MANUFACTURING FACILITIES DESIGN AND MATERIAL HANDELING

TRAVAIL REALISE PAR :

AIT OUFKIR ISMAIL
BEN-ZOHRA REDA
BZOUNE YOUSSEF
TIGHRAMTE MEHDI

Le calcul dans le livre est fait pour produire 1500 grills par jour avec trois shifts
Pour mieux comprendre les résultats et les formules de calculs on va refaire les
calculs pour produire 5000 grills par jour avec une seule shift.

1.TAKT TIME :
On produira 5000 grills par jour avec une shift, on prendra 50 min d’arrêts et
pauses.
1 shift
75 % efficiency
Available time: 430 min
Producing 5000 pcs
Takt time= 0,0645 min/pcs

2.SCRAP RATES :
 Operation scrap rates
Cutting 1%
Drilling 0.25%
Shearing 0.5%
Stamping 0.25%
Bending
Welding
Deburring 0.5%
Sanding 0.5%
Painting
Assembling
Insepectig
Packaging
Trimming 0.1%
Molding 0.1%
Quantity per
Parts NO. Part Name day Operations Needed Calculated Scrap Parts per day
STG4 Legs 20000 Cutting 355,0000 20355
Drilling
Bending
Deburing
Welding
Painting
STG7 Wood slats 25000 Cutting 444 25444
Drilling
Sanding
Control
STG12 pannel 5000 Shearing 64 5064
Stamping
Bending
Deburing
STG8 Top support 10000 Shearing 76 10076
Stamping
Bending
Bottom
STG9 support 10000 Shearing 101 10101
Stamping
Bending
Drilling
STG5 Tube plugs 20000 Molding 203 20203
STG13 Knob 5000 Molding 51 5051
STG6 Leg extensions 10000 Molding 102 10102
STG10 Tank holder 5000 Shearing 51 5051
Stamping
Bending
Drilling
STG11 Axle 5000 Cutting 51 5051
 3.FRACTION EQUIPEMENT :

4.LINE BALANCE EFFICIENCY :

Time Number of Percent Hours per
Operations standard stations Rounded up Average Time Loaded unit Pieces per hour
1 0,327 5,069767442 6 0,0545 100 0,00545 183,4862385
2 0,304 4,713178295 5 0,0608 90 0,00562963 177,6315789
3 0,293 4,542635659 5 0,0586 90 0,005425926 184,3003413
4 0,275 4,263565891 5 0,055 96 0,004774306 209,4545455
5 0,221 3,426356589 4 0,05525 92 0,004003623 249,7737557
6 0,334 5,178294574 6 0,055666667 94 0,005921986 168,8622754
7 0,234 3,627906977 4 0,0585 88 0,004431818 225,6410256
8 0,43 6,666666667 7 0,061428571 89 0,008052434 124,1860465
9 0,335 5,19379845 6 0,055833333 90 0,006203704 161,1940299
10 0,608 9,426356589 10 0,0608 62 0,016344086 61,18421053
TOTAL 3,361 58 0,066237512 15,0971853

Efficiency 0,845694
 5.ROUTING SHEETS
Part
No. Part Name Drwg.No
STG11 Axle DWG11 Date 12/29/2020
Approved EDF
Oper Fraction
No. Oper.Description Machine Machine No. Cycle Time Equipment Pcs.Hr. Hrs./Pc. Hrs/1000
5 Cutting Big 800 Saw B800 0,165 2,558139535 363,6364 0,00275 2,75

Part
No. Part Name Drwg.No
STG5 Tuble Plugs DWG5 Date 12/29/2020
Approved EDF
Oper Fraction
No. Oper.Description Machine Machine No. Cycle Time Equipment Pcs.Hr. Hrs./Pc. Hrs/1000
75 Molding NISSEI NS60 NS60 0,0625 0,968992248 960 0,001042 1,041667
Ergonomic
65 Trimming Cutters ERGCT 0,073 1,131782946 821,9178 0,001217 1,216667

Part
No. Part Name Drwg.No
STG6 Leg Extensions DWG6 Date 12/29/2020
Approved EDF
Oper Fraction
No. Oper.Description Machine Machine No. Cycle Time Equipment Pcs.Hr. Hrs./Pc. Hrs/1000
75 Molding NISSEI NS60 NS60 0,125 1,937984496 480 0,002083 2,083333
Ergonomic
65 Trimming Cutters ERGCT 0,042 0,651162791 1428,571 0,0007 0,7

