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Auxiliary Services Requirement Space

Pertemuan 10

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Auxiliary Services Requirement SpaceManufacturing departments need support services, and these services need space. There are many service functions to consider in a manufacturing plant but the activity centers that require a lion’s share of space are:

Shipping and Receiving Storage Warehousing Maintenance and Tool Room Utilities, Heating, and Air Conditioning

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Shipping and ReceivingWhile shipping and receiving are two separate departments, they have very similar people, equipment, and space requirements. These functions could be placed next to each other or across the plant from each other. The placement of the shipping and receiving departments have a significant effect on the flow of material in the plant.

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Shipping and ReceivingAdvantages

Common Equipment Common Personnel Improved Space

Utilization Reduced Facility

Costs

Disadvantages Space Congestion Poor Material Flow Lost Materials Poor

Communication

5Dock Loaders

Shipping and ReceivingMaterial Handling issues. . .

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Trucking Industry’s EffectThe trucking industry is organized nationally to deliver raw materials and parts to industry in the morning and pick up shipments in the afternoon. This is know as less than truck load quantities (LTL). Full truck loads are handled differently.

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Receiving Department Functions

1. Assist in locating a trailer at the receiving dock door

2. Assist in the unloading of materials3. Record the receipt of the number of containers4. Open, separate, inspect, and count the

received materials5. Develop an overage, shortage, or damage

reports as required6. Create a receiving report7. Route incoming material

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Receiving Department Facilities Dock DoorsDock Doors – Quantity is dependent on

arrival and service rates Dock Plates, Levelers, and BoardsDock Plates, Levelers, and Boards

– Tools used to bridge the door to floor space AislesAisles – Size aisles based upon materials

and handling equipment required Outside AreasOutside Areas – Area around the outside

of the loading dock OfficesOffices – Receiving offices are usually small

(allow 100 sq. ft. / clerk)

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Receiving AreaOffice

5’ Aisle

TURNING

AISLES

9’ Door

Parking Area

Maneuvering Area Road

Trailer parking can consume 65’ from the plant wall

Maneuvering space is usually 45’ Roadways are 11’ one way or 22’ for two-way

traffic

65’ 45’ 11’

22’

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Receiving Area

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Shipping and Receiving

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Shipping Department Functions

1. Packaging finished goods for shipping2. Addressing cartons or containers3. Weighing each container4. Collecting orders for shipping (staging)5. Spotting trailers6. Loading trailers7. Creating bills of lading

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Packaging Workstation

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Packaging Workstations

Pack Bench Packing Workstation

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Determining Shipping Space

Q: The shipping department is estimating the required shipping space for a new line of toolboxes. The company projects a maximum of 2,000 units per day shipping in an 8 x 8 x 18 inch box. The toolboxes will be packaged in the work cell. Uncle Bob’s Freightliner will be using a 40 ft long trailer. How many trailers and how much staging space will be required per day?A: (8 x 8 x 18) / (1,728 cu. in. per ft.) = .66 cu. ft.

= .66 cu. ft. x 2,000 units

= 1,333 cu. ft. per day

A trailer is 8’ wide x 40’ long x 7’ high = 2,240 cu. ft.

Number of trailers per day = 1,333 cu. ft. / 2,240 cu. ft.

= 0.6 trailers per day

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Determining Shipping Space

A: One dock door will be required to meet the expected one day demand. It should be noted that we are utilizing only 60% of the trailer capacity:

(1,333 / 2,240) x 100% = 59.5% or 60%

Internal staging requirements will be a space of:

8’ x 40’ x 60% = 192 sq. ft.

Compensating for the extra space needed for aisles and offices (not inclusive of packing. . . handled in the work cell)

192 sq. ft. x 200% = 384 sq. ft. or 400 sq. ft.

