4 Locker - 1,3 - 9 2,5,6,7,8,10,11,12,13 -
Room
5 Storage 1 11 - 8 2,3,4,6,7,9,10,12,13 -
6 Cafeteria - - 3 1,8 2,4,5,7,10,11,12,13 9
7 Health Care - - 1 3,8 2,4,5,6,10,11,12,13 9
8 Restroom - - 1 5,6,7,9 2,3,4,10,11,12,13 -
9 Musholla - - 3 4,8,10 2,5,11,12 1,6,7
10 Car Parking - - 3 1,9 2,4,5,6,7,8,11,12,13 -
Lot
11 Truck 2 1 - - 3,4,6,7,8,9,10,12,13 -
Parking Lot
12 Motorcycle - - 1 - 2,3,4,5,6,7,8,9,10,11,13 -
Parking Lot
13 Shipping 2 - 1 3 4,5,6,7,8,10,11,12 9
and
Receiving
Since A is the highest close relationship, based on the table above define that the
production floor department must located near with warehouse and storage. Then, the
warehouse department must located near truck parking lot and shipping and
receiving. Truck parking lot must located near warehouse and motorcycle parking lot
must located with shipping and receiving. The layout of ARC plant factory is shown
in the figure below.
Figure 4.5 Activity Relationship Diagram of Plant Factory
The important relationship or A will defined as blue line, E will defined as red line, I
will defined as yellow line, O will defined as purple line, U will not defined with
line and X will defined as purple line. Based on the closeness rating line, the layout
of plant factory are designed based on the figure below.
Car Parking
Musholla
Lot
Motorcycle
Parking Lot Locker Room Office Cafeteria
Truck Parking Production

Lot Warehouse Health Care
Floor
Shipping and
Receiving Storage Restroom
Figure 4.6 Activity Relationship of Plant Factory by Line
4.58
CHAPTER V
CONCLUSION
The total moment of the From- to-chart is the summation of the total
forward and total backward movement which is 709973.5475 kgs.
Activity Relationship Chart and Diagram is an activity or activity between
each part that is important or not the proximity of the room. The activity
relationship chart below have a content of 13 facilities in the office, the data
get from the space requirement report. From those 13 facilities, it can be
generated to activity relationship chart. In the activity relationship chart, it
shows the relationship between each facility. After create the ARC of office,
the nest step is create the ARC for a plant factory. The closeness rating of A
means absolutely necessary, E means especially important, I means
important, O means Okay, U means Unimportant, and X means Undesirable.
4.59
REFERENCES
Heragu,Sunderesh S. (2008). Facility Design, Third Edition. USA : CRC

Press.
Freivalds,Andris and Niebel, Benjamin. (2009). Niebel’s Methods,

Standards, andWork Design, Twelfth Edition.New York : McGraw-Hill.
Module 5 : Layout Design and
Material Handling Cost
4/3/2018
PROJECT ASSIGNMENT
Created by,
2. Kelvin (0042
Phone (021) 8910 9762-6 - Fax (021) 8910 9768 - Email:
TABLE OF CONTENTS
CHAPTER I ......................................................................................................... 5.2
INTRODUCTION ............................................................................................... 5.2
1.1. Background ........................................................................................... 5.2
1.2. Objectives .............................................................................................. 5.2
1.3. Steps ...................................................................................................... 5.3
1.4. Tool and Equipment .............................................................................. 5.3
CHAPTER II ........................................................................................................ 5.4
LITERATURE STUDY....................................................................................... 5.4
2.1. Facility Layout Design .............................................................................. 5.4
2.3. Computerized Relative Allocation of Facilities Technique (CRAFT) ..... 5.5
2.4. Material Handling ..................................................................................... 5.6
2.5. BLOCPLAN.............................................................................................. 5.8
CHAPTER III ...................................................................................................... 5.9
DATA COLLECTION......................................................................................... 5.9
3.1. Space Requirements for Production Floor ................................................ 5.9
3.2. Front to Chart for Production Floor ........................................................ 5.10
3.3. Activity Relationship Diagram for Office and Whole Plant ................... 5.11
CHAPTER IV .................................................................................................... 5.13
DATA ANALYSIS ............................................................................................ 5.13
4.1 Generating Whole Plant Factory .............................................................. 5.13
4.2. Generating Office Layout ....................................................................... 5.21
4.3. Layout Design and AAD for Production Floor....................................... 5.29
4.4. Material Handling Cost ........................................................................... 5.37
4.5. Calculation of Material Handling Tool for One Hour ............................ 5.55
4.6. Calculation of Production Cost ............................................................... 5.56
4.6.1. Direct and Indirect Labor Cost............................................................. 5.56
4.6.2. Direct/Indirect Material Cost ............................................................... 5.58
4.6.3. Investment on Machinery and Equipment Cost ................................... 5.60
4.6.4. Other Expense ...................................................................................... 5.69
4.6.5. Production Cost per Unit Product ........................................................ 5.70
CHAPTER V...................................................................................................... 5.71
CONCLUSION .................................................................................................. 5.71
REFERENCES................................................................................................... 5.72
1.1.Background
5.1
CHAPTER I
INTRODUCTION
Facility planning layout is very important, because every people and activity in
the manufacturing company usually have to deal with the layout in a long time,
any error in the determination of the current layout will be result in very high cost.
The mistakes should only occur during the planning, long before the activities
and equipment carried. Therefore, planning layout carefully is very important.
Facility planning is the decision regarding the location and composition of the
layout. Almost all studies of facility layout aim to minimize the total cost. The
facility planning layout also determine the efficiency of the production process
and influence how long the survival or success of an industrial workplace.
Besides, setting a good factory layout design can simplify the production process
and also helps when there are plans to expand the plant in the future.
In a factory, the layout of the production facilities and the work area is a basic
element which is very important for a smooth production process. Facility
planning layout is very important and often problems are arise in there. The most
important issue is whether the setting of all the production facilities have been
made as optimize as possible so that it can achieve the most efficient production
process and can support the continuity and smooth production process.
This report is written as the fourth assignment in Facility Design subject,

analyzing the previous report furthermore regarding on facility planning layout.
Some details of the facility planning layout for analyzing would be provided in
this report, such as the layout design for the whole factory, office, and production
floor, and also the material handling cost.
1.2.Objectives
To determine the most efficient and effective factory planning layout using
layout algorithm
5.2
To determine the most efficient and effective office planning layout using
layout algorithm
To determine the most efficient and effective production floor planning
layout using layout algorithm
To determine the material handling equipment that is used and the material
handling cost
1.3.Steps
There are several steps to do this report:
Acquire the data needed from the previous report

Generate the factory and office planning layout by using BLOCPLAN
software
Generate the production floor planning layout by using CRAFT software
Calculate the distance between the department in production floor
Determine which material handling equipment that is used
Calculate the material handling cost
Finalize the report
Revise the report based on the advises and suggestion given by the lecturer
1.4.Tool and Equipment

There are several tool and equipment to do this report:
BLOCPLAN software is used to generate the factory and office planning

layout
CRAFT software is used to generate the production floor planning layout
Microsoft Excel is used to calculated the material handling cost
CHAPTER II
LITERATURE STUDY
2.1. Facility Layout Design

Facilities layout design refers to the arrangement of all equipment, machinery, and
furnishings within a building envelope after considering the various objectives of
the facility. The layout consists of production areas, support areas, and the
personnel areas in the building (Tompkins, J. A., et al.,1996). The requirement for
facilities layout design arises both in the process of designing a new layout and in
redesigning an existing layout. The requirement in the former case is obvious but
in the latter case it is because of many developments as well as many problems
within the facility such as change in the product design, obsolescence of existing
facilities, change in demand, frequent accidents, more scrap and rework, market
shift, introduction of a new product etc.
2.2. Automated Layout Design Program (ALDEP)
Automated Layout Design Program (ALDEP) is one of the types of construction

methods. ALDEP is basically a construction algorithm but it can also be used to
evaluate two layouts. According to Tompkins (1996), designing with layout design
of complex algorithms using complex algorithms ALDEP is divided into two
procedures, i.e. the procedure of selection and placement procedures. First,
procedure of selection, steps being taken in the selection procedure which is
chosen department first entry randomly and to department further selected based
on proximity highest value. Second, placement procedure, the first stage begin
with the placement of the selected department on the upper left hand corner
then proceeded towards the bottom and then followed the pattern of vertical sweep
patterns.
The basic inputs to ALDEP are length and width of facility, area of each
department, minimum closeness preference (MCP) value, sweep width,
relationship chart showing the closeness rating, location and size of any restricted
area. Here are the procedures adopted for using ALDEP:
Step 1: Input the following data which are length and width of facility, area
of each department, minimum closeness preference value, sweep width,
closeness rating from relationship chart, location and size of restricted area
Step 2: Choose one department randomly and placed in the layout
Step 3: The algorithm uses minimum closeness required between
departments for the selection of departments to be placed with an earlier
placed department. Choose the department having maximum closeness
rating (A or E)
Step 4: If all the departments are placed in the layout, go to the next step
Step 5: Calculate the total score of the layout
Step 6: If the total score required is the acceptable score, then go to next step
Step 7: Print the current layout and the corresponding score.
2.3. Computerized Relative Allocation of Facilities Technique (CRAFT)

Computerized Relative Allocation of Facilities Technique (CRAFT) is a tool that
is used to help improve the existing layout of the facilities (reallocation). Craft
algorithm is developed by Armour and Buffa. The facility is improved by swaping
two or more departments to help arrange the facility to an optimal floor plan. The
algorithm continues until no further interchanges are possible to reduce the
transportation cost. Inputs of CRAFT are from-to-chart, cost matrix, distance
(determined), and initial layout. CRAFT is used when the number of departments
is enermous that the manual computation would be nearly impossible to do.
CRAFT is basically used with process layout approach, which also known as a
fuctional layout that usually used in job shops or a batch production facility.
CRAFT uses a pair of wise exhange algorithm that may not return the optimal
result because the final solution depends on the initial layout of the plant. Rather
than examine all the possible swaps, CRAFT only considers the swap of adjacent
department pair or pairs that have the same area.
CRAFT attempts to minimize transportation cost, where the transportation is the

result of multiplication between flow, distance, and unit cost. It requires the
assumption that move costs are independent of the equipment utilization and
linearly related to the length of the move. Distance metric used is the rectilinear
distance between department centroids. CRAFT is a path-oriented method, so the
final layout is dependent in the initial layout. Therefore, a number of different
initial layouts should be used as input to the CRAFT procedure. CRAFT allows
the use of dummy departments to represent fixed areas in the layout.
In determining distance between two departments, the following characteristics

are needed to be noted:
Distance (A,B) = rectelinear distance between centroids of departments A

and B
Let the centroid of department A is (xA, yA) and centroid of department B is
(xB, yB)
Then, the distance between departments A and B, Dist(A,B)
= |xA − xB| + |yA − yB|...............................................................................(2.1)
Distance traveled from department A to B = Distance (A,B) x Number of
trips from department A to B
Total distance traveled is obtained by computing distance traveled between
every pair of departments, and then summing up the results
2.4. Material Handling

Material handling is an activity that uses the right method to provide the right
amount of the right material at the right place, at the right time, in the right
sequence, in the right position and at the right cost (Tompkins et al, 2003).
Material handling has 10 principles. These principles were developed by MHIA.

