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Facility Plant Lay Out

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Submitted By Krishella
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Republic of the Philippines
Polytechnic University of the Philippines
COLLEGE OF ENGINEERING
INDUSTRIAL ENGINEERING DEPARTMENT
Sta. Mesa Manila
Tel. No. 718 – 76 – 32 to 45

Republic of the Philippines
Polytechnic University of the Philippines
COLLEGE OF ENGINEERING
INDUSTRIAL ENGINEERING DEPARTMENT
Sta. Mesa Manila
Tel. No. 718 – 76 – 32 to 45

CE VISION The College of Engineering envisions itself to be center of excellence in engineering education. CE MISSION
The College of Engineering is committed to produce competitive engineers who will serve as catalyst for sustainable growth and development in national and international levels. CE GOALS 1. Provide Quality education through instruction, advance research and extension services: 2. Produce world-class professionals as potential industry leaders and job providers 3. Develop and improve facilities through the use of adapted technology and indigenous materials and: 4. Maintain, upgrade and improve facilities through the adaptation of engineering techniques. OBJECTIVES 1. Strengthen the BSIE program consistent with global trends; 2. Develop faculty as competent mentors and quality researchers, through advanced studies, and other facets of continuing professional education; 3. Develop the critical thinking and communication skills of students, giving emphasis to research and extension services; 4. Equip graduates with appropriate knowledge and technical skills imbued with desirable work attitudes and moral values, through enhanced teaching/learning process by using multimedia facilities on top of traditional methods; 5. Create a conducive teaching and learning atmosphere with emphasis to faculty and students’ growth and academic freedom; 6. Establish network with educational institutions, Industries, GO’s and NGO’s, local and international, which could serve as: a. Funding sources and/or partners of researches, b. Sources of new technology. c. Centers for faculty and students’ exchange programs and on-the-job trainings, and d. Grantees of scholarships/ additional facilities and; 7. Continuously conduct action researches on the needs of laboratory and other facilities that could be locally produced or innovated using local materials and adapted technology.

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CE VISION The College of Engineering envisions itself to be center of excellence in engineering education. CE MISSION
The College of Engineering is committed to produce competitive engineers who will serve as catalyst for sustainable growth and development in national and international levels. CE GOALS 5. Provide Quality education through instruction, advance research and extension services: 6. Produce world-class professionals as potential industry leaders and job providers 7. Develop and improve facilities through the use of adapted technology and indigenous materials and: 8. Maintain, upgrade and improve facilities through the adaptation of engineering techniques. OBJECTIVES 8. Strengthen the BSIE program consistent with global trends; 9. Develop faculty as competent mentors and quality researchers, through advanced studies, and other facets of continuing professional education; 10. Develop the critical thinking and communication skills of students, giving emphasis to research and extension services; 11. Equip graduates with appropriate knowledge and technical skills imbued with desirable work attitudes and moral values, through enhanced teaching/learning process by using multimedia facilities on top of traditional methods; 12. Create a conducive teaching and learning atmosphere with emphasis to faculty and students’ growth and academic freedom; 13. Establish network with educational institutions, Industries, GO’s and NGO’s, local and international, which could serve as: e. Funding sources and/or partners of researches, f. Sources of new technology. g. Centers for faculty and students’ exchange programs and on-the-job trainings, and h. Grantees of scholarships/ additional facilities and; 14. Continuously conduct action researches on the needs of laboratory and other facilities that could be locally produced or innovated using local materials and adapted technology.

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IN PARTIAL FULLFILMENT IN SPECIAL PROBLEMS IN IE (INEN 4053)

Facility/Plant Layout
(A Case Study)

Submitted by:

Peñaflor, Krishella Marie C.
Preclaro, Queeny P.

BSIE 5-2

Submitted to:

Engr. Rhodora Buluran

IN PARTIAL FULLFILMENT IN SPECIAL PROBLEMS IN IE (INEN 4053)

Facility/Plant Layout
(A Case Study)

Submitted by:

Peñaflor, Krishella Marie C.
Preclaro, Queeny P.

