FACILITY LAYOUT IMPROVEMENT OF

ROCKFILL STAINLESS METAL WORKS DOT SUPPLY CORPORATION

__________________________________________
A Facility Planning and Design Study

Presented to the Faculty of

Industrial Engineering Department

Eastern Visayas State University

Tacloban City
__________________________________________
In Partial Fulfilment of the

Requirements for the Degree

Bachelor of Science in Industrial Engineering

__________________________________________
By

ROSAL, JOHN KENNETH CARLO

RUIZ, JUNEREL

SUPERADA, MARY JOY

TAMAYO, PRECIOUS RAINE

YAPAN, PRINCESS DIANNEe

March 2018
Table of Contents

APPROVAL SHEET ................................................................................................................................ 4

ACKNOWLEDGEMENTS ...................................................................................................................... 5

CHAPTER I .............................................................................................................................................. 6

INTRODUCTION .................................................................................................................................... 6
Objectives of the Study ........................................................................................................................... 7
Scope and Delimitation .......................................................................................................................... 8
Significance of the Study......................................................................................................................... 9

CHAPTER 2 ........................................................................................................................................... 10

METHODOLOGY ................................................................................................................................. 10
Research Design ................................................................................................................................... 10
Research Locale ................................................................................................................................... 10
Figure 1. Location of Rockfil Stainless Metal Works Dot Supply Corporation ................................. 11
Research Instrument ............................................................................................................................. 11
Data Gathering Procedure ................................................................................................................... 12
Principles Used for the Proposed Facility Layout ................................................................................. 12

CHAPTER 3 ........................................................................................................................................... 13

RESULTS AND DISCUSSIONS............................................................................................................ 13

Name of the Firm.................................................................................................................................. 13
Brief Description of the Product ........................................................................................................... 13
Manufacturing Process......................................................................................................................... 14
Figure 2. Manufacturing Process ...................................................................................................... 14
Plant Size and Production Schedule ..................................................................................................... 15
Plant Location ...................................................................................................................................... 16
Building and Facilities ......................................................................................................................... 16
Existing Plant Layout ........................................................................................................................... 20
Figure 3. Existing Plant Layout of Rockfil Metal Works dot Supply Corporation ............................. 20
Workflow .............................................................................................................................................. 22
Figure 4. Work flow ......................................................................................................................... 22
Machineries and Equipment ................................................................................................................. 23
Labor Requirements ............................................................................................................................. 24
 Waste Disposal ..................................................................................................................................... 24

CHAPTER 4 ........................................................................................................................................... 25

ANALYSIS AND RECOMMENDATION ............................................................................................ 25

Improved Layout .................................................................................................................................. 28
Figure 6. Proposed Facility Plan (Loft) ............................................................................................. 29
Improved Workflow .............................................................................................................................. 30
Figure 7. Proposed Facility Workflow .............................................................................................. 30

......................................................................................................................................................... 31
Improved Processes and Procedures .................................................................................................... 32
Improved Utilization of Resources ........................................................................................................ 33
Any other improvements in relation to the cited variables ..................................................................... 33
References ............................................................................................................................................ 34
 APPROVAL SHEET

In partial fulfillment of the requirements for the degree of Bachelor of Science in

Industrial Engineering, this Facility Planning and Design Study, has been prepared and

submitted by John Kenneth Carlo Rosal, Junerel Ruiz, Mary Joy Superada, Precious Raine

A. Tamayo and Princess Dianne Yapan who are recommended for Oral Examination.

ENGR. ROQUE A. COSTINIANO

Adviser

Approved by the Committee on Oral Examination with a rating of ______________.

ENGR. JOHN GLEN D. OCAÑA

Chairman

ENGR. RICHARD G. NAVALES ENGR. ROQUE A. COSTINIANO

Member Member

ENGR. LEONORA N. MANCIO

Member

Accepted in partial fulfillment of the requirements for the degree of Bachelor of Science

in Industrial Engineering.