The 10 principles are:
1. Planning
A material handling plan is a prescribed course of action that is defined in
advanced of implementation, specifying the material, moves, and the
method of handling.
2. Standardization
Standardization is a way of achieving uniformity in the material handling
methods, equipment, controls and software without scarifying needed
flexibility, modularity, and throughput.
3. Work
The measure of work is material handling flow (volume, weight, or count
per unit of time) multiplied by the distance moved.
4. Ergonomic
Ergonomics is the science that seeks to adapt work and working conditions
to suit the abilities of the worker.
5. Unit Load
A unit load is one that can be stored or moved as a single entity at one
time, regardless of the number of individual items that make up the load.
6. Space Utilization
Effective and efficient use must be made of all available space.
7. System
A system is a collection of interdependent entities that interact and form a
unified whole.
8. Automation
Automation is a technology for operating and controlling production and
services activities through electromechanical devices, electronics, and
computer based system with the result of linking multiple operations and
creating a system that can be controlled by programmed instructions.
9. Environmental
The environmental principle in material handling refers to conserving
natural resources and minimizing the impact of material handling activities
on the environment.
10. Life Cycle Cost
Life cycle cost includes all cash flows that occur between the time the first
dollar is spent on the material handling equipment or method and its
disposal or replacement.
There are some considerations in material handling system design:
1. Material characteristics
Table 2.1. Material Characteristics
2. Flow Rate
3. Plant Layout
2.5. BLOCPLAN
BLOCPLAN is an interactive program developed by Donaghey and Pire (1991)
that can develop a single or multistory layout and has a number of useful features.
Relationship Chart or From to Chart as input data can be used as a construction
type or improvement type algorithm (may not be possible to capture the exact
layout). The layout cost can be determined by distance based objective or
adjacency-based objective.
BLOCPLAN assign all the departments to the layout and calculate the width of the
band by adding the area of the departments and dividing it by the building length.
Calculate the length of the individual departments by dividing area of the
departments by the width of the band.
BLOCPLAN implicitly assume all cij’s are equal to 1.0. Input data given in the
form of a relationship chart, BLOCPLAN convert it using a closeness rating A=64,
E=16, I=4, O=1, U=0, X=-1024. Adjacency score is not affected by U
relationships and adversely affected by X relationship. Even if a From to Chart is
given BLOCPLAN computes the adjacency score on the basis of the Relationship
Chart. BLOCPLAN provides REL-DIST score based on numerical closeness
rating and distance.
CHAPTER III DATA
COLLECTION
3.1. Space Requirements for Production Floor

Production floor of Wood Manufacture Company consist of 14 departments and
additional room which are for maintenance and tools. Each of department has their
type of machine and equipment. Below are shown the area requirements needed
for each department and additional room, such as maintenance and tools (Note: F
mean Fixed Position, V mean Variable Position).
Table 3.1. Space Requirements for Production Floor
No. Department F/V Total Space (ft^2)
1 Storage F 4960.0000
Marking, Assembling, & Gluing V

2 4030.0083
3 Jointer V 209.1471
4 Attaching V 103.3335
5 Circ.Saw V 419.7925
Drill Press V
6 4822.2322
7 Router V 86.1113
8 Disc.Sand & Fillling V 930.0019
9 Table Saw V 26.3501
10 Cut off Saw V 1051.4188
11 Gun Spray V 82.6668
Inspection F
12 51.6668
13 Packaging F 51.6668
14 Maintenance Room F 516.6677
15 Tools Room F 344.4452
16 Warehouse F 8848.2400
Total 26533.7490
3.2. Front to Chart for Production Floor
Below are shown from-to department chart. The total weight (in kgs) between two departments are inputted into from-to chart.
Table 3.2. From to Chart
Storag Assemblin Attachin Cut off Gun Inspectio Packagin Warehou

From\To Jointer Circ. Saw Router Drill Press Disc. Sand Table saw
e g g saw Spray n g se
22390.263
Storage
54
Assembli 9978.947 12894.302 1909.0705 8548.3957 5552.4725 40.494003 4347.6006 4770.938
ng 8 26 6 12 99 98 8
Attaching
Jointer 7825.7033 1693.6387
Circ. Saw 12491.740 1718.65 711.75075 5305.4356 6008.346
Router 1884.5843
Drill 4347.6006 6689.596
Disc. 11630.1
Cut off 36.07345
saw 3
Gun 2517.2658 6130.9655
4347.6006
Table saw
98
8167.7 2734.206
Inspection
Packagin 8742.55
g
Warehous
5.10
3.3. Activity Relationship Diagram for Office and Whole Plant
The activity relationship chart below have a content of 13 facilities in the office,
the data get from the space requirement report. From those 13 facilities, it can be
generated to activity relationship chart. In the activity relationship chart, it shows
the relationship between each facility. The figure below shows the activity
relationship chart.
Figure 3.1 Activity Relationship Chart for Office
5.11
Based on the closeness ratings, the Activity Relationship Chart of plant factory is
created. The closeness rating of A means absolutely necessary, E means
especially important, I means important, O means Okay, U means Unimportant,
and X means Undesirable. The code are used to show the reason of closeness
ratings. The high closeness rating means the relationship are closed. The important
relationship between production floor, storage, warehouse, shipping and receiving
area, and truck parking lot. The divisions are important each other because it is the
material flow. Therefore the location of this department must close since the
relationship are closed. The Activity Relationship Chart as a tool before making
the layout of the plant factory. The ARC of plant factory are shown in the figure
below.
Figure 3.2 Activity Relationship Diagram of Whole Plant

CHAPTER IV
DATA ANALYSIS
4.1 Generating Whole Plant Factory

The layout of Waltz Company will generate using BlocPlan software. Before the
layout is create, the data will be input in BlocPlan such as the total area of each
department and activity relationship chart each department. The data of total area
already measured in previous report in space requirements report. The area in feet-
square. The data of whole Waltz Plant Factory are shown in the figure below.
Figure 4.1. Data of Whole Factory Area
Based on the figure above, the total area of whole factory is 100,700.29 ft2. The
average area of whole factory is 7746.2 ft2. The standard deviation area is 9175 ft2.
The average area and standard deviation area are automatically calculated by the
software.
Figure 4.2 Activity Relationship Diagram of Whole Factory
After input the all of the total area, then the activity relationship chart between
departments will be input. As state in the figure, “A” is absolutely essential, “E” is
essential, “I” is important, “O” is Ordinary, “U” is Unimportant, and “X” is
undesirable.
Figure 4.3 Score Vector of Whole Factory
Based on the score vector of each relationship, then the total score vector of each
department are calculated. The total score vector of production floor is 31. The
total score vector of warehouse is 30. The total score vector of office is 14. The
total score vector of locker room is 11. The total score of storage is 16. The total
score of cafeteria is -6. The total score of health care is -6. The total score vector
of restroom is 6. The total score vector of Musholla is -35. The total score vector
of car parking lot is 4. The total score vector of truck parking lot is 20. The total
score vector of motor cycle parking lot is 2. And the total score vector of shipping
and receiving area is 3.
After all the data are input and measured. Then, the output is the layout of the
whole factory. The ratio of the layout is 1:1 (Length: Width). The total score will
be shown. The total score is near “1” means the layout is good.
Figure 4.4 The Initial Layout of Whole Factory
From the figure above, the adjacent score of initial layout is 0.87. The score is
already good since the value is near 1.
Figure 4.5 The First Iteration of Whole Factory

From the figure above, it shown the first iteration layout of whole plant factory.
The total score of first iteration layout is 0.87. It’s same with the score of initial
layout. The score is already good, since the value is near “1”.
Figure 4.6 The Second Iteration of Whole Factory
From the figure above, it shown the second iteration of whole factory layout. The
adjacent score is 0.89. It means the layout is good since the score is near “1”. The
adjacent score is increases from initial layout and first iteration.
Figure 4.7 The Third Iteration of Whole Factory
From the figure above, it shown the third iteration of whole factory. The adjacent
score is 0.85. It means the layout is already good, since the value is near “1”.
It can be seen from the initial layout until third iteration layout, the best layout is
second iteration with the adjacent score is 0.89. It can be seen the data information
of each facility which are length, width, area, x – centroid and y – centroid. This
data would be used in order to calculate the distance and material handling for
further discussion. The analysis of second iteration layout is shown in the figure
below.
Figure 4.8 Analysis of Final Layout
The figure below shown the data of activity relationship diagram based on
distance matrix of second iteration of whole factory layout. The upper bound,
lower bound, Rel-Dist score, and R-score is already measured.
Figure 4.9 Distance Matrix of Final Layout

Figure 4.10 Summary of Evaluation Score
From figure 4.9, it shown the summary of evaluation score of each layout that has
been generated. It can be seen that the third layout (second iteration) is the best
layout for the whole factory. The adjacent score of third layout (second iteration)
is the closest one to 1.
After already choosen the best layout of whole plant, it will be converted to AAD.
It is represented the area of whole plant layout based on the best iteration. It will
be showed on the next page.
The information related with the number of location are showed as belows.
Figure 4.11 Information of Number

13 1 5 12
8
3 2 11 9
4 6 7 10
Figure 4.11 AAD OF Whole Plant
4.2. Generating Office Layout
The office layout of Waltz Company can be made with BlocPlan software. In
order to make the layout, BlocPlan software requires the measurement data area
of each facility in the office and the Activity Relationship Chart (ARC). The
measurement data area of each facility is already calculated in the space
requirement report. The measurement of area is in feet square. In this case, the
calculation is using feet for the unit. Figure below shows the area of each
department as the input of the blocplan.
Figure 4.11 Office Department Area Input (BLOCPLAN Software)
The next input for the blocplan is Activity Relationship Chart of the office. The
Activity Relationship Chart given in the chapter 3. There are 13 departments in
the Office. Figure below shows the input data for blocplan software. The score of
relationship each department are A, E, I, O, U, and X. the relationship will be
used to analyze the data. For example President Room and General Manager
Room has value A, so it means that those rooms should be close each other.
Figure 4.12 Activity Relationship Input (BLOCPLAN Software)
The next step is input the score of each relationship based on the chapter 2.
In this case the score are A=64, E=16, I=4, O=1, U=0 and X=- 1.024. After
input the score of each relationship, the software will automatically calculate the
score of each department which based on the ARC and the score each
relationship.
Before generating the layout, it should be determines the ratio of the layout first.
In this case the ratio of the layout is 1:1 (Length: Width). The output is the layout
with the adjacent score. In this case there will generating four times for the office
layout.
The layout is automatically generates by the software. For the first generating is
shown in the figure below, in the figure below shows that the adjacent score of
the first layout is 0.77. The score is good enough because in the Blocplan
software the good layout is the one which has the adjacent value close to 1.
Figure 4.13 Initial Generating of Office Layout
The layout generated by the software automatically. The length and width of
the layout are the number that already asked by software before generating the
layout. The outputs that can be seen from the data analysis are the length,
width, x- centroid and y-centroid. Because this is only the initial layout, data of
length, width, x-centroid and y-centroid are not shown.
Figure 4.13 First Iteration of Office Layout
5.24
In the figure above shows the first iteration of office layout. For the second
generating the adjacent value is better than first generating. The adjacent score
for the second generating is increased 0.01 become 0.78. The figure below shows
the third generating of office layout which has adjacent score is 0.70. In the
third generating the adjacent score is decreased 0.08, that is mean second
iteration is not good enough than previous generating.
Figure 4.15 Second Iteration of Office Layout

