TEMA 4

Project Overview

• International Bachelor's Degree in Industrial Engineering
• October-December 2024
• Instructors: Elena Medrano, Fernando Veiga, José Vicente Valdenebro

Preliminary Project I: Sketches and Layout

Lean Methodology

• Activities that add value: Shape or transform the product to meet customer expectations
• Non-value-adding activities (waste, residues): Activities taking time, resources, or space without adding value to the product
• Lean methodology aims to optimize processes through continuous improvement to conserve resources and eliminate waste.

Lean Principles (Womack & Jones)

• Define Value
• Map the Value Stream
• Create Flow
• Establish Pull
• Strive for Perfection

The 8 Big Wastes

• Defects: Waste from a product or service failure to meet customer expectations
• Overproduction: Waste from producing more products than customer demand
• Waiting: Waste from time spent waiting for the next process step
• Unused Talent: Wastes due to underutilization of people's talents, skills, and knowledge
• Transportation: Wasted time, resources, costs when unnecessarily moving products/materials
• Inventory: Waste from excess products/materials that aren't processed
• Motion: Wasted time & effort related to unnecessary movements by people
• Extra-processing: Waste related to more work or higher quality than required

Design the Plant Layout to Minimize Movements

• Movements of raw materials and products in production process
• Movement of materials, intermediate, final products, and stored products
• Movements of waste
• Movements of people (differentiate between workers, clients, and visitors)
• Minimum material, equipment, and surface area

2. Layout Main Criteria: Access Areas

• Design of building façade needs to be considered for the image of business (olive oil mill, in this case)
• Design various accesses for different uses.
  • People: personnel, workers, customers, visitors
  • Materials: raw materials, auxiliary materials (e.g., packaging), wastes/residues, finished products

2. Layout Main Criteria: Zoning

• Zoning is essential to optimize floor layout.
• Organize areas by similar functions to share access and services.
• Optimize use and surface areas of the plant.

2. Layout Main Criteria: Interior Movements

• Analyze internal movements to minimize/size passing zones.
• Raw material access and product movement throughout process
• Storage areas and optimization
• Worker access, work areas, auxiliary services
• Customer and visitor access, visiting area and services

Design the Plant to Minimize Internal Movements

• Layout after analyzing movements. Optimize flow and access for different functions, with sufficient space for workers, materials, etc.

Elevations and Sections

• Industrial buildings often have significant heights.
• Consider elevations & sections to accommodate production phases.
• Provide adequate heights for various areas, potentially using suspended ceilings or intermediate floors to accommodate different spaces.

3. Design Project Development: Programming

• Summarize the program.
• Document information, needs, goals, and costs.
• Present to the client for sign-off.
• Move to next design phases after programming approval.

3. Design Project Development: Schematic Design Phase

• Develop basic building layout.
• Focus on sketching options and iterating.
• Develop floor plans and elevations during the phase.
• Document design pros and cons, considering client feedback to refine the design efficiently.
• Maintain a clear and concise design.

3. Design Project Development: Design Development Phase

• Refine design details.
• Select the best options from schematic design phase.
• Use design software to dimension areas and complete drawings.
• Detail dimensions & surface areas

4. Construction Works and Final Tasks

• Pre-construction meetings
• Progress meetings
• Reviews of testing (soil, concrete)
• Contractor submittals (shop drawings, product data sheets, and samples)
• Monthly payments to contractors (detail work and requests)
• Responding promptly to requests for information
• Regular site visits to monitor construction progress and adherence to specifications.
• Issuing change orders (with caution)

4. Construction Works and Final Tasks: Post-construction Tasks

• Create punch list after construction.
• Ensure all specified items are completed.
• Certificate of Substantial Completion issued once punch list items are fulfilled.
• Project closure documents exchanged between owner and contractor:
  • Project records
  • Operation and maintenance manuals
  • As-built documents
  • Warranties and Bonds
• Warranty inspections (typically ~10 months after closeout) to ensure everything functions as intended.

5. Building Drawings

• Plant drawings
• Elevation drawings
• Section drawings
• Useful floor space (968.80m²)
• Constructed surface area (997.50m²)