Stage 3

 PATHAN Manufacturing Co. Peoria , Illinois

 By – MANSOORKHAN PATHAN- 353797
Table of contents

• Review of Stage 2

• Relationship Chart & Activity Table

• Dimensionless Block Diagram

• Total Spaces for Departments

• Block Diagram

• Summary
 1
1. Main Office
(managers’ offices) 2
I 3
2. Receiving area U 4
U E 5
3. Shipping area U U 6
E U U 7
4. Final Assembly I U U 8
Line U U 9
A U
I I 10
E U
Relationship
5. Trumatic 5000
area U U I U 11
A
U I 12
6. Truma bend V50 E U I
13
Chart Design A U I U U U
7. Rivet machines E U U U U E 14
area A U U I U A U
14
1
8. Spot welding U U I U U U
machines area
U
2
U U U U A
9. One additional U
3
restroom in the plant
U I U U
E I U
I
I
4
10. Cafeteria U U U U
5
E U U
6
U
U
7
11. Medical Services U U
8
U U I 9
12. Maintenance U U
E
10
U
E
13. Raw Material Storage
11
U 12
14. Finished Items Storage
13
 Activity Relationship Table
Activities A E I O U X
1 Main office 4,13 2,9,11 3,5,6,7,8,10,12,14
2 receiving area 13 1,8,9 3,4,5,6,7,10,11,12,14
3 shipping area 14 4 5,9 1,2,6,7,8,10,11,12,13
4 final assembly area 5 6,3,1 9,11 7,8,10,12,13,14,2
5 Trumatic 5000 area 6,4 7 11,14,3 1,2,8,9,10,12,13
6 7,5 4,8 13 1,2,3,9,10,11,12,14
trumabend V50 area
7 rivet machine areas 6,8 5 11 1,2,3,4,9,10,12,13,14
8 spot welding area 7 6 2,11 1,3,4,5,9,10,12,13,14
9 one additional restroom 10 1,2,3,4,14 5,6,7,8,11,12,13
area
10 9,11 1,2,3,4,5,6,7,8,12,13,14
Cafeteria
11 10 1,4,5,7,8 2,3,6,9,12,13,14
Medical Services
12 13,14 1,2,3,4,5,6,7,8,9,10,11
Maintenance
13 2 1,12 6 14
Raw materials storage
14 Finish good storage 3 12 5,9 1,2,4,6,7,8,10,11,13
Dimensionless Block Diagram
14 4 13,14
12.
3. shipping
Maintenance
5,9

3 12 7 6 6,8 5 10
14. Finish good 11. Medical
8. spot welding 7. rivet machine
storage Services
5,9
2,11 11 1,4,5,7,8
5 1,3,6 4,6 5,7 4,8 9,11
4. final 5. Trumatic 6. trumabend
10. Cafeteria
assembly 5000 V50
9,11 3,11,14 13

4 2 1,12 10
13. Raw
1. Main office materials 9. restroom
storage
6 1,2,3,4,14
2,9,11

13

2. receiving

1
 Total Spaces for Each Department •

•
Total Estimated Space Needed : 18050 sft

Add 50% More to Include Aisles: 27075 sft

Activities Round up to 5 ft = 1 cell/ # of

# of machines Sq ft each machine Proposed Total Sq ft 100 wide x length cells
1. Office

4000 100*40 20 x 8
2. Receiving area 600 30 x 20 6x4
3. Shipping area 800 40 x 20 8x4
4. Final assembly
2 1000 2000 2000 100 x 20 20 x 4
5. Trumatic 5000

7 600 4200 4200 84 x 50 17 x 10

6. TrumaBend V50

8 180 1440 1500 75 x 20 15 x 4

7. Riveter area
6 60 360 400 20 x 20 4x4
8. Spot Welder
11 60 660 700 35 x 20 7x4
9. Additional restroom 500 25 x 20 5x4
10. Cafeteria 10 sq ft/person 500 25 x 20 5x4

11. Medical Services 15 sq ft/worker 750 25 x 30 5x6

12. Maintainance 300 sq ft/machine (600) + other spaces 1000 50x20 10 x 4

13. Raw materials storage 10 ft x 5 ft (6 areas) + pallets 600 30x20 6x4

14. finish good storage may already set outside of PO machines 500 25x20 5x4
Block Diagram
1 cell = 5 ‘ x 5’

13,14
12. Maintenance 7 6 6,8 5

8. spot welding 7. rivet

4,8
machine
2,11 11
14 4
3. shipping 4,6
5,9

6. trumabend V50
3 12 5. Trumatic 5000
14. Finish
good storage 10
5,9 3,11,14
5 1,3,6 11. Medical
Services
4. final assembly
9,11 1,4,5,7,8

10. 9,11

5,7

13
4
Cafeteria

1. Main office 2 13. Raw

1,12 10
materials 9. restroom
6 storage 1,2,3,4,14
2,9,11
13
2. receiving
1
Making of bottom lid

• Forklift speed – 50000 ft / hr

• Conveyor Speed – 15000 ft / hr
• Labor Rate – $10 / hr
• Batch size – 100 pieces

• Efficiency – 97 % (ID: 353797)

Operation Chart

Tray Handle Tray End Tray Body Bottom Lid Top Lid Tray shelf Box ends Box Body
5 300 5 180set 5 240 5 240 5 180 5 150set 5 150set 5 180
3.33 5.56 4.17 4.17 5.56 6.66 6.66 5.56
180set
180 240 90 10 10 120
10 180 10 10 5.56
5.56 10 4.17 11.11 8.33
5.56
120set
Weld tray shelves 15
102.86 8.33
120 20 9.71
20
100 8.33 90
15 Weld tray ends 15
10 11.11

SA 120
Weld top lid 1
5 CNC Punch

e
120 8.33

Li n
15
8.33 SA 120
10 CNC Bend

bly
Weld bottom lid 2 8.33

sem
15 Weld Metal A 240

As
Place tray 4.17
20 Rivet 1
Pack out A2 102.86
A4 Manual op. 9.71
Total hours needs for produce 1000 tool boxes = 168.31 hours
Summary

• Constructed Relationship Chart, block diagrams and Process Chart

• The ideal design requires careful consideration.

• Considering machinery, manpower, takt time and standard time in order to obtain better results