Presenting final results for designing a Can manufacturing facility through assigned project of Facilities Design Class 2015-2016. Under Supervision of Prof. Nermine Harraz.

2. Contents
• Introduction
• Product
• Product Design
• Process Design
• Schedule Design
• Facility Design
• Material Handling
• Conclusion
• References

3. Introduction
Sustainability and Rexam

4. Sustainability
• Since the 1980s sustainability has been used more in the sense of
human sustainability on planet Earth and this has resulted in the
most widely quoted definition of sustainability as a part of the
concept Sustainable development.

5. Rexam
Rexam is a leading global beverage can maker.
They make beverage cans for many of the world’s favourite brands.
Our job is to make those cans as efficiently, profitably and sustainably
as possible so that Their customers can attract and retain the loyalty of
the people who consume their products. This is why, wherever you go
in Rexam, you will see a common focus on operational
excellence, innovation and safety to meet customers’ expectations.

6. Product
Product Standard and Function

7. Product Standard & Function
• Beverage Can (Standard of 330 ml )
• Beverage can of Aluminum made upon request from soda companies
for holding soda drinks.
• The product can be branded as the company request.

8. Product Design
Isometric and Main Design Features

9. Isometric and Main Design
Features
Can IsometricView Can Body Design
Can Lid Design
CanTap Design

10. Process Design
Bill of Material, Route Sheet, Assembly Chart & Operation Process Chart

11. Bill of Material
The beverage can consist of 4 parts manufactured at the facility where
the rivets are the only part to buy.
Bill of material of the can

12. Route Sheet (Body)
Product: Beverage can Part Name: Body
Raw material:
Aluminum Alloy “magnesium &
Manganese” Included
Operation No. Operation Name Machine Department
Operation Time
(sec)
10 Uncoiling Un-coiler Material Preparation 0.01
material travel from coil to next
20 Cupping Cupping press Body Making 0.02
30 Body Making Body maker Body Making 0.02
40 Trimming Trimmer Body Making 0.01
50 Washing Washing m/c Curing & Cleaning 0.02
60 Curing Oven Curing & Cleaning 0.03
70 Printing Printer Product Finalizing 0.01
80 Internal Coating Sprayer Product Finalizing 0.02
90 Necking Necking m/c Product Finalizing 0.01
100 Inspection Can inspector Inspection 0.03
110 Packaging Packaging m/c Packaging & Warehousing 0.03

13. Route Sheet (Lid)
Product: Beverage can Part Name: Lid
Raw material:
Aluminum Alloy “magnesium &
Manganese” Included
Operation No. Operation Name Machine Department
Operation Time
(sec)
10 Un-coiling Un-Coiler Material Preparation
0.01
material travel from coil
next m/c
20 Blanking Punch press Body Making 0.02
30 Punching Punch Press Body Making 0.02
40
Scored Opening laser
marking
LBM Body Making 0.03
50 Curing Oven Curing & Cleaning 0.03
60 Inspection Can inspector Inspection 0.03
70 Riveting & Assembly Assembly m/c Assembly 0.01
80 Packaging Packaging m/c Packaging & Warehousing 0.05

14. Route Sheet (Tap)
Product: Beverage can Part Name: Tap
Raw material:
Aluminum Alloy “magnesium
& Manganese” Included
Operation No. Operation Name Machine Department
Operation Time
(sec)
10 Blanking Punch press Body Making 0.02
20 Punching Punch Press Body Making 0.02
60 Inspection Can inspector Inspection 0.03
70 Riveting & Assembly Assembly m/c Assembly 0.01
80 Packaging Packaging m/c Packaging & Warehousing 0.05

15. Assembly Charts
• The can consists of two main parts, the body and the end where the facility provides the body and the end
unassembled together and they are assembled and the customer’s factory after filling the can with soda.
End Assembly ChartBody Assembly Chart

16. Operation & Process Charts
• Facility operations depend on two main
parallel manufacturing lines where the body is
manufactured and the end is manufactured on
another manufacturing line.
Body processChart End process Chart

17. Schedule Design
Required Machines, Annual Demand Plan, Machine Fraction and Operators

18. Required Machines
(2
)
(3
)
Machine Fraction Calculations

19. Annual Demand Plan
• The plan depends on customers’ demands annually, upon which the whole
production effort are concentrated in the way to fulfill customers’ needs.
Customer Demand (Can)
Coca-Cola 8.2944 B
Carlsberg 4.000 B
Pepsi 4.2944 B
Heineken 4.1472 B
Total Annual Demand 20.736 B
Daily Production 57.6 M
Hourly Production 2.4 M

20. Estimated operators No.
Machine Required no. / facility No. of operators
Un Coiler 2 4
Cupping Press 1 4
Body maker 1 5
Trimmer 1 4
Washers 1 4
Oven 3 9
Printer 1 3
Internal coating m/c 1 3
Necking m/c 1 4
Punch press 2 8

21. Facility Design
Layout Selection, Production Area, Area Calculations, Parking Area & Food
Service

22. Facility Layout Selection
• The Most Suitable layout for the kind of Can production is “Product or Line
Layout”
Justification for this Choice:
• All the processing equipment and machines are arranged according to the
sequence of operations of the product. In this type of layout, only one product of
one type of products is produced in an operating area. This product is
standardized and produced in large quantities.
• The raw material is supplied at one end of the line and goes from one operation
to the next quite rapidly with a minimum work in process, storage and material
handling.