Date of Oral Examination: DR. ANNABELLE B. PILAPIL

Dean, College of Engineering
_____________________ EVSU, Tacloban City
 ACKNOWLEDGEMENTS

This study would not have not been possible without the guidance and support of

everyone who wholeheartedly extended their hands one way or another which led to the

completion of this manuscript. Thank you so much!

RUIZ, J.
ROSAL, J. K. C.
SUPERADA, M. J.
TAMAYO, P. R.
YAPAN, P. D.

Eastern Visayas State University

Tacloban City
March 2018
 CHAPTER I

INTRODUCTION

Steel is an alloy of iron, carbon and other elements. Because of its high tensile

strength and low cost, it is a major component used in buildings, infrastructure, tools, ships,

automobiles, machines, appliances, and weapons. Steel constitutes a basic industry

prerequisite in a country’s pursuit of development and industrialization. The central role of

the industry stems from its linkages with numerous sectors, where its products serve as an

essential input to countless uses, such as building and construction, automotive,

shipbuilding and repair, electronics, packaging, etc. and its equally important contributions

to employment generation, growth, and promotion of industrial activity, etc. Therefore,

ensuring a strong domestic steel and steel‐based industry is vital in developing the

competitive edge of a country in meeting the challenges of globalization.

On a local level, construction industry of Region 8 is still booming as a direct result

of reconstruction works after Super Typhoon Yolanda hit the region in 2013 that caused

massive devastation on the region. Both residential and commercial establishments are

being reconstructed and/or constructed and demand for stainless building equipment is on

the rise, an imminent opportunity that Mr. Roque R. Kudera didn’t miss.

Mr.Kudera established the Rockfil Stainless Metal Works Dot Supply Corporation

on July 2013, a few months before Typhoon Yolanda hit the city. Fortunately, the elevated

location of the store and its manufacturing facility saved it from severe damage that it was

able to recover faster than its competitors. The firm was initially engaged in manufacturing
steel windows and steel gates until they were able to source out funds and capital from time

to time and be able to manufacture high quality products using stainless steel. They sell all

kinds of stainless steel products and accessories and offer a complete line of custom

fabrication: from railings, to kitchen sinks and working tables, stainless letters/ signage and

may more; railings, kitchen cabinets, and other home furnishing products. With the still

increasing demand, the company intends to intensify its strategy to expand its products and

services market base.

Objectives of the Study

1. To define and describe Rockfill Stainless Metal Work dot Supply

Corporation in Brgy. 110 Utap Tacloban City in terms of the following:

a. Name of Firm

b. Brief description of the Product

c. Manufacturing Process

d. Plant Size and Production Schedule

e. Plant Location

f. Existing Plant Layout

g. Work flow

h. Machineries and Equipment

i. Building and Facilities

j. Labor Requirements

k. Waste Disposal
 2. To discuss & evaluate the conditions in Rockfill Stainless Metal Work dot

Supply Corporation in Brgy. 110 Utap Tacloban City in terms of the

following:

a. Manufacturing Process

b. Plant Size and Production Schedule

c. Plant Location

d. Existing Plant Layout

e. Work flow

f. Machineries and Equipment

g. Building and Facilities

h. Labor Requirements

i. Waste Disposal

3. To design an improved facility layout for the of expansion Rockfill

Stainless Metal Work dot Supply Corporation, including proposal for

opportunities for improvement.

Scope and Delimitation

This study focuses on the manufacturing system of Rockfil Stainless Metal Works

Dot Supply Corporation in terms of its process flow, work flow, product output, layout of

the facility, building and facilities & waste disposal.

Data presented, results and findings of this study is only limited upon the

information disclosed by the management of Rockfil Stainless Metal Works Dot Supply

Corporation and its employees.

Significance of the Study

The result of this study may be beneficial to the following:

To the management, this study seeks to describe and evaluate the current facility

layout of Rockfill Stainless Metal Work dot Supply Corporation in order to come up with

an improved design that the management may adapt.