Figure below shows the third iteration of office layout. The third iteration for the
office layout has adjacent score 0.79. It is better than the previous iteration, the
value of the adjacent score increase 0.09 from the previous iteration.
Figure 4.16 Third Iteration of Office Layout

After generating four layouts it can be seen that the fourth layout has the biggest
score and the closest to the value of 1.00 than other. It indicates that the best layout
is the fourth layout before iteration. The best layout also can be seen from the Rel-
Distance score. The fourth layout has rank 1, second one fill the 2nd placed, third
layout with rank 4, and for the first layout is 3rd rank.
Figure 4.17 Summarized of Adjacent and Rel-Distance Value

The summarized of the adjacent score and Rel-Distance score data will shows in
the figure 4.17. Based that will be known which the best layout and based on the
best layout it can be used to analyze more detail about the length, width, x-
centroid and y-centroid each department.
Figure 4.18 Data Analyzing of the Office Layout

The figure above shows the data analyzing of the office layout that included the
length, width, x-centroid, and y-centroid of each department. The data above used
to calculate the distance and for the material handling calculation. Especially, for
generates the final layout, it needs the data of the length and width of each
department to make easier in drawing the final layout. The Distance of each
department for final layout shown in the distance matrix below
Figure 4.19 Distance Matrix for Final Layout (BLOCPLAN Software)

After already choosen the best layout of office, it will be converted to AAD. It is
represented the area of office based on the best iteration. It will be showed as
belows.
12
1 2
10
13
4
6
7
9
11
5 8
Figure 4.19 AAD of Office

4.3. Layout Design and AAD for Production Floor
In order to have efficient production system, the layout design for production floor must be arranged well. Where each department are
placed systematically with close distance each other based on the importance of both departments relationship. In order to generate the
layout of production floor, there will be used CRAFT program.
Table 4.1 Flow Matrix of Production Floor
From Drill Disc. Cut off Gun Table
Storage Assembling Attaching Jointer Circ. Saw Router Inspection Packaging Warehouse
Metric Press Sand saw Spray saw
Storage 22390.26
Assembling 22390.26 9978.95 25386.04 1909.07 12896.00 5552.47 40.49 2517.27 8695.20 4770.94
Attaching 36.07
Jointer 9978.95 9544.36 1693.64
Circ. Saw 25386.04 9544.36 711.75 5305.44 6130.97 6008.35
Router 1909.07 1884.58

Drill Press 12896.00 711.75 1884.58 6689.60
Disc. Sand 5552.47 1693.64 5305.44 6689.60 11630.10

Cut off saw 40.49 36.07
Gun Spray 2517.27 6130.97 11630.10 8167.70

Table saw 8695.20
Inspection 4770.94 8167.70 2734.21
Packaging 6008.35 2734.21 8742.55
Warehouse 8742.55
5.29
In the production floor, there are 16 departments including the maintenance room
and tools room. The information of each department can be seen on the table
below, where there are some departments that its location must be fixed to be
placed or cannot be changed in every iteration later. Here also the other
information that must be input to the CRAFT program which are layout data and
production facility layout.
Table 4.2 Departments Information

Departments Name F/V Area Cells
Dept. 1 Storage F 4960.00 50
Marking,
Assembling, V 4030.01 41
Dept. 2 & Gluing
Dept. 3 Attaching V 103.33 2
Dept. 4 Jointer V 209.15 3
Dept. 5 Circ.Saw V 419.79 5
Dept. 6 Router V 86.11 1
Dept. 7 Drill Press V 4822.23 49
Disc.Sand &
V
Dept. 8 Fillling 930.00 10
Dept. 9 Cut off Saw V 1051.42 11
Dept. 10 Gun Spray V 82.67 1
Dept. 11 Table Saw V 26.35 1
Dept. 12 Inspection F 51.67 1
Dept. 13 Packaging F 51.67 1
Dept. 14 Warehouse F 8848.24 89
Maintenance
F
Dept. 15 Room 516.67 6
Dept. 16 Tools Room F 344.45 4
TOTAL 26533.75 275
Based on the table above, it can be seen that each department area are converted
into cell unit. Where each cell unit represents 100 ft2 area, and the total required
cells for the production floor is 275 cells or 27500 ft2 area. The number of cells for
each department are calculated by dividing the area (ft2) with 100. The result from
this calculation will be round up into integer number. As the total of actual
required area for the production floor is 26533.75 ft2, so there are around 966.25
ft2 left as
5.30
the blank area around the required area of production floor. Based on the number
of departments with fixed position, here is the layout data that must be input into
the CRAFT program.
Table 4.3 Layout Data

Problem Name: Production
Number Depts.: 16
Fixed Points: 6
Dimension: ft
Based on the table above, it can be concluded that there are 16 departments in the
production floor which are six departments have fixed position, and the dimension
of the layout are in feet. In order to create a new layout based on the number of
required cells from the previous table which is 275 cells, then the closest cells
dimension of area is 17 x 17 cells or 289 units of cells area as it can be seen on the
table below about the facility information.
Table 4.4 Facility Information

Scale-ft/unit 10 Cells
Length-ft 170 17
Width-ft 170 17
Area-sq.ft 28900 289
Based on the table above, it can be concluded that the final production floor area
will be 289 units of cells area or 28900 ft2. Where the total left space in the
production area is 14 units of cells area in the layout. In the actual, the left space
area in the new production floor area is 2366.25 ft2. After the required data
fulfilled in the CRAFT program, then the initial layout and the centroid of each
department
as the result will be shown on the below where the initial total cost is 2,877,686.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
1 1 1 1 2 2 2 2 2 11 14 14 14 14 14 14 0 0
2 1 1 1 2 2 2 5 5 5 14 14 14 14 14 14 0 0
3 1 1 1 2 2 2 5 5 10 14 14 14 14 14 14 0 0
4 1 1 1 2 2 2 7 7 7 14 14 14 14 14 14 0 0
5 1 1 1 2 2 2 7 7 7 14 14 14 14 14 14 0 0
6 1 1 1 2 2 2 7 7 7 14 14 14 14 14 14 0 0
7 1 1 1 2 2 2 7 7 7 14 14 14 14 14 14 0 0
8 1 1 1 2 2 2 7 7 7 14 14 14 14 14 14 16 16
9 1 1 1 2 2 2 7 7 7 14 14 14 14 14 14 16 16
10 1 1 1 2 2 2 7 7 7 12 13 14 14 14 14 15 15
11 1 1 1 2 2 2 7 7 7 9 9 9 14 14 14 15 15
12 1 1 1 2 2 2 7 7 7 9 9 9 14 14 14 15 15
13 1 1 1 2 2 2 7 7 7 9 9 9 14 14 14 14 14
14 1 1 1 8 8 8 7 7 7 4 9 9 14 14 14 14 14
16 1 1 1 8 8 8 7 7 7 7 7 7 14 14 14 14 14
17 1 1 6 3 3 8 7 7 7 7 7 7 14 14 14 14 14
Figure 4.20 Initial Layout of Production Floor
Table 4.5 Initial Department’s Centroid

Department Color x-centroid y-centroid
Storage 1 1.48 8.34
Marking, Assembling, & Gluing 2 4.62 6.21
Attaching 3 4.00 16.50
Jointer 4 10.50 14.17
Circ.Saw 5 7.30 1.90
Router 6 3.00 16.50
Drill Press 7 7.91 10.83
Disc.Sand & Fillling 8 4.60 14.70
Cut off Saw 9 10.59 11.86
Gun Spray 10 9.00 2.50
Table Saw 11 9.00 0.50
Inspection 12 9.50 9.50
Packaging 13 11.00 9.50
Warehouse 14 12.85 7.97
Maintenance Room 15 16.00 10.50
Tools Room 16 16.00 8.00
After the initial layout and the department’s centroids have been obtained, then the
first iteration can be done by switching Department 7 and 8. The new layout and
the department’s centroids as the result will be shown on the below where the total
cost of 1st iteration is 2,676,063 and it is saving 201,623 compared with the total of
initial cost.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
1 1 1 1 2 2 2 2 2 11 14 14 14 14 14 14 0 0
2 1 1 1 2 2 2 5 5 5 14 14 14 14 14 14 0 0
3 1 1 1 2 2 2 5 5 10 14 14 14 14 14 14 0 0
4 1 1 1 2 2 2 7 7 8 14 14 14 14 14 14 0 0
5 1 1 1 2 2 2 7 7 8 14 14 14 14 14 14 0 0
6 1 1 1 2 2 2 7 7 8 14 14 14 14 14 14 0 0
7 1 1 1 2 2 2 7 7 7 14 14 14 14 14 14 0 0
8 1 1 1 2 2 2 7 7 7 14 14 14 14 14 14 16 16
9 1 1 1 2 2 2 7 7 7 14 14 14 14 14 14 16 16
10 1 1 1 2 2 2 7 7 7 12 13 14 14 14 14 15 15
11 1 1 1 2 2 2 7 7 7 9 9 9 14 14 14 15 15
12 1 1 1 2 2 2 7 7 7 9 9 9 14 14 14 15 15
13 1 1 1 2 2 2 7 7 7 9 9 9 14 14 14 14 14
14 1 1 1 7 7 7 7 7 7 4 9 9 14 14 14 14 14
15 1 1 1 7 7 7 7 7 7 8 4 4 14 14 14 14 14
16 1 1 1 7 7 7 7 7 7 8 8 8 14 14 14 14 14
17 1 1 6 3 3 7 7 7 7 8 8 8 14 14 14 14 14
Figure 4.21 Layout of Production Floor (1st Iteration)
Table 4.6 Department’s Centroid (1st Iteration)

Storage 1 1.48 8.34
Jointer 4 10.50 14.17
Circ.Saw 5 7.30 1.90
Router 6 3.00 16.50
Cut off Saw 9 10.59 11.86
Gun Spray 10 9.00 2.50
Table Saw 11 9.00 0.50
Packaging 13 11.00 9.50
Warehouse 14 12.85 7.97
Tools Room 16 16.00 8.00
Based on the table above, it can be seen that the centroids of Department 7 and 8
are changed. After the layout and the department’s centroids of first iteration have
been obtained, then the second iteration can be done by switching Department 4
and 9. The new layout and the department’s centroids as the result will be shown
on the below where the total cost of 2nd iteration is 2,611,402 and it is saving
64,661 compared with the total cost of 1st iteration.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
1 1 1 1 2 2 2 2 2 11 14 14 14 14 14 14 0 0
2 1 1 1 2 2 2 5 5 5 14 14 14 14 14 14 0 0
3 1 1 1 2 2 2 5 5 10 14 14 14 14 14 14 0 0
4 1 1 1 2 2 2 7 7 8 14 14 14 14 14 14 0 0
5 1 1 1 2 2 2 7 7 8 14 14 14 14 14 14 0 0
6 1 1 1 2 2 2 7 7 8 14 14 14 14 14 14 0 0
7 1 1 1 2 2 2 7 7 7 14 14 14 14 14 14 0 0
8 1 1 1 2 2 2 7 7 7 14 14 14 14 14 14 16 16
9 1 1 1 2 2 2 7 7 7 14 14 14 14 14 14 16 16
10 1 1 1 2 2 2 7 7 7 12 13 14 14 14 14 15 15
11 1 1 1 2 2 2 7 7 7 9 9 4 14 14 14 15 15
12 1 1 1 2 2 2 7 7 7 9 9 4 14 14 14 15 15
13 1 1 1 2 2 2 7 7 7 9 9 4 14 14 14 14 14
14 1 1 1 7 7 7 7 7 7 9 9 9 14 14 14 14 14
15 1 1 1 7 7 7 7 7 7 8 9 9 14 14 14 14 14
16 1 1 1 7 7 7 7 7 7 8 8 8 14 14 14 14 14
17 1 1 6 3 3 7 7 7 7 8 8 8 14 14 14 14 14
nd
Figure 4.22 Layout of Production Floor (2 Iteration) Table 4.7
Department’s Centroid (2nd Iteration)

