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BEAUTY SECRETS

FACILITY LAYOUT 2010

Done By:

Laith Rahim

Al-Mutaz Elayan

Rashed Janadieh

Izzat Zahidah


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Table of Contents

Companys profile ......................................................................................................................................... 2

Location & Layout decision ........................................................................................................................... 3

Location decision .................................................................................................................................. 3

Layout decisions .................................................................................................................................... 3

Design of parking .......................................................................................................................................... 5

Assumptions: ......................................................................................................................................... 5

Calculations ........................................................................................................................................... 5

Facility Design ............................................................................................................................................... 6

Graph based method ............................................................................................................................ 7

Steps of the graph based Procedures ................................................................................................... 8

Block plan alternatives .......................................................................................................................... 9

Beauty secrets proposed layout ................................................................................................................. 10

Layout Evaluation ........................................................................................................................................ 11

References .................................................................................................................................................. 12


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Companys profileBeauty Secrets Corporation was established at the beginning of 2004 by a group of experts in

dermatology, chemistry, marketing, advertising, and finance backed up with the most modern research

laboratories in Jordan, United States, France, and Switzerland.

From the heart of the Dead Sea, Beauty Secrets experts have formulated the magnificent line of skin careproducts Innovation in blending natural herbal floral fruity extracts with minerals of the Dead Sea to

provide you skin care system with individual use as well as in the spa industry.

Products:

Beauty secrets products can be broken down into three main categories

Facial care

1. Facial care creams: eye gel, anti-cellulite cream, day creametc.2. Soap: black mud soap, scrubbing soap, green olive soapetc.3. Facial care liquids and lotions: liquid cleanser, mineral toner, make up removal lotion4. Mud treatment: mud masks with chamomile, milk & honey, tea tree oil extract, lavenderetc.

Body care

1. Body muds: relaxing body mud mask, for men, with anti-Cellulite2. Bath bags: salts with different kind of herbals such as thyme, sage, chamomile3. Bath crystals and water: treated dead sea salts which different kind of colors and perfumes,

concentrated dead sea water.

4. Body care liquids & lotions: massage oil, hand care lotion, foot care lotionetc.5. Body scrub: dead sea salt with eucalyptus oil.

Bath preparations

1. Hair care products: shampoo with mud conditioner.2. Shower gel: shower gel with herbal extracts, milk & honey.

Companys network:

Currently Beauty secrets sells for many locations around the world their main markets are located in the

Africa (Tunisia, Algeria, Libya) Middle East (UAE and Oman) Europe (Greece, Italy, the UK, Austria

and Turkey) and North America.


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Location & Layout decision

Location decision

Describe how was the plant location decision made? And Why?

The decision to change the plant location simply goes back to official regulations that were imposed on

the company by the ministry of health, division of food and drug control. The plant was lacking some of

the essential requirements that must be found in any cosmetic plant, such as a good ventilation system.

Another problem was that it was based underground, which has many health impacts on the employees,

process and final product.

What factors were used as important criteria in determining the plant location?

The company chose to locate the plant in Altajmat industrial area for the following reasons:

1) Offering investors developed lands and buildings that are serviced with the necessary infrastructure tofacilitate the establishment of their investment projects.

2) Offering investors competitive prices for the lands and buildings.3) The city is well covered by public transportation system.4) The City also provides investors with value-added support services such as catering, housing,

maintenance, operational solid waste removal, security, as well as other essential services for the

City's investors, workers and residents.

Layout decisions

Describe how the plant layout and material handling systems were designed? Who were involved in

the design process? Why?

The company hired an expert who suggested a design for the plant, making the process flow of the

products more efficient.

Did they start with layout design then selected the material handling systems? Why?

No, they started with the layout design because:

1) They are limited with the area constraint.2) They are located on the second floor therefore the material handling system was somehow limited.These main reasons gave the preference to the layout design over the material handling system.


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Describe whether product, process, and schedule design were integrated into the facilities design?

Of course it was taken into consideration, for example:

1- The warehouse was divided into 3 main departments: Packaging, raw materials and finishedgoods.

2- A ramping level was built between the 2 main parts of the plant(warehouse and production area),to make it easier to move the raw material into the production area and move them back into the

warehouse as finished goods.

3- The different departments of the production area were divided according to the flow process ofthe product.

Is there any productivity problems related to or caused by material handling systems?

The plant is on the second floor, which make a big problem concerning the receiving and shipping

process, the company thought of purchasing an industrial elevator which will be located near the

warehouse area, but this option makes the company dependent on the elevator i.e if the elevator broken

down all their production process will be halted so we advised them to use electrical manual elevator.

