This document provides details on the design of a Tefal cooking pot production facility. It includes: 1. Drawings and bills of materials for the pot and its components. 2. Process design details like the production route sheets, assembly chart, and operation process chart. 3. Machine schedule design with the required machines listed and calculated, including the HACO 200 Ton hydraulic press. 4. Facility area designs including the production area layout in a product layout, with material flowing sequentially from stores to warehouse. The required production area is calculated to be 40 square meters.

1. TEFAL POT
Group (4)
Facility Planning Micro Project
Alexandria University
Faculty of Engineering
Production Engineering Department
Third Year
Facilities Planning and Material Handling (PE313)

2. Table of Contents
1. Introduction........................................................................................................................1
2. Product ..............................................................................................................................1
2.1. Name of the product....................................................................................................1
2.2. Function of the product................................................................................................1
3. Product design ..................................................................................................................1
3.1. Drawing of product in isometric view & exploded view ...............................................1
3.1.1. Isometric view (using solid works 2013)................................................................1
3.1.2. Exploded view (using solid works 2013) ...............................................................2
3.2. Drawing of each component (using solid works 2013)................................................2
3.2.1. Pot body drawing ..................................................................................................2
3.2.2. Pot body handle drawing.......................................................................................2
3.2.3. Pot cover drawing .................................................................................................3
3.2.4. Pot cover handle drawing......................................................................................3
3.2.5. Pot body handle installation screw drawing ..........................................................3
3.2.6. Pot body handle installation nut drawing...............................................................4
3.2.7. Rubber seal ring drawing ......................................................................................4
3.2.8. Pot Cover handle installation pin...........................................................................4
4. Process design..................................................................................................................5
4.1. Parts list.......................................................................................................................5
4.2. Bill of material (using X-mind 6) ..................................................................................5
4.3. Route sheet.................................................................................................................6
4.4. Assembly chart (using X-mind 6) ................................................................................7
4.5. Operation process chart..............................................................................................8
5. Schedule design................................................................................................................8
5.1. Machine.......................................................................................................................8
5.1.1. List of the required Machines................................................................................8
5.1.2. Annual demand for the product.............................................................................9
5.1.3. Number of required machines for each type.......................................................10
5.2. Operators ..................................................................................................................12
5.2.1. Approximate number of needed operators in the production area......................12
5.2.2. Number of operators for each machine type.......................................................12
6. Facility Areas design .......................................................................................................12

3. TEFAL POT
Group (4)
Facility Planning Micro Project
Alexandria University
Faculty of Engineering
Production Engineering Department
Third Year
Facilities Planning and Material Handling (PE313)

4. 6.1. Production Area.........................................................................................................12
6.1.1. List of departments in the production area..........................................................12
6.1.2. Name of layout for the production area...............................................................13
6.1.3. Schematic drawing showing flow of material from stores to warehouse (using
edraw max 7.8)................................................................................................................13
6.1.4. The production area drawing (using edraw max 7.8)..........................................14
6.1.5. The required production area..............................................................................15
6.2. Personal requirements areas ....................................................................................15
6.2.1. Parking area........................................................................................................15
18 employees in manufacturing section................................................................................16
6.2.2. Food service area ...............................................................................................17
6.2.3. Other areas (Locker room, rest room and health room) .....................................18
7. Material handling.............................................................................................................20
7.1. Fork lift.......................................................................................................................20
7.2. Conveyor...................................................................................................................22
8. Conclusion.......................................................................................................................23
List of figures
Figure 1 : Tefal Pot isometric view ..........................................................................................1
Figure 2 : Tefal pot exploded view ..........................................................................................2
Figure 3 : Pot body ..................................................................................................................2
Figure 4 : Pot body handle ......................................................................................................2
Figure 5 : Pot cover .................................................................................................................3
Figure 6 : Pot cover handle .....................................................................................................3
Figure 7 : Pot body handle installation screw..........................................................................3
Figure 8 : Pot body handle installation nut ..............................................................................4
Figure 9 : Rubber seal ring......................................................................................................4
Figure 10 : Pot cover handle installation pin ...........................................................................4
Figure 11 : Bill of material........................................................................................................5
Figure 12 : Assembly chart......................................................................................................7
Figure 13 : Opertaion process chart........................................................................................8
Figure 14 : Material flow........................................................................................................13
Figure 15 : Production area...................................................................................................14
Figure 16 : Parking layout......................................................................................................15
Figure 17 : Food service layout .............................................................................................17
Figure 18: Men's rest and locker room layout .......................................................................18
Figure 19 : Women's rest and locker room............................................................................19
Figure 20 : Health service......................................................................................................19
Figure 21 : Fork truck ............................................................................................................20