Storage 1 1.48 8.34
Jointer 4 11.50 11.50
Circ.Saw 5 7.30 1.90
Router 6 3.00 16.50
Cut off Saw 9 10.32 12.59
Gun Spray 10 9.00 2.50
Table Saw 11 9.00 0.50
Packaging 13 11.00 9.50
Warehouse 14 12.85 7.97
Tools Room 16 16.00 8.00
Based on the table above, it can be seen that the centroids of Department 4 and 9
are changed. After the layout and the department’s centroids of second iteration
have been obtained, then the third iteration can be done by switching Department
5 and 7 as it is the solution from the CRAFT program. But, when the ‘yes’ option
is clicked, then the next notification appeared as it can be seen on the figure
below.
Figure 4.23 CRAFT Program’s Notification
Then the layout doesn’t appeared but only shows the cost if switching Department
5 and 7, which is 2,804,032. As the cost is increased 192,630 from the total cost of
2nd iteration which is is 2,611,402, the iteration will be stopped in the second
iteration as the best result. Thus, the best layout is the 2nd iteration layout as the
final layout of production floor with total cost is 2,611,402, as the lowest cost. The
comparison of cost from initial iteration layout until the 3nd iteration layout can be
seen on the table below.
Table 4.8 Total Cost Comparison Between All Iterations

Iteration Action Total Cost Status
0 None 2,877,686 None

Decreased
1 Switch 7 and 8 2,676,063 201,623
Decreased
2 Switch 4 and 9 2,611,402 64,661
Increased
3 Switch 5 and 7 2,804,032 192,630
After already choosen the best layout of production floor, it will be converted to
AAD. It is represented the area of production floor based on the best iteration. It
will be showed as belows.
7 3 6
7
8 7
7
7
7
9
15 8
2
15
5
16
4
4 12 13 10 11
Figure 4.23 AAD of Production Floor

4.4. Material Handling Cost
After generating the production floor layout, the best layout with lowest cost can
be choose which layout from iteration 2. The x and y centroid is used as data in
calculating the distance between one department to another department. The
calculation of distance shows in the table below is using rectilinear method.
Example of the distance calculation of Assembling, Marking, Gluing Department

to Disc. Sand and Milling shown as belows.
Distance= |xa – xb| + |ya – yb| = |98-46.22| +|124 – 62.07| = 113.71 ft = 34.66 m
Table 4.9. Distance Calculation
N x- y- x- y- Distance Distance
From To
o centroid centroid centroid centroid (ft) (m)
Assemblin
Disc.
g,
1 Sand &
Marking,
Gluing 46.22 62.07 Milling 98.00 124.00 113.71 34.66
Assemblin
g,
2 Drill Press
Marking,
Gluing 46.22 62.07 68.47 112.96 73.14 22.29
Assemblin
g,
3 Table Saw
Marking,
Gluing 46.22 62.07 85.00 5.00 95.85 29.22
Assemblin
g,
4 Marking, Inspection
Gluing 46.22 62.07 95.00 95.00 81.71 24.90
Assemblin
g,
5 Jointer
Marking,
Gluing 46.22 62.07 115.00 115.00 121.71 37.10
Assemblin
g,
6 Router
Marking,
Gluing 46.22 62.07 25.00 165.00 124.15 37.84
Assemblin
g, Cut off
7 Marking, Saw
Gluing 46.22 62.07 103.18 125.91 120.80 36.82
Assemblin
g, Circular
8 Marking, Saw
Gluing 46.22 62.07 73.00 19.00 69.85 21.29
Assemblin
Circular g,
9
Saw Marking,
73.00 19.00 Gluing 46.22 62.07 69.85 21.29
Circular
10 Jointer
Saw 73.00 19.00 115.00 115.00 138.00 42.06
Circular Disc Sand
11
Saw 73.00 19.00 & Milling 98.00 124.00 130.00 39.62
Circular
12 Drill Press
Saw 73.00 19.00 68.47 112.96 98.49 30.02
Table 4.9. Distance Calculation (continued)
13 Circular Saw 73.00 19.00 Packaging 105.00 95.00 108.00 32.92
14 Cut of Saw 103.18 125.91 Attaching 40.00 165.00 102.27 31.17
15 Disc. Sand & 98.00 124.00 Gun Spray 85.00 25.00 112.00 34.14
Milling
16 Drill Press 68.47 112.96 Assembling, Marking, 46.22 62.07 73.14 22.29
Gluing
17 Drill Press 68.47 112.96 Disc Sand & Milling 98.00 124.00 40.57 12.37
18 Gun Spray 85.00 25.00 Circular Saw 73.00 19.00 18.00 5.49
19 Gun Spray 85.00 25.00 Assembling, Marking, 46.22 62.07 75.85 23.12
Gluing
20 Inspection 95.00 95.00 Gun Spray 85.00 25.00 80.00 24.38

21 Inspection 95.00 95.00 Packaging 105.00 95.00 10.00 3.05
22 Jointer 115.00 115.00 Circular Saw 73.00 19.00 138.00 42.06
23 Jointer 115.00 115.00 Disc Sand & Milling 98.00 124.00 26.00 7.92
24 Packaging 105.00 95.00 Warehouse 128.48 79.72 38.76 11.82
25 Router 25.00 165.00 Drill Press 68.47 112.96 95.51 29.11
26 Storage 14.80 83.40 Assembling, Marking, 46.22 62.07 52.75 16.08
Gluing
27 Table Saw 85.00 5.00 Assembling, Marking, 46.22 62.07 95.85 29.22
Gluing
Table below shown the material handling cost for each material handling tools.
Table 4.10. Material Handling Cost
N Cost Unload Speed Load Speed

o Volume MHE (IDR/m) (m/hr) (m/hr)
1 0-20 kgs Manual 700 4000 1500
Max 130
2 kgs Hand Truck 6000 5000 3000
Max 2500 Hand Pallet
3 kgs Truck 15000 10000 8000
After determining the distance calculation using centroids in each department, it

can be used to be calculated the material handling cost and also the transportation
time from one department to another department. On the next page, table
calculation of material handling cost and transportation time needed are shown.
Table 4.11. Material Handling Cost and Transportation Time Calculation
Dimension
Material
Choosen
(inches) Unit Total Load
From
MHE
Part Weight Total Cost/m Transportation
Code
No
To
Cost Trip Distance Cost/d Speed

Code (kg) Weight (Rp) Time (hr)
T l w (IDR/m) ay (Rp) (m/hr)
Oak 3
142 1548.9313 0.75 96 5.5

Assembling, Marking, Gluing
Fir
143 398.5600 2 36 2
Circular Saw
MHE 3
164722
1 12894.30 15000 5 21.29 13,177, 8000 0.027
6.1
809.09
12
Oak 2
141 3084.1617 0.75 0 8.5
72
Oak 1
112 821.4868 0.75 3.5

0
5.39
Table 4.11. Material Handling Cost and Transportation Time Calculation (continued)
Oak 1
72
113 985.7842 0.75 3.5
0
Oak 1
72
111 5531.8976 0.75 3.5
0
Arm and
SA
Leg
523.4806 14.5 25 2.5

A&L
Oak 3
142 1405.6552 0.75 22 5.5

Drill Press
MH 3
8. 114335
2 8548.40 15000 3 22.29 9,146,8 8000 0.019
Fir
143 3.2365 2 2
5 5.8
46.15
Oak 2
141 2747.9881 0.75 27 8.5
5.40
Surface
38
Top
TSA 4391.5159 46.5 3.5
.5
Plywood
46
120 5304.4464 0.75 38.5
.5
Birch 1
14
220 874.6640 0.75 1.5
4
Birch 1
Jointer
14
MH 3
222109
3 230 462.7852 0.75 1.5 9978.95 15000 4 37.10 17,768, 8000 0.037
4 7.7
781.73
Birch 1
14
210 858.5120 0.75 1.5
4
Birch 3
250 1520.2817 0.75 54 3.5
5.41
Birch 2
240 958.2585 0.75 42 2.5
Birch
210 410.8533 0.75 25 1.5
1
Router
MH 2
Birch 333410
4 250 958.6578 0.75 25 3.5 1909.07 6000 15 37.84 26,672, 3000 0.370
3 1.1
809.10
Birch 19
240 539.5594 0.75 2.5
2 .5
Roun
9.
261 d 13.4077 0.38
5
Cut off Saw
steel
Gl
MH 1
52183.
5 ui 40.49 700 2 36.82 417,46 1500 0.099
631
ng 9.05
Roun
17
271 d 27.0863 0.38
.5
steel
5.42
Pedes 35
PA 998.4744 35.5 27
Disc. Sand & Filling tal .5
Arm
MH 3
SAA 115462
6 and 2036.7324 14.5 25 2.5 5552.47 15000 2 34.66 9,237,0 8000 0.019
&L 5.3
Leg 02.08
34
CAC CAC 2517.2658 23.5 25
.5
Assemblin
Table Saw
Top
38 762122
MH 3
7 TSA Surfa 4347.6007 46.5 3.5 4347.60 15000 2 29.22 6,096,9 8000 0.013
g,
.5 .1
ce 76.76
Assemblin
Inspection
34 712903
MH 3
8 CAC CAC 4770.9388 23.5 25 4770.94 15000 2 24.90 5,703,2 8000 0.012
g,
.5 .96
31.64
Assemblin
Circular
159579
9 Sa 142 Oak 3 1405.6552 0.75 22 5.5 12491.74 MH 3 15000 5 21.29
9.5
12,766, 8000 0.027
w 396.21
5.43
8.
143 Fir 3.2365 2 2
5
141 Oak 2 2747.9881 0.75 27 8.5
Birch
210 410.8533 0.75 25 1.5
1
Birch
250 958.6578 0.75 25 3.5
3
Birch 19
240 539.5594 0.75 2.5
2 .5
Pedes 35
PA 659.8593 35.5 27
tal .5
5.44
Top
38
TSA Surfa 3918.8498 46.5 3.5
.5
ce
Arm
SAA
and 1847.0810 14.5 25 2.5
&L
Leg
38
112 Oak 1 782.7742 0.75 3.5
.5
Circular Saw
Jointer
MH 3
433744
10 1718.65 15000 1 42.06 3,469,9 8000 0.007
.03
52.26
46
113 Oak 1 935.8788 0.75 3.5
.5
Disc Sand
Circular
46 126133
MH 3
Saw
11 111 Oak 1 5305.4356 0.75 3.5 5305.44 15000 2 39.62 10,090, 8000 0.021
.5 5.4
683.54
Drill Press
Circular
Birch 20 986147
12 Sa 220
1
480.5334 0.75
.5
1.5 711.75 MH 2 6000 5 30.02
.9
7,889,1 3000 0.110
w 83.18
5.45
Birch 14
230 231.2173 0.75 1.5
Packaging 1 .5
Circular
46 118671
MH 3
Saw
13 ROT ROT 6008.3462 38.5 30.5 6008.35 15000 2 32.92 9,493,6 8000 0.020
.5 0.8
86.77
Roun
9.
261 d 12.6100 0.38
5
Cut off Saw
steel
Attaching
MH 1
39357.
14 36.07 700 2 31.17 314,86 1500 0.075
778
2.22
Roun
17
271 d 23.4635 0.38
.5
steel
Birch 20
Disc Sand & Filling
220 480.5334 0.75 1.5

