Facilities Layout Improvement at Rodilla's Yema Cake

FACILITIES IMPROVEM ENT
Facilities Layout Improvement at Rodilla’s Yema Cake
A Project Study
Presented to the Faculty of the
College of Engineering and Technical Department
Manuel S. Enverga University Foundation
In partial fulfillment of the
Requirements for the Degree of
Bachelor of Science in Industrial Engineering
by
Aaron Justine E. Abuel
Armando F. Anading III
Yvonne R. Casas
Sharmaine V. Comintan
Joy E. Panaligan
May 2017
FACILITIES IMPROVEM ENT 2
Approval Sheet
In partial fulfillment of the requirements for the degree of Bachelor of Science in
Industrial Engineering program. This project entitled “Facilities Layout Improvement at
Rodilla’sYema Cake”, prepared and submitted by Aaron Justine E. Abuel, Armando F. Anading
III, Yvonne R. Casas, Sharmaine V. Comintan, and Joy E. Panaligan, is here by recommended
for oral examination.
Engr. James Louie R. Meneses, CIE, AAIE

Adviser
Approval in partial fulfillment of the requirements for the Degree of Bachelor of Science
in Industrial Engineering by Oral Examination panel, November 2016 with the rating of
_________________.
Dr. Guillermo M. Rago Jr. Ed. D CE

Chairman
Engr. Gervin S. Espinosa Engr. Luzviminda Sinapilo

Member Member
Accepted in partial fulfillment of the requirements for the Degree of Bachelor of Science
in Industrial Engineering.
May 2017 Guillermo M. Rago Jr. Ed. D CE

Dean, College of Engineering
Acknowledgement
The researchers would like to acknowledge the supports and efforts of the following
people:
Firstly, we would like to express our sincere gratitude to our adviser, Engr. James Louie
R. Meneses, Engr. Gervin S. Espinosa and Engr. Agnes Aviles for the continuous support of our
study and related research, for their patience, motivation, and immense knowledge. Their
guidance helped us in all the time of research and writing of this thesis.
Beside our advisers, we would like to thank thehead thesis committee: Dr. Guillermo M.
Rago Jr., for his insightful comments and encouragement to widen our research from various
perspectives.
My sincere thanks also go to Mr. and Mrs. Vincent and Juliet Rodilla, who gave access to
their production facilities. Without their precious support it would not be possible to conduct this
research.
We thank our fellow classmates in for the stimulating discussions, for the sleepless nights
we were working together before deadlines, and for all the fun we have had in the last four years.
To our parents for all the support for our financial needs to finish this study also for
encouragement they have given them.
And lastly, to our Almighty God, the great source of the researcher’s self-confidence,
energy and strength every day.