BSIE 5-2

Submitted to:

Engr. Rhodora Buluran

I. TITLE
A Case Study: Kirby's Bread House’s Re-examination of the Utilization of Space.

II. INTRODUCTION A facility layout is an arrangement of everything needed for production of items or provide services. A facility is an entity that facilitates the performance of any job. Facility layout is an arrangement of everything needed for production of goods or delivery of services. A facility is an entity that facilitates the performance of any job. It may be a machine tool, a work center, a manufacturing cell, a machine shop, a department a warehouse and others. In industry sectors, it is important to manufacture the products which have good quality products and meet customers’ demand. This action could be conducted under existing resources such as employees, machines and other facilities. However, plant layout improvement, could be one of the tools to response to increasing industrial productivities. It is a business strategy that focuses on improving customer requirement understanding, business system productivity and financial performance. Plant layout has set a new trend of excellence in the business environment and is enjoying great popularity.
III. BACKGROUND OF THE STUDY
Company Profile:
Kirby's Bread House; that belongs to the Tipas Group of Bakeshop was owned by Mr. Rodolfo G. Flores who was one of the offspring of Atty. Rey Flores whom started the business in 1965 in Taguig.
Kirby's Bread House mainly produces foods that were made out of flour especially breads. You can find different taste, size and shape of breads. One of their best seller was hopia. Their hopia comes in different flavor. They are one of the most known supplier of hopia that is affordable, convenient at the same time delicious. Their product can be bought even in sari-sari’s stores with in Metro Manila and other places in Luzon.
An initial interview has been conducted by the students in the Kirby’s Bakeshop owned by Mr. Rodolfo G. Flores located at Brgy. Ibayo Tipas, Taguig City. Information were gathered by means of one-on-one interview with Mr. Flores; the owner of the bakeshop.
According to the owner of the bakeshop, the workers’ efficiency were affected because most of the time, the workers took so much time and distance in travelling from one workstation to another. The owner itself together with the workers, want to improve the lay out of the production area to be able to lessen the distance they travel and travel time to maximize working hours; thus increase productivity where both company and workers will benefit.

IV. DISCUSSION
This study shall focus on the elements and principles to be applied for the improvement of the Company's Facility/plant layout also in providing an alternative or solution for the current issues and challenges the Company is facing.

The following are the topics to be studied and given focus: * Tipas Group of Bakeshop (Kirby's Bread House) * Company's Facility/Plant Layout
This study limits the use of any documents and other source of information from Tipas Group of Bakeshop (Kirby's Bread House), located at Taguig City.
The students fixate on gathering data by observation and one-on-one interview with the management.

Process Layout
At the production of Hopia, the process starts with acquiring the needed ingredients from the storage room for making two different mixtures of dough. There are 2 mixers (machines) provided for the separate mixing of ingredients for dough 1 and dough 2. After several minutes of producing the two different dough, these will be transferred to the next work station where it will be kneaded and prove for a couple of minutes. After achieving the desired rose of the two dough, it will be processed on the next workstation. Dough 1 and Dough 2 will be combined and kneaded at the same time. When the dough was already kneaded well, it will be stored for several minutes to allow yeast dough to rise before baking. Next is cutting the dough into smaller pieces in a different work station, then it will be transferred to the next working area for the stuffing. Monggo, Baboy and Ube are the three major fillings of Kirby’s Breadhouse’s hopia. After several processes, the hopia is all ready for cooking then packaging. Along with these is the making of filling.

To be able to acquire optimized layout, a comparison between the existing and proposed layout is shown and studied.

Existing Plant Layout

Activity | Distance (Meter) | Time (Sec) | Brings ingredients to Mixing for first dough | 1.36 | 1.56 | Brings ingredients to Mixing for second dough | 1.03 | 1.18 | Transfers the first dough to kneading and proofing area | 2.04 | 2.35 | Transfers the second dough to kneading and proofing area | 1.3 | 1.5 | Transfers the first and second dough to Combining and proofing area | 1.2 | 1.38 | Transfers the combined dough to cutting area | 1.2 | 1.38 | Transfers the dough to filling 1 | 4.9 | 5.64 | Transfers the dough to filling 2 | 3.1 | 3.55 | Transfers the dough to filling 3 | 2.04 | 2.35 | Brings the mixed filling to Filling 1 | 5.61 | 6.45 | Brings the mixed filling to Filling 2 | 3.14 | 3.61 | Brings the mixed filling to Filling 3 | 4.71 | 5.42 | Transfers the filled dough 1 to cooking area | 6.39 | 7.35 | Transfers the filled dough 2 to cooking area | 4.37 | 5.03 | Transfers the filled dough 3 to cooking area | 2.66 | 3.06 | Transfers the cooked hopia to packing | 1.34 | 1.54 | Total: | 46.39 | 53.35 |
Time and Motion Study for Existing Layout Activity | Quantity of the products | Cycle time | No. of Manpower | Mixing of first dough | 17.5 kl | 4 | 1 | Mixing of second dough | 17.5 kl | 4 | | Kneading and proofing of first and second dough | 25 kl | 20 | 2 | Kneading, combining of first and second dough, and proof | 25 kl | 20 | 2 | Cutting the dough and proof | 25 kl | 20 | 2 | Cooking the filling 1 | 10 kl | 15 | 1 | Cooking the filling 2 | 10 kl | 15 | | Cooking the filling 3 | 10 kl | 15 | | Mixing of filling 1 | 10 kl | 4 | 1 | Mixing of filling 2 | 11 kl | 4 | | Mixing of filling 3 | 12 kl | 4 | | Filling 1 | 1 pc | 0.22 | 2 | Filling 2 | 1 pc | 0.22 | 2 | Filling 3 | 1 pc | 0.22 | 2 | Cooking the hopia | | 3 | 2 | Packaging | 20 pcs | 2 | 5 |
Data Gathered of the Existing Layout

Di ko lang alam kung isasama ko pa itong data gathered of the existing layout kasi kumbaga sa machine di na mapapabago pa ung bilis ng pag produce…..
Katulad ng scenario ng kay JUZ tingin ko lang…

V. FINAL RECOMMENDATION

Proposed Plant Layout

Activity | Distance (Meter) | Time (Sec) | Brings ingredients to Mixing for first dough | 1.36 | 1.56 | Brings ingredients to Mixing for second dough | 1.03 | 1.18 | Transfers the first dough to kneading and proofing area | 1.33 | 1.53 | Transfers the second dough to kneading and proofing area | 1.4 | 1.61 | Transfers the first and second dough to Combining and proofing area | 1.2 | 1.38 | Transfers the combined dough to cutting area | 1.2 | 1.38 | Transfers the dough to filling 1 | 3.5 | 4.03 | Transfers the dough to filling 2 | 2.7 | 3.11 | Transfers the dough to filling 3 | 1.94 | 2.23 | Brings the mixed filling to Filling 1 | 3.1 | 3.57 | Brings the mixed filling to Filling 2 | 3.15 | 3.62 | Brings the mixed filling to Filling 3 | 3.31 | 3.81 | Transfers the filled dough 1 to cooking area | 2.45 | 2.82 | Transfers the filled dough 2 to cooking area | 2.1 | 2.42 | Transfers the filled dough 3 to cooking area | 2 | 2.3 | Transfers the cooked hopia to packing | 1.4 | 1.61 | Total: | 33.17 | 38.16 |
Time and Motion Study for Proposed Layout After conducting the time and motion study to Kirby’s Bread House it results to increase the efficiency of the production by 3.51%. From 46.39 meters distance traveled of the workers that consumed 53.35 seconds it reduced by 13.22 meters and 15.19 seconds, respectively.

VI. CONCLUSION At the end of the study, the students found out that Plant layout design has become a fundamental basis of today’s industrial plants which can influence parts of work efficiency. It is needed to appropriately plan and position employees, materials, machines, equipment, and other manufacturing supports and facilities to create the most effective plant layout. An efficient layout may also contribute to the reduction in the production cycles, work-in-progress, idle times, number of bottlenecks or material handling times and to the increase in the production output, with obvious implications on productivity This case study attempts to explain and illustrate the improvement of modification of facility plant layout using the CELLULAR LAYOUT for utilizing the space and to eliminate the cumbersome because of the congestion or lengthy and unnecessary movements of product-in -progress or workers in the production.

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