For this question we want to finalize our inventory storage requirements including the

different types of racks needed, the over size of the racking and the quantity of racks

required to support the amount of inventory helped defined in Assignment #$5.$

Review the containerization plan found in the assignment document since it contains a

lot of the pertinent information needed to complete the following:

a$.$ Flow Through Racking

Assume for each component that is $$non$-$stackable$$ will use gravity fed racks to

store the smaller cardboard boxes at the assembly line. This will allow an

operator or material handler to retrieve the $12$ x $12$ x $12$ container

components without the use of a lift truck.

Therefore, calculate the number of racks required. The weights of the individual

boxes can be determined from the information found in the $$Containerization

Plan$$ document. Take the worst case from the different part numbers.

Note: It is a good assumption when sizing and determining the number of

racks required to assume that at a minimum the racks need to be able to hold

one skid of boxes for each part number.

Note: it is important for gravity fed racks that parts are not mixed up in their

individual lanes however they can share an overall racking system.

Assignment #$7$ Inventory and Plant Layout Development

$4$

b$.$ Storage Racks $($Non$-$Stackable$)$

For non$-$stackable, specify the type of rack to be used through the estimating of

the structural capacity of the rack required. Assume the worst case for weight

using the established container weights found at the end of the assignment.

Show your calculations in the Engineering Log.

NOTE: The height from the floor to the undersize of the roof truss is $18$ ft$.$ See

Lecture Notes for estimating number of shelves.

c$.$ Lift Truck Size

Determine the size and type of lift truck are you going to use $($assume a

counterbalance type$)$ and then establish the aisle size you will be proposing

$($assume $12$ ft$).$ Assume that you will need to be able to pick up $2$ of the heaviest

stackable containers at a time but only one of the non stackable containers.

Show your calculations in the Engineering Log.

Assignment #$7$ Inventory and Plant Layout Development

$5$

Section $3$: Complete the Facility Layout

$4.$ At this point we should be able to put together a layout for the proposed facility. When

doing a layout, it may change many times and what goes first $($aisles vs$.$ racking$)$ is really

up to the Engineer. The optimum goal is to minimize the floor space usage but still

achieving a safe and functional layout.

For this layout, the goal is not to use up all the available space $($there should be space

that is open for future use$)$ but to use what is available efficiently since there may be

future needs involving new production processes.

I have put together a list of items that needs to be included in the layout and it will be

up to you to decide the order of how you design them into your layout.

Complete the following:

a$.$ Draw the stackable containers or number of footprints with their part numbers

determined from Assignment #$5($which assume they can be stacked $4$ high$).$ Use

the sizes found on the Containerization Plan.

Note: Each footprint needs to be drawn to the size of the container and shown

on the layout.

Note: When drawing the location of the material, think about stock rotation

$($FIFO$)$ and Finish Product should be close to Shipping and Receiving.

b$.$ Draw the racking required for the non$-$stackable containers and label them with

the part numbers that will be stored on them. Show them as a rectangular box

to the dimensions determined.

c$.$ Do not draw the Bench Vice Process equipment just the outside box reflecting

the area taken up by the process. Only draw the flow through racking found in

part $$d$.$

d$.$ Draw the flow through racking in the area defined on the layout $($in the process

area$).$ Show them as a rectangular box to the dimensions determined with the

part numbers they will be holding. Do not draw the roller and belt conveyors.

e$.$ Draw the aisles required to ensure your process and other locations in the plant

are accessible and that pedestrian and equipment traffic have the necessary

safety elements in place $($mirrors$,$ signs, pedestrian aisle, etc.$)$SAFETY FIRST$.$

Assignment #$7$ Inventory and Plant Layout Development

$6$

f$.$ Supply a pedestrian aisle for office workers and plant employees to get to the

work cell, clock house and to the receiving and shipping department.

g$.$ Supply a Maintenance Aisle that will have access across the plant. $($Hint: Tie in

with the land door$)$

h$.$ Install the necessary guarding and bollards to protect the racks.

i$.$ Assume the building is classified as a $$Moderate Hazard Occupancy$$ and position

Class A fire extinguishers appropriately. Show them as $.$

j$.$ Position access$/$safety doors to the plant assuming that there is a sprinkler

system and there is no high hazard occupancy. Assume the door is $36$ inches

wide