To the employees, this study aims to optimize the facility layout of Rockfill

Stainless Metal Work dot Supply Corporation to provide ease of access and comfort to the

employees to conserve both cost and amount of work done, hence resulting in increased

productivity without overworking the employees.

To the market, this study aims to develop an effective and efficient facility layout

help Rockfill Stainless Metal Work dot Supply Corporation to further cater the increasing

demand for construction materials.

To the researchers, this study focuses on the facility layout of Rockfill Stainless

Metal Work dot Supply Corporation, that such exposure will serve as training ground

wherein their knowledge in operations optimization can be applied.

To the future researchers, this study is essential for future researchers in similar

field and/or locale as this study may be used as reference for further improvement.
 CHAPTER 2

METHODOLOGY

Research Design

This study employs a descriptive method since the researchers aim to look into the

current facility layout of Rockfill Stainless Metal Work dot Supply Corporation in order to

determine the factors affecting it and come up with a more efficient facility plan.

Descriptive method is defined as a process of gathering, analysing, classifying, and

tabulating about prevailing conditions, trends, and processes and then making adequate and

accurate interpretation about such data.

An interview will be conducted to gather factual information about the current

facility layout of Rockfill Stainless Metal Work dot Supply Corporation and an open survey

of the employees to collect their reviews and assessment to provide a different perspective

to strengthen the findings of this study.

Research Locale

This study will be conducted in Rockfil Stainless Metal Work Dot Supply

Corporation located in Brgy.110 Utap, Diversion Road, Tacloban City. The findings of the

study will enable the management to improve their facility layout.

 Figure 1. Location of Rockfil Stainless Metal Works Dot Supply Corporation

Research Instrument

In conducting this study, interview among the management and observation of the

researchers is done. Upon the interview the researchers identify the different parts of the

facility and what will be the focus of the study, the observation will support further

information gathered to the interview.

Data Gathering Procedure

An interview will be conducted to gather factual information about the current

status of the manufacturing system of Rockfil Stainless Metal Works Dot Supply

Corporation and an open survey of the employees to collect their reviews and assessment

to provide a different perspective to strengthen the findings of this study.

Principles Used for the Proposed Facility Layout

1. 5S

2. Continuous Flow

3. Gemba

4. Hoshin Kanri

5. Jidoka

6. Just-in-Time

7. Reorder point
 CHAPTER 3

RESULTS AND DISCUSSIONS

Name of the Firm

The name of the firm studied is Rockfil Stainless Metal Works Dot Supply

Corporation. It was established in July 2013 by Mr. Roque R. Kudera, the president of the

Corporation.

Brief Description of the Product

Rockfil Stainless Metal Works Dot Supply Corporation produces a wide variety of

products made of stainless steel such as kitchenware, architectural, cooking and baking

materials. Stainless steel is notable for its stain resistance, corrosion resistance and low

maintenance making it an ideal material for many applications. The corrosion resistance

property of Stainless Steel is due to its chromium content with a minimum value of 10%

by mass. Since the firm supplies made to order stainless steel products, the output delivered

to the consumers are best suited to the customer’s specified requirements and/or design of

the product. The most commonly ordered products are scrubs sink, kitchen sink with

cabinet, stainless steel with cabinet, stainless table and S/S gutter.
Manufacturing Process

Description Process Step Discussion

Customers place an order and Order

the company receives it. Receiving

The company creates a layout of RSMWDC employs JIT, orders

the product using the dimensions Layout must be placed before they fabricate
and specifications provided by
the customer. a product

Once the design and dimensions

Measurement
are specified, the raw materials
are measured.