1 .5
Gun Spray
MH 3
238214
15 11630.10 15000 5 34.14 19,057, 8000 0.040
2.9
143.04
Birch
210 402.6774 0.75 25 1.5
1
5.46
Pedes 35
PA 998.4744 35.5 27
tal .5
Top
38
TSA Surfa 5194.4201 46.5 3.5
.5
ce
Arm
SAA
and 2036.7324 14.5 25 2.5
&L
Leg
34
CAC CAC 2517.2658 23.5 25
.5
Disc Sand & Filling
142 Oak 3 1391.5986 0.75 22 5.5

Drill Press
MH 3
496348
16 6689.60 15000 3 12.37 3,970,7 8000 0.008
.13
85.07
141 Oak 2 2720.5082 0.75 27 8.5
5.47
Birch 20
220 480.5334 0.75 1.5
1 .5
Birch 14
230 231.2173 0.75 1.5
1 .5
Birch
210 402.6774 0.75 25 1.5
1
Birch
250 939.5805 0.75 25 3.5
3
Birch 19
240 523.4806 0.75 2.5
1 .5
Assemblin
Drill Press
Top
38 581495
17 TSA Surfa 4347.6007 46.5
.5
3.5 4347.60 MH 3 15000 2 22.29
.58
4,651,9 8000 0.010
ce 64.65
5.48
Gun Spray
Circular
46 201821
MH 3
18 ROT ROT 6130.9655 38.5 30.5 6130.97 15000 2 5.49 1,614,5 8000 0.003
.5 .56
72.46
Gun Spray
Assemblin
34 349198
MH 3
19 CAC CAC 2517.2658 23.5 25 2517.27 15000 1 23.12 2,793,5 8000 0.006
.5 .06
84.46
46
ROT ROT 6130.9655 38.5 30.5
.5
Gun Spray
Inspection
MH 3
119496
20 8167.70 15000 3 24.38 9,559,7 8000 0.020
6.9
35
34
CAC CAC 2036.7324 23.5 25
.5
Inspection
Packaging
34 50003.
MH 3
21 CAC CAC 2734.2064 23.5 25 2734.21 15000 1 3.05 400,02 8000 0.001
.5 166
5.33
Circular
Jointer
Plyw 46 197500
22 120
ood
4039.2185 0.75
.5
38.5 7825.70 MH 3 15000 3 42.06
7.2
15,800, 8000 0.033
057.29
5.49
Birch 14
220 485.3873 0.75 1.5
1 4
Birch 14
230 233.5529 0.75 1.5
1 4
Birch 14
210 415.0034 0.75 1.5
1 4
Birch
250 968.3412 0.75 54 3.5
3
Birch
240 545.0095 0.75 42 2.5
2
Pedes 35
PA 666.5245 35.5 27
tal .5
5.50
Top
38
TSA Surfa 472.6661 46.5 3.5
.5
ce
38
Disc Sand & Filling
112 Oak 1 767.1188 0.75 3.5

.5
Jointer
MH 3
80530.
23 1693.64 15000 1 7.92 644,24 8000 0.001
475
3.80
46
113 Oak 1 926.5200 0.75 3.5
.5
34
CAC CAC 2734.2064 23.5 25
.5
Warehouse
Packaging
MH 3
619774
24 8742.55 15000 3 11.82 4,958,1 8000 0.010
.26
94.04
46
ROT ROT 6008.3462 38.5 30.5
.5
Drill Press
Router
Birch 253214
25 210
1
406.7448 0.75 25 1.5 1884.58 MH 2 6000 14 29.11
2.7
20,257, 3000 0.281
141.82
5.51
Birch
250 949.0712 0.75 25 3.5
3
Birch 19
240 528.7682 0.75 2.5
2 .5
142 Oak 3 1548.9313 0.75 96 5.5

143 Fir 398.5600 2 50 2

Storage
MH 3
215982
26 22390.26 15000 9 16.08 17,278, 8000 0.036
1.1
568.74
12
141 Oak 2 3084.1617 0.75 8.5
0
72
112 Oak 1 821.4868 0.75 3.5
0
5.52
72
113 Oak 1 985.7842 0.75 3.5
0
Plyw 46
120 5304.4464 0.75 38.5
ood .5
72
111 Oak 1 5531.8976 0.75 3.5
0
Roun
9.
261 d 13.4077 0.38
5
steel
Roun
17
271 d 27.0863 0.38
.5
steel
Birch 14
220 874.6640 0.75 1.5
1 4
5.53
Birch 14
230 462.7852 0.75 1.5
1 4
Birch 14
210 858.5120 0.75 1.5
1 4
Birch
250 1520.2817 0.75 54 3.5
3
Birch
240 958.2585 0.75 42 2.5
2
Assemblin
Table Saw
Top
38 762122
MH 3
27 TSA Surfa 4347.6007 46.5 3.5 4347.60 15000 2 29.22 6,096,9 8000 0.013
.5 .1
ce 76.76
Total Material Handling Total Material Handling

Rp. 239,328,682.28 Rp 29,916,085
Cost/day Cost/hour
5.54
In order to determine the material handling needed, there are three indicators, such
as distance, weight, and dimensions. Constraints for dimensions are shown as
belows.
Table 4.12. Dimensions Contraint
No MH 1 MH 2 MH 3
Dimension 0 < X <=20 20 < X <= 30 X >30
Below are shown the way how to calculate the material handling cost and
transportation cost.
Example of Number 1:
Material Handling Cost = Rp 15,000
Number of Trip = 5 trips
Distance = 21.29 m
Cost/m = Material Handling Cost*Number of Trip*Distance
Cost/m = 15000*5*21.29 = Rp 1,596,750
Working hour/day = 8 hours
Total Cost/day/process = Cost/m *8 hours= Rp. 239,328,682.28
Transportation Time = (Total Distance/Load Speed)*2 (back and forward
load)*Trips = (21.29/8000)*2*5 = 0.027
Allocation of material handling cost for each product ROT and CAC in a hour
with fixed demand and processing time, shown as belows. (Known: 40%/hour for
CAC and 60%/hour for ROT)
Material Handling Cost for CAC = Rp. 29,916,085 *40% = Rp
12,000,000/hour
Material Handling Cost for ROT Rp. 29,916,085 *60% = Rp
18,000,000/hour
Material handling cost for each product ROT and CAC as belows (known 1 Week
= 40 hour, CAC = 650/week, ROT=300/week).
Material Handling Cost of one CAC = Rp. 12,000,000 *(650/40) = Rp
750,000/product
Material Handling Cost of one ROT Rp. 18,000,000*(300/40) = Rp
1,500,000/product
4.5. Calculation of Material Handling Tool for One Hour
There are three types of MHE which are Manual, Hand Truck, and Hand Pallet
Truck. Each process has different MHE, the considerations on choosing the MHE
are based on the weight of the material, the distance of one department to another
department, and also the dimension of the material. Below is the table of
determining the number of MHE in one hour.
5.55
Table 4.13. Material Handling Tool in One Hour
Transportation Time (in hour) Round Up
MH 1 0.174 1
MH 2 0.761 1
MH 3 0.375 1
After summing upp all of transportation time based on material handlin tool, the
total transportation time shown as above. The total transportation time for all MHE
is less than one hour so it is mean that just need one material handling tool for each
kind MHE.
4.6. Calculation of Production Cost
In order to calculate the production cost/unit, there are several cost calculated,
such as direct and indirect labor cost, direct and indirect material cost, investment
on machine and equipments, and other expenses.
4.6.1. Direct and Indirect Labor Cost
In this company, there are several direct and indirect labor cost. Direct labor cost
mean that the labor directly influence the production process. And indirect labor
cost mean that the labor do not directly influence the production process.
Table 4.14. Direct Labor Cost
No Operator No of Salary/day/pers Total Total
Operat on (IDR) salary/day salary/hour
or (IDR) (IDR)
1 Marking Assembling and 26 180,000
Glueing 4,680,000 585,000
2 Jointer 6 180,000
1,080,000 135,000
3 Circular Saw 13 180,000
2,340,000 292,500
4 Router 2 180,000
360,000 45,000
5 Drill Press 10 180,000
1,800,000 225,000
6 Disc. Sand and Filling 18 180,000
3,240,000 405,000
7 Table Saw 1 180,000
180,000 22,500
8 Cut Off Saw 2 180,000
360,000 45,000
9 Gun Spray 3 180,000
540,000 67,500
10 Inspection 2 180,000
360,000 45,000
11 Packaging 2 180,000
360,000 45,000
12 Attaching 2 180,000
360,000 45,000
Total Direct Labor Cost
1,957,500
Table 4.15. Indirect Labor Cost
No of Salary/day/person Total salary/day Total salary/hour

No Position
Worker (IDR) (IDR) (IDR)
President
1 2 1,600,000 3,200,000 400,000
Director/Vice
2 General Manager 1 1,150,000 1,150,000 143,750
Manager of
Finance,
3 1 850,000 850,000 106,250
Accounting, and
General Affair
4 Finance Staff 2 500,000 1,000,000 125,000
Purchasing
5 1 500,000 500,000 62,500
Manager
6 Purchasing Staff 2 400,000 800,000 100,000
Human Resource
7 Development 7 700,000 4,900,000 612,500
Staff
GM
8 Manufacturing 1 800,000 800,000 100,000
Dept
Production
9 1 600,000 600,000 75,000
Manager
10 Production Staff 5 400,000 2,000,000 250,000
Engineer and
11 Maintenance 6 750,000 4,500,000 562,500
Operator
Head of Quality
12 1 600,000 600,000 75,000
Control
Quality Control
13 2 400,000 800,000 100,000
Staff
Manager of Sales
14 1 500,000 500,000 62,500
and Marketing
15 Sales Staff 2 350,000 700,000 87,500

16 Marketing Staff 2 350,000 700,000 87,500
17 Receptionist 2 300,000 600,000 75,000
18 Head of Security 1 250,000 250,000 31,250
19 Security 3 200,000 600,000 75,000
20 Head of Janitor 1 230,000 230,000 28,750
Toilet Janitor
21 2 190,000 380,000 47,500
Staff
Office Janitor
22 3 200,000 600,000 75,000
Staff
Canteen Janitor
23 1 190,000 190,000 23,750
Staff
24 Head of Canteen 1 220,000 220,000 27,500
25 Canteen Staff 2 190,000 380,000 47,500
26 Doctor 2 600,000 1,200,000 150,000
27 Nurse 1 400,000 400,000 50,000
Total Indirect Labor Cost 3,581,250
5.57
4.6.2. Direct/Indirect Material Cost
In this company, there are several direct and indirect material cost. Direct material
cost mean that the labor directly influence the production process. And indirect
material cost mean that the material do not directly as main material for the
production process.
Table 4.16. Direct Material Cost
N Req/Ho Total
Component Name Material Name Price/Unit
o. ur Cost/Hour
Rectangular Oak Table (ROT)

1 111 Top Surface Slat
112 Frame Top Oak 60' x 3 1/2" x IDR IDR
2 8
Surface (B) 3/4" 175,680 1,389,190
113 Frame Top
3
Surface (C)
Plywood 4' x 4' x IDR IDR
4 120 Base Surface 8
3/4" 320,000 2,628,000
141 Pedestal Pieces ( Oak 10' x 8 1/2" x IDR IDR
5 8
E) 3/4" 112,500 923,816
Oak 8' x 5 1/2" x IDR IDR
6 142 Feet ( F ) 3/4" 8 86,250 687,152
143 Pedestal Support IDR IDR
7 Fir 3' x 2" x 2" 8
(G) 322,000 2,565,366
IDR
Total for ROT 8,193,523
Casual Arm Chair (CAC)
8 210 Front Leg ( A )
IDR IDR
9 220 Stretcher ( B ) Birch 12' x 2" x 1" 17
310,000 5,386,250
10 Side Stretcher ( C )
Birch 3 1/2' x 3" x IDR IDR
11 240 Arm ( D ) 17
1" 210,000 3,638,250
Birch 4 1/4' x 4" x IDR IDR
12 250 Rear Leg ( E ) 17
1" 230,000 3,904,250
261 Back Steel Rod (
13
I)
Rounded steel bar IDR IDR
16
3/8 x 5' 105,000 1,672,125
271 Seat Steel Rod ( H
14
)
IDR
Total for CAC 14,600,875
IDR
Total DM Cost
22,794,398
5.58
Table 4.17. Indirect Material Cost
No. Material Name Req/LT Req/Hour Price/Unit Total Cost/Hour
Rectangular Oak Table (ROT)

1 Flathead Screw 1" x #8 13200 165 IDR 100 IDR 16,500
2 Flathead Screw 2" x #8 21600 270 IDR 150 IDR 40,500
3 Flathead Screw 2 1/2" x #12 4800 60 IDR 200 IDR 12,000

4 Carriage Bolts 1/4" x 2 1/2" 4800 60 IDR 300 IDR 18,000
5 Washer 1/4" 12600 157.5 IDR 1,000 IDR 157,500
6 Nut 1/4" 4800 60 IDR 6,000 IDR 360,000
7 Aliphatic Resin 0.125 Liter IDR 40,000 IDR 5,000

8 Wood Filler 0.125 Liter IDR 22,222 IDR 2,778
9 Sand Paper 75 0.9375 IDR 14,900 IDR 13,969
10 Clear Polyurethane 0.125 Liter IDR 30,000 IDR 3,750

11 Carton ROT 600 7.5 IDR 3,500 IDR 26,250
12 Plastic Roll (ROT) 1200 15 IDR 65,000 IDR 975,000
13 Label 300 3.75 IDR 5,000 IDR 18,750
Total for ROT IDR 1,649,997
14 Dowelling ø 3/8" x 4" 10400 130 IDR 180 IDR 23,400
15 Dowelling ø 3/8" x 3" 10400 130 IDR 160 IDR 20,800
16 Dowelling ø 3/8" x 1 1/2" 10400 130 IDR 150 IDR 19,500
17 Hanger Bolt 1/4" x 2 1/2" 7800 97.5 IDR 300 IDR 29,250
18 Cap Nut 1/4" 7800 97.5 IDR 200 IDR 19,500
19 Wood Filler 0.125 Liter IDR 22,222 IDR 2,778
20 Resin Glue 0.125 Liter IDR 40,000 IDR 5,000
21 Sand Paper 300 3.75 IDR 14,900 IDR 55,875
22 Clear Polyurethane 0.125 Liter IDR 30,000 IDR 3,750
23 Carton CAC 1300 16.25 IDR 5,000 IDR 81,250
24 Plastic Roll CAC 1300 16.25 IDR 65,000 IDR 1,056,250
25 Label 75 0.9375 IDR 5,000 IDR 4,688
Total for CAC IDR 1,322,040
Total IDM Cost IDR 2,972,037
5.59
4.6.3. Investment on Machinery and Equipment Cost
To produce the products of ROT and CAC, there are several machinery and
equipments needed, such as bellows.
Table 4.18. Investment on Machinery and Equipment
Machinery/Eq Numb Total Dep. Depreciation/y Depreciation/hr
Price/m2
uipment er Investment Year r (IDR) (IDR)
Land 1558.8 IDR IDR IDR IDR
7498 1,000,000 1,558,874,975 100 15,588,749.75 2,165
Light (lamp IDR IDR IDR IDR
and socket) 98 150,000 14,700,000 1 14,700,000 2,042
1558.8 IDR IDR IDR IDR
Building Plant 7498 5,250,000 8,184,093,619 10 818,409,362 113,668
Landscaping 7498 350,000 545,606,241 10 54,560,624 7,578
IDR IDR IDR IDR
Power Panel 2 20,000,000 40,000,000 100 400,000 56
Manual IDR IDR IDR IDR
Equipment 3 200,000 600,000 1 600,000 83
Hand Truck IDR IDR IDR IDR
Equipment 1 650,000 650,000 10 65,000 9
Hand Pallet IDR IDR IDR IDR
Truck Eq. 1 350,000 350,000 10 35,000 5
Bench for IDR IDR IDR IDR
Marking Dep. 5 400,000 2,000,000 10 200,000 28
Assem. Dep. 11 800,000 8,800,000 10 880,000 122
IDR IDR IDR IDR
Circ. Saw 13 1,000,000 13,000,000 100 130,000 18
IDR IDR IDR IDR
Jointer 8 1,150,000 9,200,000 1 9,200,000 1,278
IDR IDR IDR IDR
Router 2 600,000 1,200,000 10 120,000 17
IDR IDR IDR IDR
Drill Press 9 650,000 5,850,000 10 585,000 81
IDR IDR IDR IDR
Filling 3 1,150,000 3,450,000 1 3,450,000 479
IDR IDR IDR IDR
Disc. Sand 15 100,000 1,500,000 1 1,500,000 208
IDR IDR IDR IDR
Gun Spray 3 250,000 750,000 10 75,000 10
IDR IDR IDR IDR
Cut Off Saw 1 1,500,000 1,500,000 10 150,000 21
IDR IDR IDR IDR
Table Saw 1 1,850,000 1,850,000 10 185,000 26
Inspection 1 950,000 950,000 100 9,500 1
Packaging IDR IDR IDR IDR
Tools 1 50,000 50,000 1 50,000 7
Maintenance IDR IDR IDR IDR
Tools 5 100,000 500,000 1 500,000 69
IDR IDR IDR IDR

Dust Collector 3 5,000,000 15,000,000 10 1,500,000 208
IDR IDR IDR IDR

Compressor 3 2,500,000 7,500,000 10 750,000 104
IDR IDR
Total 923,643,236 128,284
5.60
Table 4.18. Investment on Machinery and Equipment (continued)
N Machinery/E Num Total Dep.

Price/Unit Depreciation/yr Depreciation
o quipment ber Investment Year
(IDR) /hr (IDR)
Production Staff Room
141. IDR IDR IDR IDR

1 Land 2425 1,000,000 141,242,500 100 1,412,425 196
141. IDR IDR IDR IDR
2 Building 2425 5,250,000 741,523,125 10 74,152,313 10,299
IDR IDR IDR IDR
3 Desk 2 3,000,000 6,000,000 5 1,200,000 167
IDR IDR IDR IDR
4 Chair 9 1,000,000 9,000,000 5 1,800,000 250
IDR IDR IDR IDR
5 Trash Bin 1 50,000 50,000 5 10,000 1
6 and socket) 1 150,000 150,000 1 150,000 21
Air IDR IDR IDR IDR
7 Conditioner 1 2,750,000 2,750,000 3 916,667 127
IDR IDR IDR IDR
8 Computer Set 2 3,000,000 6,000,000 5 1,200,000 167
IDR IDR IDR IDR
9 Board 1 120,000 120,000 20 6,000 1
IDR IDR
Total Production Floor 80,841,404 11,228
Locker Room for Operator

1 Land 6 1,000,000 70,560,000 100 705,600 98
2 Building 6 5,250,000 370,440,000 10 37,044,000 5,145
3 and socket) 2 150,000 300,000 1 300,000 42
IDR IDR IDR IDR
4 Locker 2 1,000,000 2,000,000 3 666,667 93
IDR IDR
Total for Operator Room Locker 38,716,267 5,377
Office
CEO Room

1 Land 675 1,000,000 44,467,500 100 444,675 62
2 Building 675 5,250,000 233,454,375 10 23,345,438 3,242
IDR IDR IDR IDR
3 Desk 1 5,000,000 5,000,000 5 1,000,000 139
IDR IDR IDR IDR
4 Chair 1 3,000,000 3,000,000 5 600,000 83
IDR IDR IDR IDR
5 Table 1 50,000 50,000 5 10,000 1
Sofa IDR IDR IDR IDR
6 (Double) 2 5,000,000 10,000,000 5 2,000,000 278
IDR IDR IDR IDR
7 Sofa (Single) 2 2,500,000 5,000,000 5 1,000,000 139
8 and socket) 1 150,000 150,000 1 150,000 21
Air IDR IDR IDR IDR
9 Conditioner 1 2,750,000 2,750,000 1.5 1,833,333 255
5.61
1 IDR IDR IDR IDR
0 Trash Bin 1 5,000,000 5,000,000 3 1,666,667 231
1 IDR IDR IDR IDR
1 Bookshelf 1 3,200,000 3,200,000 4 800,000 111
1 IDR IDR IDR IDR
2 Television 1 1,250,000 1,250,000 5 250,000 35
1 44.4 IDR IDR 1 IDR IDR
3 Landscaping 675 350,000 15,563,625 0 1,556,363 216
IDR IDR
Total CEO Room 34,656,475 4,813
General Manager Room
1
24.8 IDR IDR 0 IDR IDR
1 Land 675 1,000,000 24,867,500 0 248,675 35
2 Building 675 5,250,000 130,554,375 0 13,055,438 1,813
IDR IDR IDR IDR
3 Desk 1 3,000,000 3,000,000 5 600,000 83
IDR IDR IDR IDR
4 Chair 1 1,000,000 1,000,000 5 200,000 28
IDR IDR IDR IDR
5 Table 1 50,000 50,000 5 10,000 1
IDR IDR IDR IDR
6 Sofa (Single) 2 2,500,000 5,000,000 5 1,000,000 139
IDR IDR IDR IDR
7 Light 1 100,000 100,000 1 100,000 14
Air IDR IDR 1. IDR IDR
8 Conditioner 1 2,750,000 2,750,000 5 1,833,333 255
IDR IDR IDR IDR
9 Trash Bin 1 5,000,000 5,000,000 3 1,666,667 231
1 IDR IDR IDR IDR
0 Bookshelf 1 2,300,000 2,300,000 4 575,000 80
1 Landscaping 675 350,000 8,703,625 0 870,363 121
IDR IDR
Total GM Room 20,159,475 2,800
Secretary Room
1
1 Land 8 1,000,000 10,780,000 0 107,800 15
2 Building 8 5,250,000 56,595,000 0 5,659,500 786
IDR IDR IDR IDR
3 Desk 1 3,000,000 3,000,000 5 600,000 83
IDR IDR IDR IDR
4 Chair 1 1,000,000 1,000,000 5 200,000 28
IDR IDR IDR IDR
5 Sofa (Double) 1 3,000,000 3,000,000 5 600,000 83
6 and socket) 1 150,000 150,000 1 150,000 21
7 Conditioner 1 2,750,000 2,750,000 5 1,833,333 255
IDR IDR IDR IDR
8 Trash Bin 1 5,000,000 5,000,000 3 1,666,667 231
IDR IDR IDR IDR
9 Board 1 500,000 500,000 6 83,333 12
0 Landscaping 8 350,000 3,773,000 0 377,300 52
IDR IDR
Total Secretary Room 11,277,933 1,566
5.62
Finance, Accounting, GA Room