Part
No. Part Name Drwg.No
STG8 Top Brace DWG8 Date 12/29/2020
Approved EDF
Oper Fraction
No. Oper.Description Machine Machine No. Cycle Time Equipment Pcs.Hr. Hrs./Pc. Hrs/1000
15 Shearing MINSTER 300 Ton MNS300 0,033 0,511627907 1818,182 0,00055 0,55
20 Stamping MINSTER 300 Ton MNS300 0,033 0,511627907 1818,182 0,00055 0,55
25 Bending MINSTER 300 Ton MNS300 0,033 0,511627907 1818,182 0,00055 0,55
45 Painting IR800 IR800 60 930,2325581 1 1 1000
Part
No. Part Name Drwg.No
STG9 Bottom Brace DWG9 Date 12/29/2020
Approved EDF
Oper Fraction
No. Oper.Description Machine Machine No. Cycle Time Equipment Pcs.Hr. Hrs./Pc. Hrs/1000
15 Shearing MINSTER 300 Ton MNS300 0,033 0,511627907 1818,182 0,00055 0,55
20 Stamping MINSTER 300 Ton MNS300 0,033 0,511627907 1818,182 0,00055 0,55
25 Bending MINSTER 300 Ton MNS300 0,033 0,511627907 1818,182 0,00055 0,55
10 Driling E2 E2 0,246 3,813953488 243,9024 0,0041 4,1
45 Painting IR800 IR800 60 930,2325581 1 1 1000

Part
No. Part Name Drwg.No
STG7 Wood Slats DWG7 Date 12/29/2020
Approved EDF
Oper Fraction
No. Oper.Description Machine Machine No. Cycle Time Equipment Pcs.Hr. Hrs./Pc. Hrs/1000
5 Cutting Big 800 Saw B800 0,165 2,558139535 363,6364 0,00275 2,75
10 Driling E2 E2 0,123 1,906976744 487,8049 0,00205 2,05
Ryobi Drum
40 Sanding Sander RBS 0,167 2,589147287 359,2814 0,002783 2,783333

Part
No. Part Name Drwg.No
STG10 Tank Holder DWG10 Date 12/29/2020
Approved EDF
Oper Fraction
No. Oper.Description Machine Machine No. Cycle Time Equipment Pcs.Hr. Hrs./Pc. Hrs/1000
15 Shearing MINSTER 300 Ton MNS300 0,033 0,511627907 1818,182 0,00055 0,55
20 Stamping MINSTER 300 Ton MNS300 0,033 0,511627907 1818,182 0,00055 0,55
25 Bending MINSTER 300 Ton MNS300 0,033 0,511627907 1818,182 0,00055 0,55
10 Driling E2 E2 0,246 3,813953488 243,9024 0,0041 4,1

Part
No. Part Name Drwg.No
STG13 Knob DWG13 Date 12/29/2020
Approved EDF
Oper Fraction
No. Oper.Description Machine Machine No. Cycle Time Equipment Pcs.Hr. Hrs./Pc. Hrs/1000
75 Molding NISSEI NS60 NS60 0,125 1,937984496 480 0,002083 2,083333
Ergonomic
65 Trimming Cutters ERGCT 0,06 0,930232558 1000 0,001 1
Part
No. Part Name Drwg.No
STG4 Legs DWG4 Date 12/29/2020
Approved EDF
Oper Fraction
No. Oper.Description Machine Machine No. Cycle Time Equipment Pcs.Hr. Hrs./Pc. Hrs/1000
5 Cutting Big 800 Saw B800 0,033 0,511627907 1818,182 0,00055 0,55
10 Driling E2 E2 0,123 1,906976744 487,8049 0,00205 2,05
25 Bending Jutec 850 MNS300 0,167 2,589147287 359,2814 0,002783 2,783333
35 Deburing Handheld Grinder IR625 0,125 1,937984496 480 0,002083 2,083333
Lincoln
30 Welding Resistance LR560 0,5 7,751937984 120 0,008333 8,333333
45 Painting IR800 IR800 60 930,2325581 1 1 1000

Part
No. Part Name Drwg.No
STG12 Control Panel DWG12 Date 12/29/2020
Approved EDF
Oper Fraction
No. Oper.Description Machine Machine No. Cycle Time Equipment Pcs.Hr. Hrs./Pc. Hrs/1000
15 Shearing MINSTER 300 Ton MNS300 0,033 0,511627907 1818,182 0,00055 0,55
20 Stamping MINSTER 300 Ton MNS300 0,099 1,534883721 606,0606 0,00165 1,65
25 Bending MINSTER 300 Ton MNS300 0,033 0,511627907 1818,182 0,00055 0,55
35 Deburing Handheld Grinder IR625 0,125 1,937984496 480 0,002083 2,083333
45 Painting IR800 IR800 60 930,2325581 1 1 1000

6. Assembly chart : Filtre de robinet à base de charbon actif

Après avoir itéré les calculs et avoir appris comment faire on choisira
de réaliser l’assembly chart pour notre projet : Filtre de robinet à
base de charbon actif :

Indented bill of material for the product:

Level Part number Part name Qty per unit Make/Buy

Filtre d'eau à base de charbon
0 actif 1 Make
..2 1 Attache-robinet 1 Buy
..2 2 Capsule de charbon 1 Buy
..2 3 Disque fritté 1 Buy
..2 4 Filling de charbon 5g Make
.1 SSA1 Capsule remplie 1 Make
.1 SSA2 Attache-fritté 1 Make
Assembly line: