Auxiliary Services Requirement Space
Pertemuan 10
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Auxiliary Services Requirement
Space
Manufacturing departments need support services, and
these services need space. There are many service
functions to consider in a manufacturing plant but the
activity centers that require a lion’s share of space
are:
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Shipping and Receiving
Storage
Warehousing
Maintenance and Tool Room
Utilities, Heating, and Air Conditioning
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Shipping and Receiving
While shipping and receiving are two separate
departments, they have very similar people, equipment,
and space requirements. These functions could be
placed next to each other or across the plant from
each other. The placement of the shipping and
receiving departments have a significant effect on the
flow of material in the plant.
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Shipping and Receiving
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Advantages
Common Equipment
Common Personnel
Improved Space
Utilization
Reduced Facility
Costs
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Disadvantages
Space Congestion
Poor Material Flow
Lost Materials
Poor Communication
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Shipping and Receiving
Material Handling issues. . .
Dock Loaders
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Trucking Industry’s Effect
The trucking industry is organized nationally to deliver
raw materials and parts to industry in the morning and
pick up shipments in the afternoon. This is know as
less than truck load quantities (LTL). Full truck loads
are handled differently.
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Receiving Department
Functions
1.
2.
3.
4.
5.
6.
7.
Assist in locating a trailer at the receiving dock door
Assist in the unloading of materials
Record the receipt of the number of containers
Open, separate, inspect, and count the received
materials
Develop an overage, shortage, or damage reports
as required
Create a receiving report
Route incoming material
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Receiving Department
Facilities
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Dock Doors –
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Dock Plates, Levelers, and Boards –
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Aisles –
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Outside Areas –
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Offices –
and service rates
Quantity is dependent on arrival
used to bridge the door to floor space
Tools
Size aisles based upon materials and
handling equipment required
loading dock
Area around the outside of the
Receiving offices are usually small (allow
100 sq. ft. / clerk)
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Receiving Area
65’
T
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N
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G
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A
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S
L
E
S
Office
22’
45’
11’
Parking Area
9’ Door
5’ Aisle
Maneuvering
Area
Road
Trailer parking can consume 65’ from the plant wall
Maneuvering space is usually 45’
Roadways are 11’ one way or 22’ for two-way traffic
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Receiving Area
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Shipping and Receiving
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Shipping Department
Functions
1.
2.
3.
4.
5.
6.
7.
Packaging finished goods for shipping
Addressing cartons or containers
Weighing each container
Collecting orders for shipping (staging)
Spotting trailers
Loading trailers
Creating bills of lading
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Packaging Workstation
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Packaging Workstations
Pack Bench
Packing Workstation
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Determining Shipping Space
Q: The shipping department is estimating the required shipping space for a
new line of toolboxes. The company projects a maximum of 2,000 units
per day shipping in an 8 x 8 x 18 inch box. The toolboxes will be packaged
in the work cell. Uncle Bob’s Freightliner will be using a 40 ft long trailer.
How many trailers and how much staging space will be required per day?
A:
(8 x 8 x 18) / (1,728 cu. in. per ft.) = .66 cu. ft.
= .66 cu. ft. x 2,000 units
= 1,333 cu. ft. per day
A trailer is 8’ wide x 40’ long x 7’ high = 2,240 cu. ft.
Number of trailers per day = 1,333 cu. ft. / 2,240 cu. ft.
= 0.6 trailers per day
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Determining Shipping Space
A: One dock door will be required to meet the expected one day demand.
It should be noted that we are utilizing only 60% of the trailer capacity:
(1,333 / 2,240) x 100% = 59.5% or 60%
Internal staging requirements will be a space of:
8’ x 40’ x 60% = 192 sq. ft.
Compensating for the extra space needed for aisles and offices (not
inclusive of packing. . . handled in the work cell)
192 sq. ft. x 200% = 384 sq. ft. or 400 sq. ft.
