Tool Room Assignment
This report is that planning of the manufacturing and office layout for the Tool Room including the spacing in the area. As manufacturing of contact tooling, there are many steps and manufacturing processes to produce the product. There are currently 12 stations in the manufacturing part and 13 sections for the office part. For the outside space, three types of car parks and two security points will be added. There are a totally of 64 personnel in this facility, 25 personnel working day shift and 23 personnel working night shift in manufacturing area and 16 personnel in the office area.
Facility objectives
The objective of designing the layout is to optimise the space and make the factory the most efficient. To achieve this, it is needed to make sure that each sections are put in the right place with the right neighbours by considering all factors such as the transportation frequency, the material flows, the information flows, the environment condition of each section.
Space requirements
For this factory, there are many sections with certain area required for each. It is vital to get the positioning of each section right as these will define the efficiency of the factory layout. The layout was considered the flow of material, environmental condition of the work station and the ease of transporting between the stations. The following table illustrates all the sections in the facility and the area required for each section. For the turning section, drilling section, milling section, jig grinding section, grinding section, hard turning section, the machine has working footprint of 3x2 metres approx for the sufficient space of machine and operator working. The grinding section is divided into cylindrical grinders and surface grinders where operators are trained to run either type of the machine.
For the manufacturing area, most areas required are stated by the company. For the sections with machines located, the area is calculated by number of machine times the area of the machine which is 6 m2.
Section
Area (m2)
No. of machine/ station No. of people on day (night) shift
Location
Goods inwards inspection
80

2(1)
Manufacturing
Stores (raw mat, bought in items)
200

3(1)
Manufacturing
Turning section
24
4
4(2)
Manufacturing
Drilling section
30
5
3(2)
Manufacturing
Milling section
18
3
3(1)
Manufacturing
Jig Grinding section
30
5
3(1)
Manufacturing
Grinding section
30
5
5(2)
Manufacturing
Hard turning section
6
1
1(1)
Manufacturing
Heat treatment and plating
120

3
Manufacturing
Packing and dispatch
100

5
Manufacturing
Maintenance department
40

3
Manufacturing
Tool stores
40

1(1)
Manufacturing
General Manager
20
1
1
Administrative
Production supervisors
20
2
2
Administrative
Process Engineers/Machine programmers
20
3
3
Administrative
Production planners/schedulers
14
2
2
Administrative
Buyers
14
2
2
Administrative
Sales and order processing staff
26
4
4
Administrative
Accountant/Administrator
8
1
1
Administrative
Receptionist/Secretary
16
1
1
Administrative
Toilet
12
2

Administrative
Conference and meeting room
30
1

Administrative
First Aid room
10
1

Administrative
Mail and files room
6
1

Administrative
Coffee counter
2
1

Administrative
Front gate security
9
1

Outdoor space
Back gate security
9
1

Outdoor space
Car park for employee
300

Outdoor space
Car park for lorry/van from suppliers
186

Outdoor space
Car park for vans for good dispatch
256

Outdoor space

For the office area, the standard work space for one person can be from 4.5 to 22.5 m2 depending on the available area, position, open or close space, amount of work and usage. The space chosen for this layout is 4.5m2 workspace for one person except for the general manager and production supervisors section. For the general manager and production supervisor, the workspace is