5. Figure 22 : Fork truck 1 flow..................................................................................................21
Figure 23 : Fork truck 2 flow..................................................................................................21
Figure 24 : Fork truck 3 motion..............................................................................................21
Figure 25 : Conveyor.............................................................................................................22
List of tables
Table1 : Parts list....................................................................................................................5
Table2 : Pot body Route sheet...............................................................................................6
Table3 : Pot cover Route sheet..............................................................................................7
Table 4 : List of required machines .........................................................................................8
Table 5 : Number of required machines ................................................................................10
Table 6 : Operators distribution.............................................................................................12
Table 7 : Parking calculations................................................................................................16
Table 8 : Food service calculations.......................................................................................18
Table 9 : Material handling ....................................................................................................20

6. 1 | P a g e
Tefal Pot
1. Introduction
 Our Product was Tefal Cooking Pot
 The Product is The Base™
2 Pot Set provides essential non stick performance
for people who love to cook but hate to clean up. It’s the perfect size and weight
for use on any backcountry excursion. Its compact design is pack friendly, and
there’s room inside for adding mugs and plates to customize your kitchen
without taking up more space
 Material Used: Stainless Steel Alloy with PTC Non-Stick Coating that also can
resist thermal shocks
 So we can control the manufacturing process of the pot with maximum
efficiency we needed to achieve near optimum results for 2 main parameters in
our project:
 Facility Design & Planning for the entire process of production
 Product Design & Evaluation Process (Design & Manufacturing Process)
2. Product
2.1. Name of the product
Tefal pot
2.2. Function of the product
Cook and distribute heat in the whole pot body equally so it can cook your meals in
most delightful and tasty way possible
3. Product design
3.1. Drawing of product in isometric view & exploded view
3.1.1. Isometric view (using solid works 2013)
Figure 1 : Tefal Pot isometric view

7. 2 | P a g e
3.1.2. Exploded view (using solid works 2013)
3.2. Drawing of each component (using solid works 2013)
3.2.1. Pot body drawing
3.2.2. Pot body handle drawing
Figure 2 : Tefal pot exploded view
Figure 3 : Pot body
Figure 4 : Pot body handle

8. 3 | P a g e
3.2.3. Pot cover drawing
3.2.4. Pot cover handle drawing
3.2.5. Pot body handle installation screw drawing
Figure 5 : Pot cover
Figure 6 : Pot cover handle
Figure 7 : Pot body handle installation screw

9. 4 | P a g e
3.2.6. Pot body handle installation nut drawing
3.2.7. Rubber seal ring drawing
3.2.8. Pot Cover handle installation pin
Figure 8 : Pot body handle installation nut
Figure 9 : Rubber seal ring
Figure 10 : Pot cover handle installation pin

10. 5 | P a g e
4. Process design
4.1. Parts list
Table1 : Parts list
Make /
buy
SizeQuantity
Per unit
NameNumber
MakeBase 220X10 mm
Rest of body
240X145 mm
1Body01
Buy55 X 55 mm2Body Handle02
Buy230 mm Diameter1Cover03
Buy60 mm Dia. X 40
mm height
1Cover Handle04
Buy20 mm Dia. X 30
mm height
2Screws05
Buy8 mm Dia. X 7 mm
long
2Nuts06
Buy236 mm
Diameter
1Rubber seal ring07
Buy20 mm Dia. X 30
mm height
1Pin08
4.2. Bill of material (using X-mind 6)
Figure 11 : Bill of material

11. 6 | P a g e
4.3. Route sheet
Table2 : Pot body Route sheet
Product: Tefal pot Part number: 01 Part name: Pot body Raw material: Stainless steel
Operation
time
Setup
time
Dept.ToolM/C typeOperation
Description
Operation
Number
8 sec.s6 min.sTefal Pot
Production
Line
Designed
for
variable
sizes
HACO 200 Ton
Hydraulic Press
Semi Automatic
Machine
Deep drawing for
blanks
0101
6 sec.s4 min.sTefal Pot
Production
Line
Single
point
cutting
tool
MT 22 FR LatheTearing0102
38 sec.s12 min.sTefal Pot
Production
Line
Twist drill,
Spot
welding
contact
point
Semi Robotic
Machine
Drilling and spot
welding for nuts
0103
7 sec.s------Tefal Pot
Production
Line
Pneumatic
driver
Pneumatic Screw
Driver
Handling
installation
0104
22 sec.s------Tefal Pot
Production
Line
--------RC Thermal
Packaging Oven
Packaging oven0105

