Contents• Introduction• Product• Product Design• Process Design• Schedule Design• Facility Design• Material Handling• Conclusion• References

IntroductionSustainability and Rexam

Sustainability• Since the 1980s sustainability has been used more in

the sense of human sustainability on planet Earth and this has resulted in the most widely quoted definition of sustainability as a part of the concept Sustainable development.

RexamRexam is a leading global beverage can maker.They make beverage cans for many of the world’s favourite brands.Our job is to make those cans as efficiently, profitably and sustainably as possible so that Their customers can attract and retain the loyalty of the people who consume their products. This is why, wherever you go in Rexam, you will see a common focus on operational excellence, innovation and safety to meet customers’ expectations.

Product Product Standard and Function

Product Standard & Function• Beverage Can (Standard of 330 ml )• Beverage can of Aluminum made upon request from

soda companies for holding soda drinks.• The product can be branded as the company request.

Product DesignIsometric and Main Design Features

Isometric and Main Design Features

Can Isometric View Can Body Design

Can Lid Design

Can Tap Design

Process DesignBill of Material, Route Sheet, Assembly Chart & Operation

Process Chart

Bill of MaterialThe beverage can consist of 4 parts manufactured at the facility where the rivets are the only part to buy.

Bill of material of the can

Route Sheet (Body)Product: Beverage can Part Name: Body

Raw material:Aluminum Alloy

“magnesium & Manganese” Included

Operation No. Operation Name Machine Department Operation Time

(sec)

10 Uncoiling Un-coiler Material Preparation0.01

material travel from coil to next m/c

20 Cupping Cupping press Body Making 0.0230 Body Making Body maker Body Making 0.0240 Trimming Trimmer Body Making 0.0150 Washing Washing m/c Curing & Cleaning 0.0260 Curing Oven Curing & Cleaning 0.0370 Printing Printer Product Finalizing 0.0180 Internal Coating Sprayer Product Finalizing 0.0290 Necking Necking m/c Product Finalizing 0.01

100 Inspection Can inspector Inspection 0.03110 Packaging Packaging m/c Packaging & Warehousing 0.03

Route Sheet (Lid)Product: Beverage can Part Name: Lid

Raw material:Aluminum Alloy “magnesium &

Manganese” Included

Operation No. Operation Name Machine Department Operation Time(sec)

10 Un-coiling Un-Coiler Material Preparation0.01

material travel from coil to next m/c

20 Blanking Punch press Body Making 0.02

30 Punching Punch Press Body Making 0.02

40 Scored Opening laser marking LBM Body Making 0.03

50 Curing Oven Curing & Cleaning 0.03

60 Inspection Can inspector Inspection 0.03

70 Riveting & Assembly Assembly m/c Assembly 0.01

80 Packaging Packaging m/c Packaging & Warehousing 0.05

Route Sheet (Tap)Product: Beverage can Part Name: Tap

Raw material:Aluminum Alloy “magnesium &

Manganese” Included

Operation No. Operation Name Machine Department Operation Time

(sec)

10 Blanking Punch press Body Making 0.02

20 Punching Punch Press Body Making 0.02

60 Inspection Can inspector Inspection 0.03

70 Riveting & Assembly Assembly m/c Assembly 0.01

80 Packaging Packaging m/c Packaging & Warehousing 0.05

Assembly Charts• The can consists of two main parts, the body and the end where the facility provides

the body and the end unassembled together and they are assembled and the customer’s factory after filling the can with soda.

End Assembly ChartBody Assembly Chart

Operation & Process Charts• Facility operations depend on two

main parallel manufacturing lines where the body is manufactured and the end is manufactured on another manufacturing line.

Body process Chart End process Chart

Schedule DesignRequired Machines, Annual Demand Plan, Machine Fraction

and Operators

Required Machines

(2)

(3)

Machine Fraction Calculations

Annual Demand Plan• The plan depends on customers’ demands annually, upon which

the whole production effort are concentrated in the way to fulfill customers’ needs.

Customer Demand (Can)Coca-Cola 8.2944 BCarlsberg 4.000 BPepsi 4.2944 BHeineken 4.1472 BTotal Annual Demand 20.736 B

Daily Production 57.6 MHourly Production 2.4 M

Estimated operators No.Machine Required no. / facility No. of operatorsUn Coiler 2 4

Cupping Press 1 4Body maker 1 5

Trimmer 1 4Washers 1 4

Oven 3 9Printer 1 3

Internal coating m/c 1 3Necking m/c 1 4Punch press 2 8

Facility DesignLayout Selection, Production Area, Area Calculations, Parking Area

& Food Service

Facility Layout Selection• The Most Suitable layout for the kind of Can production is

“Product or Line Layout”Justification for this Choice:• All the processing equipment and machines are arranged

according to the sequence of operations of the product. In this type of layout, only one product of one type of products is produced in an operating area. This product is standardized and produced in large quantities.• The raw material is supplied at one end of the line and goes from

one operation to the next quite rapidly with a minimum work in process, storage and material handling.