1
120. IDR IDR 0 IDR IDR
1 Land 785 1,000,000 120,785,000 0 1,207,850 168
2 Building 785 5,250,000 634,121,250 0 63,412,125 8,807
IDR IDR IDR IDR
3 Desk 5 3,000,000 15,000,000 5 3,000,000 417
IDR IDR IDR IDR
4 Chair 5 1,000,000 5,000,000 5 1,000,000 139
IDR IDR IDR IDR
5 Trash Bin 5 50,000 250,000 3 83,333 12
IDR IDR IDR IDR
6 Bookshelf 1 2,300,000 2,300,000 4 575,000 80
7 and socket) 2 150,000 300,000 1 300,000 42
8 Conditioner 2 2,750,000 5,500,000 5 3,666,667 509
IDR IDR IDR IDR
9 Computer Set 5 5,000,000 25,000,000 5 5,000,000 694
1 IDR IDR IDR IDR
0 Board 1 500,000 500,000 6 83,333 12
1 120. IDR IDR 1 IDR IDR
1 Landscaping 785 350,000 42,274,750 0 4,227,475 587
IDR IDR
Total Finance, Accounting and GA Room 82,555,783 11,466
Sales and Marketing Room
1
1 Land 785 1,000,000 120,785,000 0 1,207,850 168
2 Building 785 5,250,000 634,121,250 0 63,412,125 8,807
IDR IDR IDR IDR
3 Desk 4 3,000,000 12,000,000 5 2,400,000 333
IDR IDR IDR IDR
4 Chair 4 1,000,000 4,000,000 5 800,000 111
IDR IDR IDR IDR
5 Trash Bin 4 50,000 200,000 3 66,667 9
IDR IDR IDR IDR
6 Bookshelf 1 2,300,000 2,300,000 4 575,000 80
6 and socket) 2 150,000 300,000 1 300,000 42
7 Conditioner 2 2,750,000 5,500,000 5 3,666,667 509
IDR IDR IDR IDR
8 Computer Set 4 5,000,000 20,000,000 5 4,000,000 556
IDR IDR IDR IDR
9 Board 1 500,000 500,000 6 83,333 12
1 120. IDR IDR 1 IDR IDR
0 Landscaping 785 350,000 42,274,750 0 4,227,475 587
IDR IDR
Total Sales and Marketing Room 80,739,117 11,214
Meeting Room
1
1 Land 625 1,000,000 86,362,500 0 863,625 120
2 Building 625 5,250,000 453,403,125 0 45,340,313 6,297
IDR IDR IDR IDR
3 Meeting Table 1 6,000,000 6,000,000 5 1,200,000 167
5.63
IDR IDR IDR IDR
4 Chair 12 1,000,000 12,000,000 5 2,400,000 333
IDR IDR IDR IDR
5 Trash Bin 1 50,000 50,000 3 16,667 2
6 and socket) 2 150,000 300,000 1 300,000 42
7 Conditioner 2 2,750,000 5,500,000 5 3,666,667 509
IDR IDR IDR IDR
8 Projector Set 1 4,000,000 4,000,000 3 1,333,333 185
IDR IDR IDR IDR
9 Board 1 500,000 500,000 6 83,333 12
0 Landscaping 625 350,000 30,226,875 0 3,022,688 420
IDR IDR
Total Meeting Room 58,226,625 8,087
Lobby
1
1 Land 375 1,000,000 21,437,500 0 214,375 30
2 Building 375 5,250,000 112,546,875 0 11,254,688 1,563
IDR IDR IDR IDR
3 Sofa (Double) 2 6,000,000 12,000,000 5 2,400,000 333
IDR IDR IDR IDR
4 Sofa (Single) 2 1,000,000 2,000,000 5 400,000 56
IDR IDR IDR IDR
5 Trash Bin 1 50,000 50,000 3 16,667 2
6 and socket) 2 150,000 300,000 1 300,000 42
7 Conditioner 2 2,750,000 5,500,000 5 3,666,667 509
IDR IDR IDR IDR
8 Table 1 4,000,000 4,000,000 3 1,333,333 185
IDR IDR IDR IDR
9 Pot 1 500,000 500,000 6 83,333 12
0 Landscaping 375 350,000 7,503,125 0 750,313 104
IDR IDR
Total Lobby 20,419,375 2,836
Restrooms
1
1 Land 475 1,000,000 11,147,500 0 111,475 15
2 Building 475 5,250,000 58,524,375 0 5,852,438 813
3 and socket) 2 150,000 300,000 1 300,000 42
IDR IDR IDR IDR
4 Closet 2 1,250,000 2,500,000 5 500,000 69
IDR IDR IDR IDR
5 Sink 2 875,000 1,750,000 5 350,000 49
IDR IDR IDR IDR
6 Urinoir 2 1,500,000 3,000,000 5 600,000 83
IDR IDR IDR IDR
7 Exhaust Fan 2 300,000 600,000 5 120,000 17
Place for IDR IDR IDR IDR
8 Tissue 1 100,000 100,000 3 33,333 5
IDR IDR IDR IDR
9 Hand Dryer 1 273,000 273,000 2 136,500 19
5.64
1 IDR IDR IDR IDR
0 Place for Soap 1 75,000 75,000 3 25,000 3
1 Landscaping 475 350,000 3,901,625 0 390,163 54
IDR IDR
Total Restroom for Office 8,418,908 1,169
Pantry Room
1
1 Land 5 1,000,000 12,250,000 0 122,500 17
2 Building 5 5,250,000 64,312,500 0 6,431,250 893
3 and socket) 1 150,000 150,000 1 150,000 21
IDR IDR IDR IDR
4 Sink 1 875,000 875,000 5 175,000 24
IDR IDR IDR IDR
5 Table 1 300,000 300,000 5 60,000 8
IDR IDR IDR IDR
6 Chair 6 100,000 600,000 5 120,000 17
IDR IDR IDR IDR
7 Kitchen Set 1 2,500,000 2,500,000 5 500,000 69
8 Landscaping 5 350,000 4,287,500 0 428,750 60
IDR IDR
Total Pantry 7,987,500 1,109
Janitor Room
1
1 Land 5 1,000,000 12,250,000 0 122,500 17
2 Building 5 5,250,000 64,312,500 0 6,431,250 893
3 and socket) 1 150,000 150,000 1 150,000 21
IDR IDR IDR IDR
4 Closet 1 1,250,000 1,250,000 5 250,000 35
IDR IDR IDR IDR
5 Sink 1 875,000 875,000 5 175,000 24
IDR IDR IDR IDR
6 Table 2 100,000 200,000 5 40,000 6
IDR IDR IDR IDR
7 Chair 6 273,000 1,638,000 5 327,600 46
IDR IDR IDR IDR
8 Locker 1 75,000 75,000 7 10,714 1
IDR IDR
Total Janitor 7,507,064 1,043
IDR IDR 1 IDR IDR
1 Power Panel 1 20,000,000 20,000,000 0 2,000,000 278
IDR IDR
Total for Office Room and Facilities 333,948,256 46,382
Health Care
1 Land 3 1,000,000 96,530,000 0 1,930,600 268
2 Building 3 5,250,000 506,782,500 0 50,678,250 7,039
3 Landscaping 3 350,000 33,785,500 0 3,378,550 469
4 and socket) 1 150,000 150,000 1 150,000 21
5.65
IDR IDR IDR IDR
5 Bed 2 1,000,000 2,000,000 5 400,000 56
IDR IDR IDR IDR
6 Table 1 500,000 500,000 5 100,000 14
IDR IDR IDR IDR
7 Chair 4 350,000 1,400,000 5 280,000 39
IDR IDR IDR IDR
8 Shelf 1 1,000,000 1,000,000 7 142,857 20
IDR IDR IDR IDR
9 Closet 1 1,250,000 1,250,000 5 250,000 35
1 IDR IDR IDR IDR
0 Sink 1 875,000 875,000 5 175,000 24
1 IDR IDR IDR IDR
1 Pharmacist 3 300,000 900,000 1 900,000 125
IDR IDR
Total for Health Care 58,385,257 8,109
Musholla
1 Land 075 1,000,000 47,407,500 0 948,150 132
2 Building 075 5,250,000 248,889,375 0 24,888,938 3,457
3 Landscaping 075 350,000 16,592,625 0 1,659,263 230
4 and socket) 1 150,000 150,000 1 150,000 21
IDR IDR IDR IDR
5 Sajadah Set 39 120,000 4,680,000 3 1,560,000 217
IDR IDR IDR IDR
6 Shelf 2 500,000 1,000,000 5 200,000 28
IDR IDR IDR IDR
7 Carpet 2 50,000 100,000 1 100,000 14
IDR IDR
Total for Musholla 29,506,350 4,098
Cafetaria
1
IDR IDR 0 IDR IDR
1 Land 413 1,000,000 412,580,000 0 4,125,800 573
IDR IDR 1 IDR IDR
2 Building 413 5,250,000 2,166,045,000 0 216,604,500 30,084
IDR IDR 1 IDR IDR
3 Landscaping 413 350,000 144,403,000 0 14,440,300 2,006
4 and socket) 15 150,000 2,250,000 1 2,250,000 313
Table for IDR IDR IDR IDR
5 Eating 17 120,000 2,040,000 3 680,000 94
IDR IDR IDR IDR
6 Chair 65 500,000 32,500,000 5 6,500,000 903
IDR IDR IDR IDR
7 Cooking Tools 3 50,000 150,000 1 150,000 21
Sink for IDR IDR IDR IDR
8 Wasing Hand 4 875,000 3,500,000 5 700,000 97
IDR IDR IDR IDR
9 Trash Bin 3 100,000 300,000 2 150,000 21
1 Sink for IDR IDR IDR IDR
0 Washing Kits 2 500,000 1,000,000 5 200,000 28
1 IDR IDR IDR IDR
1 Shelf 1 300,000 300,000 5 60,000 8
1 IDR IDR 1 IDR IDR
2 Rerigerator 1 1,500,000 1,500,000 0 150,000 21
5.66
1 Water IDR IDR IDR IDR
3 Dispenser 1 300,000 300,000 5 60,000 8
1 Kitchen 23.2 IDR IDR IDR IDR
4 Set 2 1,500,000 34,830,000 10 3,483,000 484
1 IDR IDR IDR IDR
5 Plant 2 100,000 200,000 1 200,000 28
1 IDR IDR IDR IDR
6 Gas Stove 1 2,500,000 2,500,000 5 500,000 69
IDR IDR
Total for Food Service 250,253,600 34,757
Truck Parking Lot
1506 IDR IDR 10 IDR IDR
1 Land .75 1,000,000 1,506,750,000 0 15,067,500 2,093
Outdoor IDR IDR IDR IDR
2 Lighting 4 500,000 2,000,000 10 200,000 28
IDR IDR IDR IDR
3 Asphalt 50 100,000 5,000,000 1 5,000,000 694
IDR IDR IDR IDR
4 Parking 401 30,000 12,030,000 4 3,007,500 418
IDR IDR
Total for Truck Parking Lots 23,275,000 3,233
Motorcycle Parking Lot
1 Land 5 1,000,000 955,500,000 0 9,555,000 1,327
2 Lighting 26 200,000 5,200,000 10 520,000 72
IDR IDR IDR IDR
3 Asphalt 63 100,000 6,300,000 1 6,300,000 875
IDR IDR IDR IDR
4 Parking 449 30,000 13,470,000 4 3,367,500 468
IDR IDR IDR IDR
5 Flowers 2 400,000 800,000 10 80,000 11
IDR IDR 20 IDR IDR
6 Trees 17 600,000 10,200,000 0 51,000 7
IDR IDR
Total for Motorcycle Parking 19,873,500 2,760
Car Parking Lot
IDR IDR 10 IDR IDR
1 Land 4410 1,000,000 4,410,000,000 0 44,100,000 6,125
2 Lighting 60 200,000 12,000,000 10 1,200,000 167
IDR IDR IDR IDR
3 Asphalt 185 100,000 18,500,000 1 18,500,000 2,569
IDR IDR IDR IDR
4 Parking 413 30,000 12,390,000 4 3,097,500 430
IDR IDR IDR IDR
5 Grass 3812 300,000 1,143,600,000 5 228,720,000 31,767
Landscapin IDR IDR IDR IDR
6 g 4410 350,000 1,543,500,000 10 154,350,000 21,438
IDR IDR
Total for Car Parking Lots 449,967,500 62,495
Shipping and Receiving
1041 IDR IDR 10 IDR IDR
1 Land .25 1,000,000 1,041,250,000 0 10,412,500 1,446
5.67
Outdoor 65.07 IDR IDR 1 IDR IDR
2 Lighting 8125 200,000 13,015,625 0 1,301,563 181
3 Parking 5 30,000 22,687,500 1 22,687,500 3,151
IDR IDR IDR IDR
4 Asphalt 285 100,000 28,500,000 4 7,125,000 990
IDR IDR 1 IDR IDR
5 Trucks 4 230,000,000 920,000,000 0 92,000,000 12,778
IDR IDR
Total Shipping and Receiving 133,526,563 18,545
Storage
1
IDR IDR 0 IDR IDR
1 Land 607.6 1,000,000 607,600,000 0 6,076,000 844
IDR IDR 1 IDR IDR
2 Building 607.6 5,250,000 3,189,900,000 0 318,990,000 44,304
IDR IDR 1 IDR IDR
3 Landscaping 607.6 350,000 212,660,000 0 21,266,000 2,954
IDR IDR IDR IDR
4 Lamp 130 100,000 13,000,000 1 13,000,000 1,806
Long Shelf IDR IDR 1 IDR IDR
5 for DM 1 100,000,000 100,000,000 0 10,000,000 1,389
Shorter Shelf IDR IDR 1 IDR IDR
6 for DM 5 70,000,000 350,000,000 0 35,000,000 4,861
Shelf for IDR IDR 1 IDR IDR
7 IDM 10 60,000,000 600,000,000 0 60,000,000 8,333
Air IDR IDR IDR IDR
8 Circulator 80 1,000,000 80,000,000 5 16,000,000 2,222
IDR IDR
Total Storage 480,332,000 66,713
Warehouse
1
1 Land 88 1,000,000 1,083,880,000 0 10,838,800 1,505
2 Building 88 5,250,000 5,690,370,000 0 569,037,000 79,033
3 Landscaping 88 350,000 379,358,000 0 37,935,800 5,269
IDR IDR IDR IDR
4 Lamp 88 100,000 8,800,000 1 8,800,000 1,222
5 CAC 5 50,000,000 250,000,000 0 25,000,000 3,472
6 ROT 5 60,000,000 300,000,000 0 30,000,000 4,167
Air IDR IDR 1 IDR IDR
7 Circulator 56 1,000,000 56,000,000 5 3,733,333 519
IDR IDR
Total Warehouse 685,344,933 95,187
IDR
Total Office and Other Facilities Equipment Investment 2,583,970,629.7 IDR
Depreciation 6 358,884.81
5.68
Table 4.19. Depreciation on Machinery and Equipment
N
Type Depreciation/Year
o Depreciation/hr
Investment on Machinery and Equipment for IDR IDR