The measured raw materials are

cut into parts prior to the
assembly.
The cut parts are assembled
The ends and the part meeting
points are welded
The semi-finished product is
forwarded to the finishing area
for sanding to achieve its final
look.
Cutting
There are working tables all over
Assembly the working area but he workers
does not use them, instead, they opt
to work on the floor where in return
they pose danger not only to
Welding
themselves but to other workers or
employees inside the facility as well
Sanding

The final product is packaged for
pick up
The product is placed at the pick
up point for the customer to pick
up
Packaging The pickup point of the product is
also the same drive they use when
installing bumpers to cars, the pick
up point also serves as the entrance
Pickup
into the working area

Figure 2. Manufacturing Process

Rockfil Stainless Metal Works dot Supply Corp. supplies customized stainless-steel

products and figure 2 showcases the major steps taken in manufacturing any stainless-steel

unit. First, orders are placed and the buyer provides the desired design or layout of the unit
to be ordered. Once the design is settled, necessary measurements are forwarded to the

workers to make sure that the dimensions of the unit is accurate and no raw material will

go to waste. Raw materials are cut according to the measurements forwarded and further

proceeds into the assembly process. In assembling, the raw materials are processed for it

to achieve the design and specifications provided by the buyer. After the assembly, the

semi-finished product is forwarded for finishing; this is where the product is shined and

finished for it to achieve its final look. Once all steps are completed, the unit can now be

claimed by the buyer.

Plant Size and Production Schedule

The plant operates 6 days a week on a single continuous production shift daily.

Displayed on the table below is annual volume of production per product.

Product Production Volume/Year

Scrub sink 144

Kitchen sink w/ cabinet 60

Stainless table 180

S/S gutter 540

Total

Table 1. Annual Volume of Production

The volume indicated above does not include major customized projects such as

installation of railings which at times, requires them to do the assembly right on the site.
Hence, showing that the maximum plant capacity of Rockfil Stainless Metal Works dot

Supply Corporations is not only limited to the standard products they produce but can

accommodate customer specified product like custom made catering lamps, commercial

kitchen appliances and many other.

Plant Location

Rockfil Stainless Metal Works Dot Supply Corporation is located in Brgy.110

Utap, Diversion Road, Tacloban City. The raw materials used in producing stainless steel

products are shipped from Sta. Rosa Manila which arrives in huge wing vans. Basic utilities

such as water, electricity and fuel are accessible. The manufactured products are distributed

with the aid of their shop located right in front of the manufacturing plant, also along the

National Highway. The retail shop may be accessed by customers through any vehicle

passing along Maharlika High-way, although commuting through multicabs can be a bit of

a hassle tricycles can take you there, or if residing near Utap one may just walk.

Building and Facilities

Listed in Table 2 are the list of buildings and facilities in Rockfil Stainless Metal

Works Dot Supply Corporation.

No. of
Building/Facility Description/Illumination/Ventilation
workers

▪ Located on a different building. This is where walk-

Shop 2 in buyers purchase ready-made stainless-steel

products.
 ▪ The shop being open on one side is well lit with

natural light, light bulbs are also present in the shop

in case natural light can’t suffice the illumination

needs of the area.

▪ The shop being open on one side is well ventilated.

▪ The office on the same building as the shop and you

had to pass through the shop to get to the office.

▪ The room is well lit from the light bulb. However, in

the absence of artificial light, natural light cannot

Office 1 2
illuminate the place

▪ Since enclosed what keeps the room from being too

hot is the air conditioner installed, hence, the room

requires artificial cooling

▪ The office on the manufacturing site

▪ The office is closed and have one-way tinted

windows decreasing the level of illumination of

natural light. Artificial light on the other hand make

Office 2 2
up for this.

▪ Since enclosed what keeps the room from being too

hot is the air conditioner installed, hence, the room

requires artificial cooling

▪ All major operations such as the cutting, assembling

Working Area 9
and welding of the products is conducted in this area
 ▪ The working area is open on one side (driveway) and

the walls were designed with screen on the upper

parts to serve as an entry to natural light and vent as

well

▪ The working area is ventilated but if artificial

cooling is required high powered fans are provided

▪ The raw materials are stored here

▪ The only ventilation and illumination that reaches

Raw Materials
- the raw materials storage area comes from the
Storage Area
opening in the finishing area, as there are no

openings on the area.

▪ After the final assembling the product undergoes

finishing process to achieve its final look.

Finishing Area 3 ▪ The finishing area is outside the building and is an

open area, therefore ventilation is natural wind and

illumination is from the sun.

▪ There are two comfort rooms in total: the one near

the shop and the other near the manufacturing plant

Comfort Room - ▪ The comfort rooms do not have their own exhaust

fans for ventilation, and the room needs artificial

illumination

▪ An area inside the manufacturing plant resembling a

Vacant Space -
kitchen (has a sink)
 ▪ The area is eat da poo poo

Table 2. Building and Facilities

Rockfil Stainless Metal Works dot Supply Corporation has two main buildings both

in Brgy. 110 Utap Tacloban City along the national highway. The first building consists of

their retail store and a small office. On the other hand, their manufacturing facility is

located on the other side of the road. Travelling from the retail store to the manufacturing

plant can be risky given the number of cars travelling along the National Highway, being

a road away from each though is an advantage. Apart from the manufacturing plant, there

is also an office situated within the manufacturing facility. The working area indeed is

messy and can be disorganized during working hours, however good housekeeping can be

observed every after a day’s work since the workers clean the area in preparation for the

next day. The raw material’s storage has its own entrance and can be accessed from the

working area with a few travel time along a non-straight path. The manufacturing plant has

a driveway designed to accommodate either pick-up of bulky orders or projects like

attaching car bumpers, the space however can accommodate a single unit of vehicle at its

maximum creating a space and traffic problem in cases when more than one vehicle is

involved. Scrap materials are contained in sacks and stacked in a corner, held by straws.

The location and stacking of scrap materials can be a cause of serious injury in case of

accidents. On the other hand, the working area-to-finishing-to-pick up point travel path is

loop, hence, backtracking.

Existing Plant Layout

RAW MATERIALS

*WORKING TABLE
USED FOR
CUTTING,
ASSEMBLING AND
WELDING

Figure 3. Existing Plant Layout of Rockfil Metal Works dot Supply Corporation

The existing manufacturing facility of Rockfil Stainless Metal Works dot Supply

Corporation which they have been using since 2013 is rented. The working area covers the

driveway as well since some installation such as in car bumpers are performed on the

driveway. Assembling, welding and all other major procedures in stainless-steel

manufacturing are performed in a pretty narrow space considering the size of products they

are working on, the working area also serves as a path from the finishing area to the pick-

up point which is basically still inside the working area. An office is located in front of the

facility. The storage area is very accessible in terms of enclosure as no wall serves as a

divider or separator between it and the working area, however this may pose a problem in

controlling the usage of raw materials if not well regulated. The transfer of raw materials

from the storage to the working area is restricted by the limited space inside the facility,

hence slowing down material transfer from one point to another. Workers also tend to work

on the floor rather than on the working table which causes disorganized workplace,

unhealthy and unsafe acts.

Workflow

Figure 4. Work flow

 Workflow Path Description
The specifications of the
(1) Office to Raw
order received is forwarded
Material’s
so the raw materials can be
Storage
prepared
(2) Raw The raw materials are
Material’s forwarded to the workplace
Storage to for the fabrication (cutting,
Workplace assembly, welding)
Clippings from the raw
(3) Workplace to materials which may have
Scrap Materials caused by measurement
Storage errors are stored in sacks
and stacked
The semi-fished product is
(4) Workplace to
forwarded to the finishing
Finishing Area
area
(5) Finishing The finished product is
Area to Entrance forwarded to the pickup
(Pickup) point
Strengths Weaknesses
The specifications
are finalized prior
to the manufacture
There is an The path from the
acquisition wherein storage to the
they log the raw working area is
materials taken narrow
These raw
materials are stored Scrap takes up space
and sold for in the working area
reworking
The dust from the
finishing is not
Backtracking
stored in an
enclosed facility
The exit of product
Blocks the entrance
is accessible

Machineries and Equipment

Machine Dimension Usage

TIG Welding Machine 14x21x27 inches Used in connecting ends and

combining parts
Bender Machine 2680*910*1650 Used to attain a certain curve and
mm or to cut materials
Handheld Grinder 495x 185x 325mm Used for cutting or sanding
Drill 38 x 37-1/2 x 42 in Used to drill holes on the raw
material
Miscellaneous
(screwdriver etc.)