Material handling equipment used in the factory:


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Design of parking

Assumptions:

Number of employees 25 employee (10 management, 15 workers (blue collar))We have assumed that the worker doesnt need parking spaces since they are either living in theindustrial city or uses public transportations

Since the transportation system covering that area is good we assumed that each two employees(management) needs one parking lot

We noticed from other similar facilities that visitors requires from three to five parking lots, sowe designed our parking space to contain five parking spaces.

The available land for parking is 60 feet wide and 75 feet deep We assumed that all the cars are standard car susing stall width of 8 6 We will have one parking space for handicapped We assumed that double loaded wall to wall (with continuous concrete curb) (W2) will be used

Calculations

So based on the above assumptions we need ten parking lots

We have checked if the depth of the lot (75) can accommodate a parking layout consisting of one modulefor standard cars. We refered to table 4.1 P:140 and found that we need 66 feet for model width so itsless than 75 feet so this configuration suits our parking lot.

Each standard module row will yield a car capacity based on the width of the lot (60) divided by the width

requirement per stall (8.5) times the number of rows per module (2).

( which is good. (2 rows/modules X 1 standard module)

Handicap space requirement = 1*12= 12


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Facility Design

In our case its a construction layout type method, but the manager provided us with a proposed layout

based on his experience and according to GMP (Good Manufacturing Practice). We decided to use the

graphedbased method since its a construction type layout algorithm.

In order to start planning the layout we must have the from- to- chart on hand.

The quantities to be produced and the component routings are shown in table 1.

Table 1

The first step in creating the from to chart is to list the departments in order of the overall flow down the

rows and across the columns, then by considering each unit of Mud to be equivalent to 2 of salt product

and the cream is half the salt. The flow volumes may be recorded as in table 2.

Mix 1 Mix 2 Mix 3 sifting Fill 1 Fill 2 stage packing LAB

Mix 1 -- 0.5

Mix 2 -- 0.125

Mix 3 -- 0.25

sifting 333 --

Fill 1 -- 865

Fill 2 -- 8

stage 865 8 --

packing --

LAB 873 --

Table 2

Product

Prodcction

quantities per day

(Kg)

Movment factorEquivalent flows

per monthRoute

Mud 266.00 2 532 Mix 1- lab-stage -filling 2- packing

Salt 333.00 1 333sifting- Mix 3- lab-stage- filling 1-

packing

Cream 16.00 0.5 8 Mix 2 - lab - stage - filling 1 - packing


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Graph based method

Procedure:

1. From the from to chart in table.2 we selected the department pair with the largest productionquantity, thus Lab and staging are selected to enter the graph.

2. Next we select the 3rd department to enter. The third department is selected based on the sum ofthe quantities with respect to department lab and staging as shown in (figure.1). The mud mixing

department (Mix 1) is chosen.

Figure 1

3. We then pick the 4th department to enter by evaluating the value of adding one of the unassigneddepartments represented by a node on a face on the graph.

4. The remaining task was to determine on which face to enter the 5th department and the procedureswere done as shown in the following figure.(figure.2)


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Steps of the graph based Procedures

Figure.2


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Beauty secrets proposed layout

Figure.5

Figure.6


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Layout Evaluation

Evaluation is the fourth step in the design process, the evaluation process includes the assessment of

each alternative.

We have used the weighted factor comparison due to the simplicity of use and it also is much better

than the ranking and the adv/dis method since the factors weight are not equal which is more realistic

and gives a more objective result.

This method use numerical values or weights that are assigned proportionally to each factor based on its

degree of importance, as can be seen in table 3.

Factor Weight

Annual material handling cost 20Space utilization 25

Ease of expansion 15

Material flow 10

Employee s preference 30

Total 100Table.3

Each layout alternative was ranked on the basis of each factor, with following result (table .4):

Table.4

The weighted factor comparison for the three layouts is summarized in figure.3

Factor wt RT SC RT SC RT SCAnnual material handiling cost 20 10 200 10 200 5 100

Special Utilization 25 9 225 9 225 4 100

easiness of expansion 15 6 90 4 60 9 135

material flow 10 7 70 9 90 3 30

Employees preference 30 6 180 8 240 9 270

Total 100 765 815 635

A B C

Factor A B C

1 10 10 5

2 9 9 4

3 6 4 9

4 7 9 3

5 6 8 9

Layout Alternatives

Figure.7


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References

1) Beauty secrets company2) Facility planning book by Tompkins, White, Bozer, Tanchoco 4th edition

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