12. 7 | P a g e
Table3 : Pot cover Route sheet
Product: Tefal pot Part number: 03 Part name: Pot Cover Raw material: Stainless steel
Operation
time
Setup timeDept.ToolingM/C typeOperation
Description
Operation
Number
7 sec.s--------Tefal Pot
Production
Line
Pneumatic Screw
Driver
Plunger (Handle)
installation
0201
6 sec.sManualPackaging0202
4.4. Assembly chart (using X-mind 6)
Figure 12 : Assembly chart

13. 8 | P a g e
4.5. Operation process chart
Figure 13 : Opertaion process chart
5. Schedule design
5.1. Machine
5.1.1. List of the required Machines
Table 4 : List of required machines
Machine
Name
Machine Picture Operation
Name
Operation picture
HACO 200 Ton
hydraulic Press
Deep
drawing

14. 9 | P a g e
MT 22 FR
lathe
Tearing
Semi Robotic
Machine
Drilling and
spot
welding for
nuts
Pneumatic
screw driver
Handling
installation
Thermal
packaging
oven
Packaging
oven
5.1.2. Annual demand for the product
16,000 Parts

15. 10 | P a g e
5.1.3. Number of required machines for each type
Table 5 : Number of required machines
Machine Name Operation
Name
Scrap
estimate
S Q
(units/year)
H E R Setup
time
F
HACO 200 Ton
hydraulic press (A)
Deep
drawing
6% 8 sec.s 22385 8 hrs 81% 90% 6 min.s 1
MT 22 FR Lathe (B) Tearing 8 % 6 sec.s 21042 8 hrs 86% 85% 4 min.s 1
Semi Robotic
machine (C)
Drilling and
spot welding
for nuts
5 % 38 sec.s 19358 8 hrs 90% 95% 12 min.s 1
Pneumatic screw
driver (D)
Handling
installation
No scrap in
pots but
scrap in
threads may
reach 13%
14 sec.s 18390 8 hrs 78% 90% ---------- 1
RC Thermal
Packaging oven (E)
Packaging No scrap 22 sec.s 16000 8 hrs 80% 60% ---------- 1
5.1.3.1. Calculations of Q and F
 Annual production for the product (Output) = 16,000 units
 Number of working days = 5 days / week
For machine (A)
Q =
/
( )( )( )( )( )
=
( . )( . )( . )( . )( )
= 22385.22396 units/year

16. 11 | P a g e
F = +
=
∗ .
. ∗ . ∗ ∗ ∗ ∗ ∗ ∗
+
∗ ∗ ∗ ∗
∗ ∗ ∗ ∗
=
0.296 m/c = 1 Machine
For Machine (B)
Q =
/
( )( )( )( )
=
( . )( . )( . )( )
=
21042.11052 units/year
F= +
=
∗ .
. ∗ . ∗ ∗ ∗ ∗ ∗ ∗
+
∗ ∗ ∗ ∗
∗ ∗ ∗ ∗
=
0.033 m/c = 1 Machine
For Machine (C)
Q =
/
( )( )( )
=
( . )( . )( )
=
19358.74168 units/year
F= +
=
∗ .
. ∗ . ∗ ∗ ∗ ∗ ∗ ∗
+
∗ ∗ ∗ ∗
∗ ∗ ∗ ∗
=
0.149 m/c = 1 Machine
For Machine (D)
Q =
/
( )( )
=
( . )( )
= 18390.8046 units/year
F= +
=
∗ .
. ∗ . ∗ ∗ ∗ ∗ ∗ ∗
+ 0 = 0.053 m/c = 1 Machine
For Machine (E)
Q =
/
( )
=
( )
= 16,000 units/year
F= +
=
∗
. ∗ . ∗ ∗ ∗ ∗ ∗ ∗
+ 0 = 0.106 m/c = 1 Machine