The machineries and equipment ranges from manual to semi-automatic. The

capabilities of some of their machines are limited that they to outsource some procedures

in order to satisfy a customer requirement.

Labor Requirements

The current workforce in Rockfill Stainless Metal Works dot Supply Corporation

are as follows:

Corporation

President 1

Vice President 1

Treasurer/Secretary 1

Director 2

Direct Labor

Welder/Painter 9

Finisher & Installer 3

Total

Table 3. Labor Requirements

Waste Disposal

Waste products generated from the cutting and assembling period are collected and

stored. The waste products are sold to firms engaged in reworking stainless-steel scrap.

The scrap varies in shape but sizes range from as little as an inch up to 3 inches. The pickup

of wastes is very erratic that the company usually end up with a huge stack before it being

disposed.
 CHAPTER 4

ANALYSIS AND RECOMMENDATION

The facility layout proposal is designed considering the findings based on the

results and discussion of Rockfil Stainless Metal Works dot Supply Corporation’s existing

facility layout, workflow, plant size, waste management and other factors such as the

impending plan of the management for expansion. The proposed Layout is designed with

the help of different Lean Manufacturing Tools as follows:

5S

Though the steps in 5S is described mostly in terms of the materials and equipment

present in a facility, in this study 5S was applied to the evaluate the current manufacturing

process of Rockfil Stainless Metal Works dot Supply Corporation.

Sort – Each of the steps in the existing manufacturing process was assessed to

determine whether this step should be retained, eliminated or combined with another step.

This is done in order to minimize the production time of all products.

Set in order – In reference to the current sequence of operation, these steps were

grouped to forming a set of procedures that can be performed in one go.

Shine – This step aims to assure the that all steps shall be done orderly to avoid

wastage of work.

Standardize – This is step is necessary to have a specific set of guidelines that will

help the workers and employees in following the steps.

 Sustain – The implemented layout and process shall be sustained until such time

that there is a need for change and improvement.

Bottleneck Analysis and Continuous Flow

This tool aims to make sure that the work-in-process smoothly flows through the

production with minimal to no buffers in between the manufacturing process. This step

helps eliminate wastes such as waiting time and transport.

What inhibits the smooth flow of work in Rockfil Stainless Metal Works dot Supply

Corporation is the arrangement of different facilities and storage in their existing plant.

Backtracking is evident and needs to be eliminated. By making related processes performed

in areas as close to each other and avoiding arrangements that leads to backtracking,

wastage of time and transport is lessened if not eliminated.

Gemba

Gemba reminds the administrators to get of their offices and spend time on the plant

floor to furtherly understand the manufacturing process. This promotes a deep and

thorough understanding of the actual manufacturing issues through communicating with

the workers.

The proposed facility layout ensures that the manufacturing facility is easily

monitored and accessed from the loft office. The office is located in a mezzanine that can

be accessed through a door outside the plant so that employees won’t have to travel extra

distance if they want to get into the office right away, and a terrace leading inside the
manufacturing facility for easy access when inspections are conducted. Wide windows also

are installed for easy viewing of the manufacturing facility.

Just-in-Time

Rockfil Stainless Metal Works dot Supply Corporation adopts Just-in-Time

manufacturing wherein no products are produced unless they are ordered. There are other

tools that if implemented correctly can help them meet demand while reducing wastes.

Heijunka may be used to maximize the utilization of both man and machine. There has to

be a properly logged set of orders with their steps identified such that similar steps of

different orders can be combined. If the same task is assigned to a specific person, that

person’s learning curve in terms of that particular task increases making him an expert on

that process. Hoshin Kanri or Policy Deployment can also be a great help to make sure

that goals are consistent and thorough to eliminate waste coming from poor communication

and inconsistent direction.