Dedication
As one of the authors, I would like to extend my sincerest thank with deepest gratitude
and acknowledgement to the following:
Above all, to Almighty God for His presence, love, wisdom and guidance, to God be thy
glory.
To my family; my sisters, Janine and Jessah; to my brother and niece, Jeff and Jacob,
most especially to my parents who never stopped supporting me in whatever I do and who
inspired me the most finish this study.These two persons gave me the tools and values necessary
to be where I am standing today. My parents support me on every step I make, and decision I
take; but is necessary to understand that they let me take my decisions alone in order for me to
learn from my personal mistake and as my father says to “learn and grow from each seatback”.
My thanks and gratitude to them will never end for all the opportunities that they have offered
and gave me, for all the teachings that they have taught me and for every advise that come out of
their mouth. I am so grateful with them for trusting me that I would do a good job in the
university, and letting me come to achieve a higher education.
To PIIE MSEUF-SC, my classmates and friends, and especially to my thesis mates who
spent time and effort for this study.
To everyone I love, thank you for inspiring me and bringing out the best in me. .
Joy E. Panaligan 
I would like to dedicate this work to those people who supported me through my ups and
downs. First is to God for giving me life, strength, wisdom, and guidance that they given us . To
my Family for supporting me financially, emotionally, and mentally, and encourage me to study
well .To my professors for their endless support and guidance throughout my college life. To my
Friends who are always there to help me and especially my teammates who supported me
throughout the process. For giving their time effort, and skills, I will always appreciate all they
have done to make this research possible. Thank you!!!
Sharmaine V. Comintan
I would like to dedicate our project study, to my parents Casius P .Casas and Nida R.
Casas, for your love and support. To my sisters, Mary Grace and Gynica Justine thank you for
giving me strength and inspire me to reach and chase my dreams;
To my group mates, Anading, Abuel, Sharmaine, and to our leader Joy, thanks for the
fun, grumpy days, and everything that we had gone through. “Team Relax /Attitude, will always
be ngarag when the deadline is tomorrow’’.
To my friends, especially IE Gagz , my classmates , my batch mates and PIIE, thanks for
sharing knowledge that we could use in our study.
And lastly, to Papa Jesus thank you for giving us the strength, knowledge patience and
everything we have without your guidance the lord this would have never become possible.
~yvonne
As a symbol of gratitude I dedicate this project study to God Almighty. His presence has
continuously inspired me and given me strength.
I dedicate this project to my parents. Also to my friends who have shared with me all the
hardship and delight of being BSIE student. To my adviser, I acknowledge his contribution,
Engr. James Louie R. Meneses who share his knowledge in doing this project. And lastly I
dedicate this to myself, the fruit of my labor has finally paid off.
This is perhaps the easiest and hardest chapter in our project study to write. It will be
simple to name all the people that helped to get this done, but it will tough to thank them enough.
This piece of work is heartily dedicated to my parents and guardians, who taught me that even
the largest task can be accomplished if it is done one stage at a time, and for always reminding
me to value my vision.
I also dedicate this Project Study to my friends “IE GAGZ” , “JEG” and “Team Chaka” for
encouraging me even they bullying me and to the one who is special to me who waking me up
early when I need to do some papers in our study and to Hatchi to conquering my stress and
relieving my tiredness`
And to IE Professors who imparted their knowledge and become part of my college life.
Armando Anading
Table of Contents
Title Page………………………………..………………………………..……………………….1
Approval Letter………………………………..………………………………..…………………2
Acknowledgement………………………………..………………………………..……………...3
Dedication………………………………..………………………………..………………………4
Table of Contents………………………………..………………………………..……………….7
List of Tables………………………………..………………………………..…………………...9
List of Figures………………………………..………………………………..…………………10
Abstract………………………………..………………………………..………………………..11
Unit I – Introduction……..………………………………..………………………………..……12
Background of the Study………………………………..……………………………….13
Objectives of the Study………………………………..…………………………………14
Conceptual Framework…………………………………………………………………..15
Scope and Limitations……………………………………………………………………16
Significance of the Study………………………………………………………………...16
Definition of Terms………………………………..………………………………..……17
Acronyms……………………………………………………………………….………..18
Unit II - Review Of Related Literature and Studies.………………………...…………………..19
Unit III - Methods and Procedure….……………………………………...……………………..32
Research Design………………………………………………………………………….32
Research Environment……………………………………...……………………………33
Procedures………………………………………………………………………………..34
Design Concepts………………………………………………………………………....37
Unit IV – Results and Discussion……….……………..……………...………………………..41
Data Gathering………………………………………………...…………………………41
Data Analysis………………………………………………………………………….…53
Design of Improved Facility Layout…………………………………………..…………54
Development……………………………………………………………………………..62
Evaluation…………………………………………………………………………….….64
Unit V - Conclusions and Recommendations…………………..…………………………...…72
Conclusions………………………………………………………………………………72
Recommendations………………………………………………………………………..73
References………………………………………………………………………………..74
Appendices…………………………………………………………………………….....77
A. Project Study Gantt Chart……………………………….……………..……..77
B. Result of Interviews & Observations……………………………………......78
C. Survey Result………………….…………………………..………………….83
D. Cost Benefit Analysis……………………………..….………………………86
Transmittal letter…………………………………………...…………………….89
Curriculum Vitae…………………………………….…………………………………..90
List of Tables
Table No. Title Page No.
1 Modified Likert scale………………………………………………………...…..38
2 Present time study for small cakes…………………………………………..…...48
3 Present time study for big cakes……………………………...………………….49
4 Summation of the present time study for small and big cakes………...………...50
5 Present time study data ………………………………………………….………51
6 Whys Analysis – Causes of the problem in Rodilla’s Yema Cake………………54
7 Validation of Root Cause Using Why’s Analysis………………………………..55
8 Validation of Root Cause Using Ishikawa Diagram……….…………………….56
9 Proposed time study for small cakes……………………….…………………….60
10 Proposed time study for big cakes……………………….………………………61
11 Comparison of Total Time between the Present and Proposed Layout of Small
Yema Cakes…………………………...……………………………………...….66
12 Comparison of Total Time between the Present and Proposed Layout of Big
Yema Cakes……………………………...………………………………………67
13 Survey Result……………………………….……………………………………70
14 Result of the survey based on Likert Scale………………………………………71
15 Cost benefit analysis…………………………………………….……………….72

List of Figures
FIgure No. Title Page No.
1 Conceptual Framework Paradigm ..….…………………………………………..16
2 Present flow process chart ……..………………………….……………...……..43
3 Present flow diagram ……………………………...…………………...………..44
4 Present relationship diagram ………………………..……..…………………….45
5 Present facility layout ……………………...…………………..………………..46
6 Present flow process chart for small cakes …………………………..…….……52
7 Present flow process chart for big cakes ……………………………………..….53
8 Ishikawa Diagram………………………………………………………………..55
9 Activity relationship chart………………………………………………………..57
10 Space relationship diagram………………………………………………………58
11 Block diagram……………………………………………………………...…….59
12 Proposed flow process chart for small cakes…………………………………….62
13 Proposed flow process chart for big cakes……………………………………….63
14 Proposed flow diagram…………………………………………………………..64
15 Proposed facility layout………………………………………………...………..65
16 Graphical representation of the compared present and proposed time study……68
17 Graphical representation of the compared present and proposed time study……69

