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facility planning

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Ocean View Kayaks & Accessories Table of Contents Page # Design of product 3 Product Description 4 Materials 5 Market Research 6 Cost Estimates 7 Bill of Materials 8 Product Drawing 9 Initial Plant Layout 10 Assembly Sequence 11 Indented bill of materials 12 Operations Chart 13 Machinery 14 Draft Layout 15 Relationship Diagram 15 Activity Relationship Worksheet 15 Dimensionless Block Diagram 16 Material Flow 18 Flow Chart 19 Layout 20 Additional Layout Requirements 21 Warehousing Workstation Ergonomics Kayak Make-up Table Paddle Make-up Table Materials Handling Requirements Layout Optimization String Diagram From/To Chart Final Layout Final Layout Drawing Design of Product Product Description Window Kayak The Window kayak is a relatively new product on the market. It is a sit-on-top kayak with a difference. Our Kayak allows the user to view the majestic beauty not only around them but bellow them. This is done by incorporating an acrylic glass window between the user's legs so that they can view the world bellow. Sit-on-top kayaks were developed in the past for lower end recreational users. However have now evolved into one of the highest selling personal non powered water craft. In fact 7 out of 10 kayaks sold are sit-on-tops. The growth in popularity is owed too many factors. The following is a list of key factors; Price: These crafts are much cheaper as made from plastics in mass numbers Ease of Use: If the user falls out of the craft it is very simple to jump back on, unlike with conversional kayaks were this is an impossible feet. This is why sit-on-tops are popular with fishing and SUCUBA diving users. This is because these users require to leave and enter the craft constantly, change seating position, and access storage hatches. Functionality: Sit-on-tops may be used for a variety of applications. In rapids, the bay, rivers, cave exploring, lakes, surf, almost any application thinkable. ...read more.


Buy 0 Kayak With Paddle 1 Make .1 A1 Window Assembly 1 Make ..2 SA1 Fixed Window Assembly 1 Make ...3 0001 Kayak Hull 1 Make ...3 0002 Plexiglas Window 1 Make ...3 0015 Silicone * Buy ..2 0003 Plexiglas Protector 1 Make ..2 0015 Silicone * Buy .1 A2 Rear Hatch Assembly 1 Make ..2 SA2 Lid Assembly 1 Make ...3 0006 Large Storage Lid 1 Make ...3 0012 Rubber Seal 'A' 0.6M Buy ...3 0015 Silicone * Buy ..2 0007 Bungee Rope 1M Buy ..2 0022 Rubber Seal 'B' 0.6M Buy ..2 0020 Hatch Clips 2 Buy ..2 0015 Silicone * Buy .1 A3 Front Hatch Assembly 1 Make ..2 0004 Storage Fitting 1 Buy ..2 0010 Self tapping Screws 6 Buy ..2 0005 Storage Lit 1 Buy ..2 0015 Silicone * Buy .1 A4 Safety Rail & Handle 1 Make ..2 SA4 Handle 1 Make ...3 0011 Handle 2 Make ..2 0008 Nylon Rope 6.5M Buy ..2 0009 Rope Clips 18 Buy ..2 0010 Self tapping Screws 36 Buy .1 A5 Paddle 1 Make ..2 SA5 Paddle Shaft Assembly 1 Make ...3 0014 Shaft 1 Make ...3 0016 Shaft Caps 2 Buy ...3 0015 Silicone * Buy ..2 0013 Paddle 2 Make ..2 0021 Pop Rivet 2 Buy ..2 0015 Silicone * Buy Fig 2.2 Operations Chart Fig 2.3 Machinery Table of Machines Fig 3.1 The following two routing sheets (Fig 3.2 & 3.3) are for the two items which are made in-house, and used in the production of the paddle. Routing Sheet Part #: 0014 Part Name: Shaft Raw Material: Aluminum Order Qty: 1 Fig 3.2 Part #: 0013 Part Name: Paddle Raw Material: Plastic Order Qty: 2 Fig 3.3 Draft Layout Relationship Diagram Fig 4.1 Activity Relationship Worksheet Fig 4.2 Dimensionless Block Diagram First Design 1 2 7 5 11 6 10 8 3 4 9 15 13 c 14 12 Fig 4.3 Second Design 12 13 15 8 7 2 14 9 10 5 1 3 4 6 11 Fig 4.4 Final Design 12 13 15 10 6 Toilet Lunch Cleaning kayak Dispatch Lockers Maint. ...read more.


Optimization of Design Layout For the following techniques applied to our process flow, some assumptions should be pointed out. Upon the completion of any individual part, it is stored in dispatch ready to be used. In our actual factory this is not the case, as parts will be stored as WIP were they will be needed next. Area Key Fig 8.2 Operation Sequence Fig 8.3 String Diagram R A B C D E F G H Fig10.1 From this we see that there is no back tracking, so from a multi-column process chart we would find that this process is 100% efficient. For this reason it was chosen not to do a multi-column process chart. From-To Chart Fig 10.2 Initial From to chart Fig 10.3 Fig 10.4 Fig 10.5 From Fig 10.4 and Fig 10.5 it is easy to find the efficiency of the alphabetical layout. Efficiency = (411/3220) x 100 = 12.7% From Fig 10.5 it is shown that G needs to be closer to D, and D is required closer to R to dramatically improve the efficiency. Fig 10.6 With the rearrangement of area distances there are both improvement in the larger weighted items, and some backtracking for the less weighted items. It is now possible to find the efficiency of the second From-To Chart (Fig 10.6) Efficiency = (411/1255) x 100 = 32.7% This is a huge saving in efficiency. N.B. Ocean view does not work on a production line type basis, so these optimization techniques do not have full relevance when used with processes such as ours. However from the from/to diagram we find the relative importance of having some of the major departments closer to each other. This was also shown on the Block Diagram analysis. Our design allows for this with superior materials handling equipment which almost makes all items have the same relative importance when relating to the table Fig 10.2. As this is the case we have chosen not to change our process or layout as it originally contained no backtracking. ...read more.

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