Jidoka

Jidoka or automation may be partially applied since their production is sometimes

limited to the capacity of their machines. The company outsources usage of hydraulic press,

hence, investing in a new equipment will save them cost from outsourcing and they can

also expand the variety of product they can fabricate.

3 Mus

The 3 Mus shall be eliminated to reduce wastage. The most common waste in the

current manufacturing layout is transport and waiting. Backtracking causes waste in

transport, while outsourcing causes waste in waiting.

Improved Layout

WORKING TABLES

(CUTTING, ASSEMBLY, WELDING)

Figure 5. Proposed Facility Plan (Ground floor)

 Figure 6. Proposed Facility Plan (Loft)

The new location of Rockfil Stainless Metal Works dot Supply Corporation is still

on Brgy. 110 Utap Tacloban City. The owner decided to keep the roadside store as it will

confuse their buyers if they suddenly change location and most importantly, the location is

very ideal for attracting customers, it being on a most populated road in the City with

people from all over the region passing through the National Highway. The manufacturing

plant on the other hand, will be on the right-hand side of the road if facing north. Legal

transactions and local barangay agreement are currently being undertaken prior to the start
of the construction of the new facility. The proposed layout considered essential Lean

Manufacturing Tools (5S)

Improved Workflow

Figure 7. Proposed Facility Workflow

Process Flow

1. Pre-Fabrication – commences in the office then forwarded to working area.

2. Fabrication – once the order is received all necessary steps in fabrication happens

in the working area (raw material storage, fabrication area and finishing area).

3. Post-Fabrication – the finished product is packed and prepared for pick-up.

Elimination of Bottleneck to ensure Continuous Workflow

The workflow in Figure 7 shows no backtracking as opposed to their existing

layout. This eliminates wastage in travel time, motion and alleviate workload from the

workers.
Gemba, Heijunka and Hoshin Kairi

The placement of the offices promotes communication and encourages thorough

understanding between the administration and the workers. The administration’s

understanding of how the manufacturing works will help them come up with policies and

solutions that will improve productivity.

Improved Processes and Procedures

In developing a new facility plan it is important to learn from the issues and

problems of the previous, in order to come up with techniques and methods to avoid,

control or eliminate them. The proposed facility plan is designed such that all processes

and procedures will be improved in reference to the previous layout. The improvements

and advantages of the proposed facility plan are as follows:

➢ Smoother flow of work

➢ Lesser material handling

➢ Maximized utilization of space

➢ A healthier work environment for workers and employees alike

➢ Zero backtracking

Ventilation and Illumination

The facility shall be surrounded with door-like entries which serves both as

ventilation and entry/exit points. Parts of the roof are covered transparent roofing material

to allow natural light inside the manufacturing facility which will save electric cost.
Improved Utilization of Resources

The proposed facility layout for the manufacturing plant of Rockfil Stainless Metal

Works dot Supply Corporation greatly improve the utilization of its human resource. The

facility plan is designed to minimize unnecessary travel time hence, conserving the

workers’ energy to avoid over fatigue. Proper management of a company’s human

resources creates a huge impact on the company’s productivity as a whole.

Any other improvements in relation to the cited variables

New policies shall be implemented complementary to the new facility layout, as

follows:

1. All scrap materials coming from one unit of order shall be recorded in order

to account the total utilization of raw material used and to have an estimate

of the amount that can be collected if the scrap is to be sold.

2. Tools and equipment comes with every working table and be assigned to

specific worker/s per shift. It is the worker’s responsibility to make sure that

at the end of his shift, all tools and equipment are returned to their respective

containers.

3. Working tables and benches are designed to best suit user requirements and

work requirements, hence, it is highly encouraged that the workers work on

their respective working tables instead of working on the floor which may

lead to musculoskeletal diseases.

4. Strict imposition of Personal Protective Equipment.

References

IE 473: FACILITIES PLANNING AND DESIGN