1. Designing A New Layout
for a Manufacturing Facility
Asma A. Qassemi U00021076
Mahra Al Hammadi U00022069
Doaa Waleed Abuyousef U00022692
Dana A. Abdelrahman U00022873
Senior Design Project II (0405491)
2. PROJECT OUTLINE
■ INTRODUCTION
■ PROBLEM STATEMENT
■ PROEJECT OBJECTIVES
■ Design CONSTRAINTS
■ METHODOLOGY
■ CURRENT LAYOUTS
■ DEVELOPMENT of A NEW LAYOUT
■ CONCLUSION AND RECOMMENDATIONS
4. PROBLEM STATEMENT
Emirates Metallic Industries Company (EMIC) is an exclusive and
unique company, which is manufacturing cans as well as sheets in
variety of sizes and shapes using high technology methods.
assembly painting printing pressing packaging
Production Lines
cans Tuna cans
coated
sheets
printed
sheets
Easy open
Ends
Running 24 hours to produce different products such as;
5. PROBLEM STATEMENT
Service
center
EMIC
NEW
manufacturer
company
The Company identified that there is a need to design an efficient layout in a
new location with the area of 130,000 (260 x 500).
6. PROEJECT OBJECTIVES
The objective of this project is to get hands on experience working on a real life
problem, aimed at designing a layout for the combined two branches of EMIC in
order to:
To utilize available space most effectively.
Minimize material handling cost.
Minimize overall production time.
Provide for employee convenience, safe, healthy, and comfort workplace.
7. DESIGN CONSTRAINTS
Design
Constrains
1) Space
Requirements
3) Health
and Safety
2) Efficiency
Rate
11. Area Requirement (Service Center)
Departm
ent NO.
Department Name Area( 𝒎 𝟐) Total Area( 𝒎 𝟐)
1 coil storage area (22.70x76.10)+(14.85x24
.30)
2088.3
2 ink storage area 22.9x5.10 116.8
3 new cutting area (8x24.3)+(4x50.4) 396
4 old cutting area 6.9x42.2 291.2
5 coil cutting area 6.9x11.3 78
6 Coating and printing
department
51.15x40.40 2066.5
7 food section 51.885x56.6 2936.7
8 food section store 40.2x25.5 1025.1
9 coating store 25.5x16 408
10 design section 15.55x7.2 112
11 Finish good store 40.2x16.2 651.2
14. Departm
ent NO.
Department Name Area( 𝒎 𝟐
) Total Area( 𝒎 𝟐
)
1 sheet cutting area 26x34.1 886.6
2 Store1 28x34.1 954.8
3 assembly department 30.7x57.4 1762.2
4 pressing department 17.0x57.4 975.8
5 finish good store 31.7x45.7 1448.7
Area Requirement (EMIC 1)
15. Personnel Requirements
According to analysis and data provided from survey following
problems were identified:
There isn’t enough parking for employees.
Employees don’t have any lockers or cabinet where they can put
their clothes or any personal staff.
Only few restrooms available for employees and it’s located far
away from working environment.
There is only one small kitchen which is far from production area,
no vending machines offered along the factory and no specific
cafeterias are there.
16. Material Handling
NO. Material Handling
Equipment
Description Type Quantity Fuel Type
1 Forklift Move the material
between departments.
(3 tons) 14 Gas
(15 tons) 2 Gasoline
2 Trolley Move the materials
within department.
- 10 -
3 Bridge Crane Move heavy weight of
coils in production area.
- 2 Gas
17. Health and Safety
Service Center of EMIC Company suffers from two main problems that may
affect the health of employees which are noise and air contaminate.
1) Noise
18. 2) Air Contaminate
Coating department due to the painting process. This is because they use
thinner to paint without having any ventilation system
The workers don’t wear masks to protect themselves from the bad smell.
Paint thinners emit fumes, which can cause nausea, headache or breathing
trouble.
The toxins in the paint thinner can absorbed into the body, so it will causes
skin irritation or skin inflammation.
In the long term inhale the thinner for long time will causes Kidney
problems, Cancer, Muscle weakness, Lack of coordination and Deaths from
heart failure or asphyxiation
19. DEVELOPMENT OF A NEW LAYOUT
Developing Blocks Using SLP Developing Blocks Using CORELAP
20. Space Requirements
Departmen
t NO.
Department Name Total Area (𝒎 𝟐)
1 Coil storage 9835
2 Coil cutting 1443
3 Printing and Coating 2860
4 Coating and Ink store 1439
5 Store 1 950
6 Food section 6866
7 Store 2 1989
8 Prepress(design) 484
9 Sheet cutting 1439
10 Pressing 1470
11 Assembly 1426
12 Store 3
2966
13 Store 4
2946
Total Area
36113
31. CONCLUSION & FUTURE WORK
Summary
The new one require area 271 x 166 = 44,986 m2
The efficiency of the alternatives ranged from
76% to 87% and the recommended alternative
efficiency= 76.05%
33. Recommendations for Future
Improve the personnel requirement
Improve the material handling
Solve the safety problems
Improve the ventilation system