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Storage

Raw Materials Stores Finished Parts Stores Office Supplies Stores Maintenance Supplies

Stores Janitorial Supply Stores

Stores is a term used to denote an area set aside to hold raw materials, parts, and supplies. There are many different types:

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Storage

Maintenance Supply Stores

Example

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StorageThe space requirements for stores is dependent on the stated inventory policy of the company. It may be as simple as “Provide space to store a one-month supply.” Another method is the ABC philosophy. . .Inventory Class

Percentage of Parts

Percentage of $

Inventory Policy

ABC

20%20%60%

80%15%5%

1 wk. supply2 wks. supply1 mth. supply

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Just-in-Time Inventory Storage

Just in time (JIT) is the inventory policy that has begun to roll across the United States after a very successful beginning in Japan. This is a special type of inventory that can affect the plant layout in many ways:

Adjust or eliminate receiving, receiving reports, etc.

Eliminate quality control checks Eliminate or greatly reduce stores

area requirements

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Storage GoalsJIT will not be considered in this course because designing a layout for a non-JIT system is more difficult and, unfortunately, is more common. The goals of any stores department should be:

To maximize the use of the cubic space

To provide immediate access to everything (selectively)

To provide for the safekeeping of the inventory including damage and count control

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WarehousingWarehousing is the storage of finished products. As in the storeroom, the area requirement will depend on management policy. Additional issues include seasonality of products. These may require outside warehousing during peak times. Awarehouse can be a department or an entire building.

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WarehousingThree basic warehousing functions: To safekeep the finished product To maintain some stock of every

product sold by the company To prepare customer orders for

shipment

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Warehousing

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Warehousing

Cantilever Racks Carton Flow Rack Carousel Rack

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Pallet Position ExampleQ: A company wants to store a single part number consisting of 5,000 cartons each containing 20 cartons. How many pallet positions are needed if the pallets are stored three high?

A: Number of pallets required = total cartons / cartons per pallet

= 5,000 / 20

= 250 pallets

Number of pallet positions = total pallets / stored height

= 250 / 3

= 83.33 = 84 pallet positions

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Maintenance and Tool Room

The maintenance and tool room function is to provide and maintain production tooling. These functions vary widely from one company to another. Tool rooms may not exist is some plants because all tools are purchased from outside sources.

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Maintenance and Tool Room

Maintenance is service to the company’s equipment. A mobile service cart may be used, but more commonly, a central maintenance area would include equipment, machine overhead areas, maintenance supplies, and spare parts storage.

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Maintenance and Tool Room

Maintenance can account for 2 to 4 percent of the plant personnel. An extreme may be upwards of 33 percent (paper mills). As a rule of thumb, allow 400 sq. ft. of space for each maintenance employee. This would allow for everything except maintenance stores, which were covered previously.

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Determining Tool Room Space

Q: Our toolbox plant historically used 0.13702 hours per unit of the rate of 100 percent. History indicates that 85 percent equipment performance is more realistic. Determine the number of maintenance personnel required as well as the amount of space allocated for the tool room. Assume production projections of 2,000 toolboxes per day and 3% maintenance.

A: 0.13702 / .85 = 0.16120 hours each

0.16120 x 2,000 units per day

= 322.4 hours of production people

Each person works 8 hours per day, so 41 production people are required

41 x 3% = 1.2 maintenance people

Space = 2 x 400 sq. ft. = 800 sq. ft. for the tool room

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Maintenance and Tool Room

Add a 10 x 10 ft. controlled storeroom for tools and supplies to most plant layouts. This 100 sq. ft. storage area is just a minimum size area for controlling supplies. Therefore in the previous example, total square footage for maintenance will be 900 sq. ft.

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UtilitiesHeat, air conditioning, electrical panels, air compressors, etc. must be considered when

determining space. These areas must be kept separate from normal traffic – electrical panels should be fenced off, heaters must be kept clean, air compressors require

special noise handling. There are few rules of thumb concerning these. . .safety should take precedence

when placing these into the facility plan.

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Questions?