Production Area Design

Production Area Calculations (Body Making Section)Machine

No. neede

d

length dimensio

n(m)

width dimensio

n(m)

Area(m2)

Clearance1.524*L+1.2

19*W(m)

auxiliary equipme

nt

in process inventor

ytotal

un coiler 1 1.7 5.1 8.67 8.8077 0 11.25 28.7277cupping 1 3 1 3 5.791 0 0 8.791

Body maker 1 2.98 2.5 7.45 7.58902 0 0 15.03902

trimmer 1 1.4 2 2.8 4.5716 0 0 7.3716washer 1 2.45 1.8 4.41 5.928 0 0 10.338

oven 2 2.716 1.89.777

6 6.333384 0 0 16.11098printer 1 2.75 2 5.5 6.629 0 2 14.129internal coating 1 2.45 4.8 11.76 9.585 0 0 21.345necking 1 1.4 2 2.8 4.5716 0 0 7.3716

Inspection 1 4 2.5 10 9.1435 0 0 19.1435Total Area               148.3674

Production Area Calculations (End Making Section)Machine

No. neede

d

length dimensio

n(m)

width dimensio

n(m)

Area(m2)

Clearance1.524*L+1.219*

W(m)

auxiliary equipme

nt

in process inventor

ytotal

Un coiler 1 1.7 5.1 8.67 8.8077 0 11.25 28.7277blanking 1 3 1 3 5.791 0 0 8.791

punch 1 3 1 3 5.791 0 0 8.791scored

opening laser

marking1 2.5 5 12.5 9.905 0 0 22.405

oven 1 2.716 1.8 4.8888 6.333384 0 0 11.2221

8inspection 1 4 2.5 10 9.1435 0 0 19.1435Assembly

& Reviting

1 2 2 4 5.486 0 2 11.486

Total Area              110.566

4

Parking Area• Employees are transported to the facility through facility

buses to ensure showing up on time and to decrease efforts and space waste.• Other officers who reach the facility by their own cars,

the facility provides for them smart parking systems which ensures protection of their cars and space saving and facilitates the trucks movements through the parking, thereby facilitating forwarding cans process.• Smart Parking system is a smart new innovative system

where cars are stored in a vertical manner to save space and energy and protect cars.

Parking Area Calculations

ItemNo. of

required Spaces

Stall length(m)

Stall Width(m)

Angle(degrees)

Outside turning radii

(m)Clearance

(m)Bus 2 12.2 3.7 90 - 4.25

Back-up Spaces 10 2.75 2.75 90 Module Module Width

W2 20.15

Smart Parking system needed Space No. of needed Parking units

Length(m)

Width(m)

Height(m) 6 units of 12 car

capacity unit6.370 5.100 13.500

Parking Layout

Parking Area Design

Food Service Area• Food service area is to provide Full kitchen for employees to

ensure they are getting healthy and sufficient complete meals helping in working circumstances, Service line to serve meals and cafeteria.• Break Duration is 60 minutes per working shift, 60 employee is

served in a period of 3o minutes.Serving shifts time table

Shift BeginsEmployees start to sit

downShift ends

11:00 11:10 11:30

11:20 11:30 11:50

Required Spaces for Food Service Area

Section No. of Employees Required Space (m2)

Cafeteria 60 275Service Line 60 – 7 Served/min 92

Kitchen 60 153Total Required Area 520

Food Service Layout• The Food Service Area is

divided into three main areas Kitchen area, Service Line area and Cafeteria Area

Food Service Area Layout

Material HandlingMass Conveyor and Fork lift

Mass ConveyorMass conveyors are preferred to single conveyors for the transportation of Cans to the Empty Can Riser from the De-palletiser, which will optimize the storage capacity and allow a constant Can flow, reducing the risk of can damage.To transport empty cans made during the production line.

Mass Conveyor

Fork lift• A forklift (also called a lift

truck, a fork truck, or a forklift truck) is a powered industrial truck used to lift and move materials short distances. 

• Used to lift Aluminum Coils and Can Pallets.

Fork lift

Conclusion• Facility Design depends mainly on the most optimized

way to save space, energy and efforts, where the facility depends on automated production line and smart operations.

References• Manufacturing Facilities _ Location, Planning, and

Design, Third Edition-CRC Press (2008) - Sule, Dileep R. • Facilities Planning -Tompkins - 3rd Edition.• Rexam Annual Report 2015.