1 Production Floor 923,643,236 128,284
IDR IDR
2 Investment on Office and Other Facilities 2,583,970,629.76 358,884.81
IDR IDR
Total Depreciation 3,507,613,866 487,169
After calculate the investment on machinery and equipment for production and on
office and other facilities, the depreciation of the facility calculated, the total
depreciation is IDR 487,169/hr.
4.6.4. Other Expense
Beside labor, material, machinery and equipments cost, there are several expenses
needed, such as belows.
Table 4.20. Other Expenses
No Type Depreciation/Year Depreciation/hr

1 Utilities IDR 12,000,000 IDR 5,000
2 Office Supplies IDR 35,000,000.00 IDR 14,583
3 Machinery Maintenance Cost IDR 15,000,000 IDR 6,250
4 Building Maintenance Cost IDR 15,000,000 IDR 6,250
5 Water Cost IDR 18,000,000 IDR 7,500
6 Electricity IDR 311,474,198 IDR 129,781
7 Tax IDR 10,000,000 IDR 4,167
Total Other Expense IDR 416,474,198 IDR 173,531
5.69
4.6.5. Production Cost per Unit Product
After summarize the total cost from material, job, machinery and equipment, and
other expenses, the production cost are summed all and the result are shown as
belows.
No Cost ROT CAC

1 Direct Cost:
Direct Material IDR 8,193,523 IDR 14,600,875
Direct Labor IDR 1,182,741 IDR 774,759
MHC IDR 18,000,000 IDR 12,000,000
2 Indirect Cost:
Indirect Material IDR 1,649,997 IDR 1,322,040
Indirect Labour IDR 2,163,826 IDR 1,417,424

Depreciation IDR 294,352.04 IDR 192,816.55
Other Expense IDR 104,849.08 IDR 68,681.83
Total Production Cost per Hour IDR 31,589,288 IDR 30,376,597
Total Production Cost per Unit per Hour IDR 2,632,440.68 IDR 1,898,537.28
The production cost of ROT per unit, is IDR 2,632,440.68 and the production cost
of CAC per unit, is IDR 1,898,537.28.
CHAPTER V
CONCLUSION
The summary of evaluation score of each layout that has been generated. It can be
seen that the third layout (second iteration) is the best layout for the whole factory.
The adjacent score of third layout (second iteration) is the closest one to 1.
The fourth layout has the biggest score and the closest to the value of 1.00 than
other. It indicates that the best layout is the fourth layout before iteration. The best
layout also can be seen from the Rel-Distance score. The fourth layout has rank 1,
second one fill the 2nd placed, third layout with rank 4, and for the first layout is
3rd rank.
The best layout is the 2nd iteration layout as the final layout of production floor
with total cost is 2,611,402, as the lowest cost.
The production cost of ROT per unit, is IDR 2,632,440.68 and the production cost
of CAC per unit, is IDR 1,898,537.28.
REFERENCES
Freivalds,Andris and Niebel, Benjamin. (2009). Niebel’s Methods, Standards, and
Work Design, Twelfth Edition.New York : McGraw-Hill.

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4/17/2018 FINAL PROJECT

Subject : Facility Design

Lecturer : Anastasia Lidya Maukar, S.T., M.Sc., M.MT.

Subject : Facility Design

Lecturer : Anastasia Lidya Maukar, S.T., M.Sc., M.MT.

Facility layout and design is an important component of a whole operations both

a. To determine the weaknesses of the flow of the production in the company.

1.3 Tools and Equipment(s)

a. Gather all of the information that required to the facilities design

2.1 Company Profile

2.4. Company Logo

Figure 2.1. Waltz Company

2.5 Company Services

Waltz Company leverages its expertise in material experience and expertise to

2. System design and production process

3. Product management design

4. Material handling services

5. Project management services

2.6. Structure of Company

Figure 2.2. Structure Organization

2. Production and Design Department

3.1. Engineering Drawing

Engineering Drawing can produce a picture of an item with 2Dimension

3.1.1. 2 Dimension Projection

3.1.2 3 Dimension Projection

3.2. Operation Process Chart

Gives everyone a clear understanding of the process

3.3 Assembly Chart

3.5 Part Specification

Each part is of a certain type

3.6 Material Specification

The specification is applicable to a raw material or a semi-fabricated material

DATA COLLECTION AND ANALYSIS

4.1. Product’s Engineering Drawing

4.2. Bill of Material

Table 4.1. Bill of Material ROT

Level Part Part Name Quantity Make/Buy

Level To p Surface Assembly Pedestal Assembly

Figure 4.1. Product Structure ROT

Table 4.2. Bill of Material CAC

Level Part No. Part Name Qty Make

SA Arm & Hanger Bolt Washer 1/4" Cap Nut 1/4"

Dowelli Dowelli Side

Figure 4.2. Product Structure CAC

Table 4.3 Material Specification of ROT

Materi Mater Specification Number

Mater Mater Specification Number

4.4. Machine Specification and Dimension

Figure 4.3. Jointer Machine

Motor 2 HP ( 1.500 Watt )

Figure 4.4. Circular Saw

3. Radial Arm Saw

Figure 4.5. Radial Arm Saw

Table 4.8. Radial Arm Saw Specifications

Dimension (mm) 1,110 x 1,476 x 1,710

Table 4.9. Router Specifications

A disc sander is most commonly implemented as a stationary machine that consists of

Figure 4.7. Disc Sander

Table 4.10. Disc Sander Specifications

Disc diameter 305mm (12")

Figure 4.8. Drill Press Machine

Figure 4.9. Table Saw Machine