17. 12 | P a g e
5.2. Operators
5.2.1. Approximate number of needed operators in the production area
15 operators
5.2.2. Number of operators for each machine type
This approach for selection the proper number of workers in the production line (no
services is included) based on the aggregate planning of the production line
Note: The production line has 3 Engineers to Maintain, monitor & control the
production line
The Handle Installation Workstation consist from two sub branches handle installation
1) Handle installation for Pot body
2) Handle Installation for Cover
The Distribution of workers on the main production line is as following:
Table 6 : Operators distribution
Number of
Workers
Workstation M/C Used
1 Deep drawing for blanks
HACO 200 Ton
Hydraulic Press
Semi Automatic Machine
1 Tearing
MT 22 FR Lathe
1 Drilling and spot welding for nuts Semi Robotic Machine
5 Handling installation Pneumatic Screw Driver
3 Cleaning Manual
4 Packaging RC Thermal Packaging Oven
6. Facility Areas design
6.1. Production Area
6.1.1. List of departments in the production area
1. Manufacturing (Body making + Handle Assembly + Inspection + Packaging)
2. Design Office
3. Management
4. Cafeteria
5. Health Office
6. Rest rooms / Locker Room

18. 13 | P a g e
6.1.2. Name of layout for the production area
Product Layout
And that for the following reasons:
Product layouts are found in flow shops (repetitive assembly and process or
continuous flow industries).
Flow shops produce high-volume, highly standardized products that require highly
standardized, repetitive processes. In a product layout, resources are arranged
sequentially, based on the routing of the products. In theory, this sequential layout
allows the entire process to be laid out in a straight line, which at times may be totally
dedicated to the production of only one product or product version. The flow of the
line can then be subdivided so that labour and equipment are utilized smoothly
throughout the operation. So that will be the most suitable layout for us.
6.1.3. Schematic drawing showing flow of material from stores to warehouse
(using edraw max 7.8)
Figure 14 : Material flow

19. 14 | P a g e
6.1.4. The production area drawing (using edraw max 7.8)
Figure 15 : Production area

20. 15 | P a g e
6.1.5. The required production area
 Total machine length = 1.5+1.5+4+12+1.5 = 20.5 m
 Total length = 1.5+1.5+4+12+1.5+1.5 = 22 m
 Machine area = 22 × 1.8 = 40 m2
 Cover assembly machine area = 22 × 1.5 = 33 m2
 Total layout area = 13.8 × 22 = 305 m2
Required production area = 13.8 m X 22 m
6.2. Personal requirements areas
6.2.1. Parking area
6.2.1.1. Parking layout drawing
Figure 16 : Parking layout

21. 16 | P a g e
6.2.1.2. Calculation of the required area of parking
+ Number of employees in the firm= 65 employees distributed as the following:
18 employees in manufacturing section
12 employees in workshop (Maintenance)
3 employees for material handling
8 employees in inventory section
7 employees for service (Cafeteria-cleaning- Security)
17 employees for management
+ As the firm is neither centralized nor served by public transportation so 1 parking
place is provided for every 1.25 employees
∴ The number of spaces in firm = 50 spaces
+Types of cars:
 45% of all cars driven to work are compact cars.
 50% of all cars driven to work are standard cars.
 5% of the spaces allocated for handicapped cars
 PW=SW = 12 feet
Estimated parking area:
 90 feet width
 200 feet depth
 Cross aisle width = 15 feet
Notes:
 No walls and no walking edge
 Parking angle of 90 degrees
“Module used is module 4”
Table 7 : Parking calculations
Type of car PW=SW W Number of spaces per
module
Compact 8 57’2’’ (90/8)*2= 23
Standard 8’6’’ 66’ (90/8.5)*2= 23

22. 17 | P a g e
 Required spaces for compact cars:
 45% × 50 = 22 spaces
 Required spaces for standard cars:
 50% × 50 = 25 spaces
 Required spaces for handicapped cars:
 5% × 50 = 3 spaces
 Therefore parking layout includes 1 module for compact cars and 2 modules for
standard cars.
Assume handicapped cars will park in Row 1 with standard cars:
 Therefore, remaining space in row (1) = 60 – (12×3) = 54 feet.
 Calculating number of spaces in each row:
Row (1): Number of spaces = 54/8.5 = 6 spaces
Row (2, 3, 4): Number of spaces = (60-30)/8.5 = 7 spaces
Row (5): Number of spaces = 60/8 = 8 spaces
Row (6): Number of spaces = 90/8 = 12 spaces
NOTE:
“Row (4) will include 5 standard cars and 2 compact cars”
6.2.2. Food service area
6.2.2.1. Food service layout drawing
Figure 17 : Food service layout

