Facility Planning _Group 1_Roll No 61 to 65

7/31/2019 Facility Planning _Group 1_Roll No 61 to 65

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CASE STUDY ON

CONSOLIDATION OF ACCRO PLASTICS AND

BAXTER AUTOMOTIVE MATERIALS

1

Name Roll No.

Neha Kulkarni 61

Nibha Priyadarshani 62

Nilesh Wankhade 63

Nirpeksh Joshi 65

Facility PlanningAssignment

By



PROBLEM DEFINITION 2

Acquisition of Accro Plastic Corporation by Baxter Automotive

Baxter planned to consolidate Accro's existing technologies

Objective: Retain all of Accro's market share without disruption of

deliveries to its customers

The company has the pressure to prepare the St. Louis facility for

the installation of the new operations and to start up full scaleproduction of Accro's product lines

The decision has to be made regarding where the major work

centers of Accro's operations would be located in the new facility

expansion



DELIVERABLES 3

Layout block plan for the major workcenters,

Material flow plan,

Materials handling methods and equipment specifications,

Supporting storage system design.



DESIGN OF BLOCK LAYOUT

Note: Please see the attached excel document for the detailedcalculations

4



PROCEDURE FOLLOWED 5

Identified the major work centers

Calculate the movement of materials across the

departments

Develop the relationship chart

Design the block layout from above input



WORK DEPARTMENTS 6

1. #4 Compounding Line

2. Lg. Ribbon Blender

3. Viki

4. Hog

5. Luigi Extruder

6. #9 Workstation

7. Sm. Ribbon Blender

8. #4 Calendar Line9. Sterling Extruder

10. Die Cutter



CALCULATION OF PER DAY REQUIREMENT

OF DIFFERENT CAR MODELS 7

Input 1



8

Bill of Material for the 40different car models

BOM BY CAR MODEL IS GIVEN AS BELOW

Input 2



F INISHED PRODUCT REQUIREMENT PER DAY 9

From input 1 & 2 the

requirement of each productfamily for each day iscalculated as shown in thetable

From Input 1 &

Input 2



FROM INPUT 3 AND PER DAY REQUIREMENT OF

PRODUCT FAMILY THE RAW MATERIAL REQUIREMENTS

IS CALCULATED



TOTAL INTER DEPARTMENT MOVEMENT

CALCULATIONS 11

Compounding

Line

Lg. Ribbon

Blender Viki Hog

Luigi

Extruder

#9

Workstation

Sm. Ribbon

Blender

#4 Calendar

Line

Sterling

Extruder

Die

Cutter

#4 Compounding

Line 0 0 0 0 28 0 0 0 0 0

Lg. Ribbon

Blender 0 0 0 0 0 83 0 0 0 0

Viki 0 0 0 0 0 0 0 0 0 0

Hog 0 0 0 0 0 0 0 0 0 0

Luigi Extruder 0 0 0 0 0 28 0 95 0 24

#9 Workstation 0 0 0 0 0 0 0 0 0 117

Sm. Ribbon

Blender 0 0 0 0 0 34 0 230 0 0

#4 Calendar Line 0 0 0 0 24 0 0 0 85 145

Sterling Extruder 0 0 0 0 0 0 0 0 0 85

Die Cutter 0 0 0 0 0 0 0 0 0 0

The amount of movement between departments is calculated by the help

of total finished good requirement and the amount of raw material

movement in each move .

The procedure is repeated for each product category .

The final movement table is shown as below(from –

to chart)



DEVELOPMENT OF RELATIONSHIP

CHART 12

Step 1, 2 and 3



DEVELOPMENT OF RELATIONSHIP

CHART 13

Step 4

Step 5

Step 6

Step 7



RELATIONSHIP GRAPH 14

H

E

A

FB

I

J

G

A-4 COMPOUND LINE

B-LG RIBBON

C-VINI

D-HOG

E-LUIGI EXTRUDER

F-#9 WORKSTATION

G-SM.RIBBON

H-#4 CALENDAR LINEI-STERLIN EXTRUDER

J-DIE CUTTER



BLOCK LAYOUT 15

H

G

B FE J

A

I

R A W M

A T E R I A L

F I N I S H E D G O O D S

OUTDOOR STORAGE AREA

200

2 1 0



MATERIAL FLOW PLAN

Note: Please see the attached excel document for the detailedcalculations of Material Flow Plan

16

Raw materials:

R i l



17

H

G

B

E

J

A

I

R A W M

A T E R I A L

F I N I S H E D G O O D S

F

OUTDOOR STORAGE AREA

Raw materials:

Resin =18lbs

Regrind = 546lbs

Rubber pigment = 60lbs

Raw materials:

Resin =24lbs

Fiber = 18lbs

Zecco 110 = 12lbs

Slate = 24 lbs

Calcium Oxide = 132lbs

Zefree = 12lbs

Mica = 96 lbs

Raw

materials:

Asphalt =

210lbs

Raw materials:

Regrind = 438lbs

Pierex = 222lbs

Asphalt = 498lbs

Scrim = 18lbs

Raw materials:

Resin = 102lbs

Fiber = 66lbs

Zecco 110 = 36lbs

Slate = 24lbsCalcium oxide =

288lbs

Zefree = 60lbs

Mica = 66lbs

Rubber = 42lbs

Oil = 30lbs

Raw materials:

Regrind = 162lbs

Asphalt = 396lbs

Dolamite = 132lbs

Raw materials:

Asphalt = 300lbs

WIP: 114lbs

Resin = 24lbs

Regrind = 90lbs

Containers:

Gaylord box(1 unit, 3 stacks)

= 108lbs

Pallets(1 unit with 31 bags) =

108 + 108 + 390 = 606lbs

WIP:

Carrier

Sheets =

108lbs

WIP:

DryPowder

Mix =

198lbs

WIP: 318lbs

Dry Powder

Mix = 156 +

162

Containers: 402lbs

Gaylord box(1 unit, 3 stacks)

= 162 + 240

WIP: 108lbs

Containers: 300lbs

Pallets(1unit, 15

bags) = 300lbs

1800lbs(

600 * 3)

1200lbs(

600 * 2)

600lbs

600lbs

Die =

2964lbs

Offal =

1236lbs



DESIGN OF NEW STORAGE

SYSTEM



ASSUMPTIONS

Total working days per month are assumed to be 24

Raw material required is calculated for max demand of each

product per day

Buffer storage requirement for next 5 years is 30%

Requirement Analysis is done for Maximum demand

including the buffer requirement.



SPACE REQUIREMENT ANALYSIS

Procedure

Calculate the estimated raw material demand for every

month for given finished product s

Calculate the maximum raw material required per day

Add the buffer capacity considering future growth

Calculate the number of pallets required every day for

every product



S350 plain MM S600P S350P Ex CL RequirementBuffer

Capacity

Total

Capacity

Resin 496.6 1514.625 1712.45 1618.93 1395.333 1454.75 2055.6 8192.69 2457.81 10650.50

Regrind 6290.27 6664.35 11416.33 2023.67 13953.33 7273.75 13361.4 47621.70 14286.51 61908.21

Fiber 165.53 1211.7 1141.63 1011.83 697.66 0 0 4228.37 1268.51 5496.88

Zecco 110 165.53 0 1141.63 809.47 348.8333333 0 0 2465.47 739.64 3205.11

Slate 331.07 0 1712.45 202.37 697.6666667 0 0 2943.55 883.07 3826.62

Calcium oxide 2151.93 3029.25 9133.07 1416.57 3139.50 0 7708.5 18870.32 5661.10 24531.41

Zefree 165.53 0 3424.90 809.47 348.8333333 0 0 4748.73 1424.62 6173.35

Mica 1324.27 908.78 2283.27 809.47 2790.67 0 0 8116.44 2434.93 10551.37

Pierex 2151.93 0 0 2833.13 3488.333333 0 0 8473.40 2542.02 11015.42

Asphalt 3310.67 11814.08 15412.05 8297.03 7674.333333 5091.625 25695 51599.78 15479.94 67079.72