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Storage
Stores is a term used to denote an area set aside to
hold raw materials, parts, and supplies. There are
many different types:
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Raw Materials Stores
Finished Parts Stores
Office Supplies Stores
Maintenance Supplies
Stores
Janitorial Supply Stores
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Storage
Maintenance
Supply Stores
Example
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Storage
The space requirements for stores is dependent on the
stated inventory policy of the company. It may be as
simple as “Provide space to store a one-month supply.”
Another method is the ABC philosophy. . .
Inventory
Class
A
B
C
Percentage
of Parts
20%
20%
60%
Percentage
Inventory
of $
Policy
80%
1 wk. supply
15%
2 wks. supply
5%
1 mth. supply
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Just-in-Time Inventory Storage
Just in time (JIT) is the inventory policy that has
begun to roll across the United States after a very
successful beginning in Japan. This is a special type of
inventory that can affect the plant layout in many
ways:
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Adjust or eliminate receiving, receiving
reports, etc.
Eliminate quality control checks
Eliminate or greatly reduce stores area
requirements
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Storage Goals
JIT will not be considered in this course because
designing a layout for a non-JIT system is more
difficult and, unfortunately, is more common. The
goals of any stores department should be:
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To maximize the use of the cubic space
To provide immediate access to
everything (selectively)
To provide for the safekeeping of the
inventory including damage and count
control
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Warehousing
Warehousing is the storage of finished products. As in
the storeroom, the area requirement will depend on
management policy. Additional issues include seasonality
of products. These may require outside warehousing
during peak times. A
warehouse can be a
department or an entire
building.
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Warehousing
Three basic warehousing functions:
 To safekeep the finished product
 To maintain some stock of every
product sold by the company
 To prepare customer orders for
shipment
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Warehousing
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Warehousing
Cantilever Racks
Carton Flow Rack
Carousel Rack
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Pallet Position Example
Q: A company wants to store a single part number consisting
of 5,000 cartons each containing 20 cartons. How many
pallet positions are needed if the pallets are stored three high?
A: Number of pallets required = total cartons / cartons per pallet
= 5,000 / 20
= 250 pallets
Number of pallet positions = total pallets / stored height
= 250 / 3
= 83.33 = 84 pallet positions
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Maintenance and Tool Room
The maintenance and tool room function is to provide
and maintain production tooling. These functions vary
widely from one company to another. Tool rooms may
not exist is some plants because all tools are purchased
from outside sources.
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Maintenance and Tool Room
Maintenance is service to the company’s equipment. A
mobile service cart may be used, but more commonly, a
central maintenance area would include equipment,
machine overhead areas, maintenance supplies, and
spare parts storage.
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Maintenance and Tool Room
Maintenance can account for 2 to 4 percent of the
plant personnel. An extreme may be upwards of 33
percent (paper mills). As a rule of thumb, allow 400 sq.
ft. of space for each maintenance employee. This
would allow for everything except maintenance stores,
which were covered previously.
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Determining Tool Room Space
Q: Our toolbox plant historically used 0.13702 hours per unit of the rate of
100 percent. History indicates that 85 percent equipment performance is
more realistic. Determine the number of maintenance personnel required
as well as the amount of space allocated for the tool room. Assume
production projections of 2,000 toolboxes per day and 3% maintenance.
A:
0.13702 / .85 = 0.16120 hours each
0.16120 x 2,000 units per day
= 322.4 hours of production people
Each person works 8 hours per day, so 41 production people are
required
41 x 3% = 1.2 maintenance people
Space = 2 x 400 sq. ft. = 800 sq. ft. for the tool room
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Maintenance and Tool Room
Add a 10 x 10 ft. controlled storeroom for tools and
supplies to most plant layouts. This 100 sq. ft. storage
area is just a minimum size area for controlling
supplies. Therefore in the previous example, total
square footage for maintenance will be 900 sq. ft.
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Utilities
Heat, air conditioning, electrical panels, air compressors,
etc. must be considered when determining space. These
areas must be kept separate from normal traffic – electrical
panels should be fenced off, heaters must be kept clean, air
compressors require special noise handling. There are few
rules of thumb concerning these. . .safety should take
precedence when placing these into the facility plan.
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Questions?
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