23. 18 | P a g e
6.2.2.2. Calculation of the required area of the food service
 As number of employees is less than 200 employees so we use a vending
machine + Cafeteria
 1 hour (from 11.00 am to 12.00 am) is provided daily for meals divided into 2
sections as the following
Table 8 : Food service calculations
Begin of meal Time sat down in chair End of lunch break
11.00 11.10 11.30
11.20 11.30 11.50
 So the Vending machine area and the cafeteria area is provided for 33
employees in the shift
 Vending machine requires 1 ft2
per person
 Cafeteria requires 15 ft2
per person using 36-in square tables
6.2.3. Other areas (Locker room, rest room and health room)
6.2.3.1. Men’s rest and locker room
Figure 18: Men's rest and locker room layout
Area = 29.26 m2

24. 19 | P a g e
6.2.3.2. Women’s rest and locker room
Figure 19 : Women's rest and locker room
Area = 29.26 m2
6.2.3.3. Health service room
Figure 20 : Health service
Area= 132 m2

25. 20 | P a g e
7. Material handling
7.1. Fork lift
 Flexible motion
 Variety of load capacity ( can handle up to one ton load of material)
 Load is one carton which is low quantity material moved
 Distance moved from warehouse to production line which is long distance
 And according to Material Handling Equipment diagram which help us choose
optimum type of material handling equipment
Powered trucks are best solution for long distance and small quantity (carton)
We choose one ton fork truck as load handled is less than load capacity of it
and decrease costs .One ton fork truck needs 9 aisle widths
Table 9 : Material handling
Equipment usage
Fork truck 1 Blanks to deep drawing
Nuts for spot welding
Screw & Handle for pot body
Fork truck 2 Pins , Seals , Cover , Handle (for
covers)
Thermal packages , Cartons
Fork truck 3 Cover to final packaging
Products to warehouse
Figure 21 : Fork truck

26. 21 | P a g e
Fork truck 1
First one moves from storage to deep drawing machine holding 1000 Blank and
back to storage holding zero material then go to spot welding machine holding
2000 nuts , 1000 handle for cover then go back to storage to begin new cycle
Figure 22 : Fork truck 1 flow
Fork truck 2
Moves from storage holding body handles, Packages and cartons to pneumatic
screw driver then to oven then to packaging and go back to storage to begin a new
cycle
Figure 23 : Fork truck 2 flow
Fork truck 3
Moves from Cover packaging holding 1000 Cover Packaged to final packaging
area to be packed with body in cartons then holding cartons from final packaging
area to Warehouse and the go back to cover packaging to begin new cycle
Figure 24 : Fork truck 3 mo on
Storage
Deep
drawing
Storage
Handle
installition
of cover
Nuts for
spot
welding
machine
Storage
Storage
pnematic
screw
driver
Thermal
packaging
oven
final
Packaging
Storage
Cover
Packaging
Final
packaging
area
Warehouse
Cover
packaging

27. 22 | P a g e
7.2. Conveyor
Second Material handling equipment in production line
In Line production case:
 Load is unity and high quantity material moved
 Need accumulation of loads at Packaging
 Linear motion between machines which is short distance
 Don’t need any inclination motion
 And according to Material Handling Equipment diagram which help us choose
optimum type of material handling equipment
Conveyors are best solution for short distance and large quantities handled
Usage (Specific): Tefal body handling from deep drawing machine to the end of the
process
Figure 25 : Conveyor

28. 23 | P a g e
8. Conclusion
In this report we have discussed our design approach & its implementation in terms of
design, manufacturing & process, and then we discussed the major elements
effecting the production of that product (Machines, Tools, Materials & work force).
After that we took a look on the facility strategic planning in respect to 3 major points
 Production Line
 Personnel Requirement
 Logistics
Then we introduce a solution based on real data acquired from Zahran Co. Egypt we
used the Six Sigma implementation for trying to improve productivity and lower the
waste
In this report we used many tools that helped us in collecting, processing & analysis
the data to get the required information that we need for the discussion of this project
like:
 MS Office Package
 CAD using Solidworks
 FEA using JMAG Designer
 Plant Simulation using Siemens Plant Simulation
 Layout Drawing using Edraw Max
 Charts Design & Drawing using Xmind
In the end we hope we could have managed to give a basic foundation of the effect of
facility planning on the production quality based on our case study.