23. Production Area Design

24. Production Area Calculations
(Body Making Section)
Machine
No.
needed
length
dimension
(m)
width
dimension
(m)
Area
(m2)
Clearance
1.524*L+1.21
9*W
(m)
auxiliary
equipment
in process
inventory
total
un coiler 1 1.7 5.1 8.67 8.8077 0 11.25 28.7277
cupping 1 3 1 3 5.791 0 0 8.791
Body maker 1 2.98 2.5 7.45 7.58902 0 0 15.03902
trimmer 1 1.4 2 2.8 4.5716 0 0 7.3716
washer 1 2.45 1.8 4.41 5.928 0 0 10.338
oven 2 2.716 1.8 9.777 6.333384 0 0 16.11098
printer 1 2.75 2 5.5 6.629 0 2 14.129
internal
coating 1 2.45 4.8 11.76 9.585 0 0 21.345
necking 1 1.4 2 2.8 4.5716 0 0 7.3716
Inspection 1 4 2.5 10 9.1435 0 0 19.1435
Total Area 148.3674

25. Production Area Calculations
(End Making Section)
Machine
No.
needed
length
dimension
(m)
width
dimension
(m)
Area
(m2)
Clearance
1.524*L+1.219*W
(m)
auxiliary
equipment
in process
inventory
total
Un coiler 1 1.7 5.1 8.67 8.8077 0 11.25 28.7277
blanking 1 3 1 3 5.791 0 0 8.791
punch 1 3 1 3 5.791 0 0 8.791
scored
opening
laser
marking
1 2.5 5 12.5 9.905 0 0 22.405
oven 1 2.716 1.8
4.888
8
6.333384 0 0
11.2221
8
inspection 1 4 2.5 10 9.1435 0 0 19.1435
Assembly &
Reviting
1 2 2 4 5.486 0 2 11.486
Total Area
110.566
4

26. Parking Area
• Employees are transported to the facility through facility buses to
ensure showing up on time and to decrease efforts and space waste.
• Other officers who reach the facility by their own cars, the facility
provides for them smart parking systems which ensures protection
of their cars and space saving and facilitates the trucks movements
through the parking, thereby facilitating forwarding cans process.
• Smart Parking system is a smart new innovative system where cars
are stored in a vertical manner to save space and energy and protect
cars.

27. Parking Area Calculations
Item
No. of
required
Spaces
Stall length
(m)
Stall Width
(m)
Angle
(degrees)
Outside
turning radii
(m)
Clearance
(m)
Bus 2 12.2 3.7 90 - 4.25
Back-up
Spaces
10 2.75 2.75 90
Module Module Width
W2 20.15
Smart Parking system needed Space
No. of needed Parking
units
Length
(m)
Width
(m)
Height
(m) 6 units of 12 car
unit
6.370 5.100 13.500

28. Parking Layout
Parking Area Design

29. Food Service Area
• Food service area is to provide Full kitchen for employees to ensure they are
getting healthy and sufficient complete meals helping in working circumstances,
Service line to serve meals and cafeteria.
• Break Duration is 60 minutes per working shift, 60 employee is served in a period
of 3o minutes.
Serving shifts time table
Shift Begins
Employees start
start to sit down Shift ends
11:00 11:10 11:30
11:20 11:30 11:50
Required Spaces for Food Service Area
Section No. of Employees Required Space (m2)
Cafeteria 60 275
Service Line 60 – 7 Served/min 92
Kitchen 60 153
Total Required Area 520

30. Food Service Layout
• The Food Service Area is divided
into three main areas Kitchen
area, Service Line area and
Cafeteria Area
Food Service Area Layout

31. Material Handling
Mass Conveyor and Fork lift

32. Mass Conveyor
Mass conveyors are preferred to single
conveyors for the transportation of Cans
to the Empty Can Riser from the De-
palletiser, which will optimize the
storage capacity and allow a constant
Can flow, reducing the risk of can
damage.
To transport empty cans made during
the production line.
Mass Conveyor

33. Fork lift
• A forklift (also called a lift truck,
a fork truck, or a forklift truck) is a
powered industrial truck used to lift
and move materials short distances.
• Used to lift Aluminum Coils and Can
Pallets.
Fork lift

34. Conclusion
• Facility Design depends mainly on the most optimized way to save
space, energy and efforts, where the facility depends on automated
production line and smart operations.

35. References
• Manufacturing Facilities _ Location, Planning, and Design,Third
Edition-CRC Press (2008) - Sule, Dileep R.
• Facilities Planning -Tompkins - 3rd Edition.
• Rexam Annual Report 2015.