Rubber 0 605.85 2854.08 0 0 0 0 3459.93 1037.98 4497.91

Oil 0 908.78 1141.63 0 0 0 0 2050.41 615.12 2665.53

Dolamite 0 3635.10 5708.17 0 0 0 0 9343.27 2802.98 12146.25

Rubber-Pigment 0 0 0 0 0 727.375 2569.5 727.38 218.21 945.59

Scrim 0 0 0 404.73 348.83 0 0 753.57 226.07 979.64

SPACE REQUIREMENT ANALYSIS FOR RAW MATERIAL

STORAGE



Raw Material Total Capacity Pallet StorageStorage Weight

per Pallet

Total Pallets

Required

Resin 10650.50 Yes (Max 4 ) 2000 6Regrind 61908.21 Yes (Max 3 ) 600 104

Fiber 5496.88 Bags (Max 50) 1000 6

Zecco 110 3205.11 Bags (Max 50) 1000 4

Slate 3826.62 Bags (Max 50) 1000 4

Calcium oxide 24531.41 Bags (Max 50) 1000 25Zefree 6173.35 Bags (Max 50) 1000 7

Mica 10551.37 Bags (Max 50) 1000 11

Pierex 11015.42 Yes (Max 4 ) 2000 6

Asphalt 67079.72 Yes (Max 4 ) 2000 34

Rubber 4497.91 Bags (Max 50) 1000 5

Oil 2665.53 Yes (Max 4) 2000 2

Dolamite 12146.25 Yes (Max 4 ) 2000 7

Rubber-Pigment 945.59 Bags (Max 50) 1000 1

Scrim 979.64 Bags (Max 50) 1000 1

Total 223

SPACE REQUIREMENT ANALYSIS FOR RAW MATERIAL

STORAGE

Total Number of Pallets required are for Raw Material Storage are 223



SPACE REQUIREMENT ANALYSIS FOR F INISHED PRODUCT

STORAGE S350 plain MM S600P S350P Ex CL

Resin 496.6 1514.625 1712.45 1618.93 1395.333 1454.75 2055.6

Regrind 6290.27 6664.35 11416.33 2023.67 13953.33 7273.75 13361.4

Fiber 165.53 1211.7 1141.63 1011.83 697.66 0 0

Zecco 110 165.53 0 1141.63 809.47 348.8333333 0 0

Slate 331.07 0 1712.45 202.37 697.6666667 0 0

Calcium oxide 2151.93 3029.25 9133.07 1416.57 3139.50 0 7708.5

Zefree 165.53 0 3424.90 809.47 348.8333333 0 0

Mica 1324.27 908.78 2283.27 809.47 2790.67 0 0

Pierex 2151.93 0 0 2833.13 3488.333333 0 0

Asphalt 3310.67 11814.08 15412.05 8297.03 7674.333333 5091.625 25695

Rubber 0 605.85 2854.08 0 0 0 0

Oil 0 908.78 1141.63 0 0 0 0

Dolamite 0 3635.10 5708.17 0 0 0 0

Rubber-Pigment 0 0 0 0 0 727.375 2569.5

Scrim 0 0 0 404.73 348.83 0 0

Requirement 16553.33 30292.5 57081.67 20236.67 34883.33 14547.5 51390

Buffer Space 3310.667 6058.5 11416.33 4047.333 6976.667 2909.5 10278

Total Requirement 19864 36351 68498 24284 41860 17457 61668



SPACE REQUIREMENT ANALYSIS FOR F INISHED PRODUCT

STORAGE S350 plain MM S600P S350P Ex CL

Total Requirement 19864 36351 68498 24284 41860 17457 61668

Pallet Storage Yes Yes Yes Yes Yes Yes Yes

Wt per Pallet 1200 1200 1200 1200 1200 1200 1200

Number of Pallet

Required 17 30 57 20 35 15 51

Total Number of Pallets required are for Finished Product Storage are 225



Available Options1. Carton or Full Case Storage Systems

2. Block stacking

3. Stacking Frames

4. Single Deep Selective Pallet Rack

5. Drive In Rack

6. Drive Through Rack7. Gravity Flow Pallet or Carton Rack

8. Push Back Rack

9. Pick Tunnel

10. Mobile Shelving or Storage Units

25

Source: Chapter 9, Warehouse Manual

Storage Type

Selection

DESIGN OF NEW STORAGE SYSTEM

FOR RAW MATERIAL

Advantage of Single Deep Selective Pallet Rack:

Permits unimpeded access to every carton it stores.

It can be used in a variety of aisle configurations

It can be paired with any type of lift truck

It is the least expensive style of rack

Less automation

Simple and easy fabrication

Cons

Low-density rack



SELECTED STORAGE TYPE

Single Deep Selective Pallet Rack:

Usually one pallet deep, this pallet rack system, usually referred to as a

standard pallet rack, can be built to accommodate two or three pallets placed

side by side in the row bay.

With this style of rack system, the first pallet load is placed on the ground and a

second rack level holds another set of pallets, with these two lower levels

serving as the pick position.

26



ASSUMPTIONS

27

On the basis of following assumptions Maximum number of racks required

are calculate

Rack Height in feet = 8 feet

No. of racks = 2

Rack Depth in feet = 4

Rack Length = 8 feet

Number of pallets stored on each rack 2+2+2 = 6



STORAGE SYSTEM LAYOUT

Total Number of Racks required Raw Material Storage are 35

Total Number of Racks required Finished Product Storage are 38

Area required for the storage are 200 feet X 16 Feet for raw material as well asfinished product storage



Thank You End of Presentation

Date post:	05-Apr-2018
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Facility Planning _Group 1_Roll No 61 to 65

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