Abstract
Abuel, Aaron Justine E., Anading, Armando F. III, Casas, Yvonne R., Comintan,
Sharmaine V., Panaligan, Joy E., “Facilities Layout Improvement At Rodilla’s Yema Cake”,
Unpublished Project Study for the Degree of Bachelor of Science in Industrial Engineering,
Manuel S. Enverga University Foundation, November, 2016.
Facility planning and design is an important component of all business overall operations,
both in terms of maximizing the effectiveness of the production process and meeting the needs of
employees. Rodilla’s Yema Cake is one of the most popular and well known delicacies not just
here in Quezon but also in other places in Central Luzon. For the past years, it had encountered
error in production of yema cakes because of the substandard arrangement of the assembly lines
in the working area that causes the long transportation of the operation. Through the observations
in the workplace and interview with the owner and employees, the researchers conclude to
improve the design of facility layout of their production area using time and motion study.
In designing the layout, various factors were assessed by the researchers in creating the
proposed facility layout. Process layout was selected as type of layout because it aims to improve
efficiency in Rodilla’s production area. Another factor that they consider is the availability of the
facilities, workers, and space in the production area. As the proposed layout was evaluated, the
flow processing time of production of the existing layout which is 51.32 minutes was decreased to
46.10 minutes for the production of small yema cakes, while the flow processing time of
production of the existing layout which is 50.40 minutes was decreased to 45.58 minutes for the
production of big yema cakes. Rodilla’s Yema Cake saves 5.2 minutes in the whole processing of
small yema cakes and 4.23 minutes in the whole processing of big yema cakes. Thus, this result
has a great effect on the annual savings of the Rodilla’s Yema Cake.
Unit I
Introduction
Today, Rodilla‟s Yema Cake is one of the most popular and well known delicacies not
just here in Quezon but also in other places in Central Luzon. And because of this there are so
many Rodilla‟s outlets and resellers that are scattered around the area, and therefore we cannot
stop wondering how these delicious and mouth-watering cakes are being produced. As an
Industrial Engineering students and researchers, we know that the production process is needed
to have a lower cost with a great effectiveness and much higher productivity. To achieve this
productivity there has to be a good and effective facility layout.
Facility planning and design is an important component of all business overall operations,
both in terms of maximizing the effectiveness of the production process and meeting the needs of
employees. The basic objective of the layout is to ensure a smooth flow of work, material, and
information through system. The basic meaning of facility is the space in which a business's
activities take place. The layout and design of that space impact greatly how the work is done, and
the flow of work, materials, and information through the system. Layout affects the cost of material
handling and the movement of time, and hence affects the overall productivity and efficiency in the
plant. The key to a good facility layout and design is the integration of the needs of people
(personnel and customers), materials (raw, finishes, and in process), and machinery in such a way
that they create a single, well-functioning system. Poor facility layout leads fatigue to the workers,
much spending in one machine to another that can result in increasing the material handling costs.
Background of the Study
Today, people are fond of discovering different variety of food that are unusual but are
very palatable. Filipinos are popularly known as food lovers and this is probably the reason why
many delectable Pinoy delicacies had risen. Filipino culture is noticeably seen from the inviting
appetizers and aperitifs, flavorful main dishes and toothsome sweets to their refreshing drinks in
festivities and celebrations. These dishes served on the table of every Filipino family reflect to
their nation‟s history as many had visited and colonized the country.
Quezon, a historic province in south of Manila, is popular for its food and spiritual
destinations. It's also famed for its numerous pasalubongs. Pasalubong giving has been a
beautiful tradition and a well-known trait of Filipinos. No wonder there are pasalubong stores all
over the archipelago. From various kalamay (Rice cakes) to a variety of delicacies like broas,
lady fingers (camachile), pastillas, yema cakes, and boat tarts, there's never a shortage of
selections for someone with the sweet tooth.
One of the most famous pasalubong in Quezon that can be found specifically in Tayabas
is the Rodilla‟s Yema Cake. The Rodilla‟s Yema Cake is fast catching up as an irresistible,
mouth-watering dessert among food lovers. It is a creamy and delicious custard cake originates
in southern part of Luzon. This dessert is made from 2 layer chiffon cake coated with yema
frosting. The custard is almost similar to brazo de mercedez and dulce de leche that consists of
egg yolks, condensed milk, evaporated milk and vanilla extract.
The researchers interviewed the manager/head of the operations and some of the workers
at the production area of Rodilla‟s Yema Cake; they informed us that one of the major problems
they encounter during their production is the unstandardized time in the process of making yema
cake and the FLP (Facility Layout Problem). We were able to observe the present facility area
and the present production area wherein they do the process of baking, mixing, cooling, slicing,
icing, cheesing, packing and loading of the finished products; and we discover that the causes of
the problem are the imbalance line, slow transportation and long processing time because of a
poor facility layout of the workplace.
Facility layout considers available space, final product, safety of users and facility and
convenience of operations. An effective facility layout ensures that there is a smooth and steady
flow of production material, equipment and manpower at minimum cost. Facility layout looks at
physical allocation of space for economic activity in the production area. Therefore, the main
objective of the facility layout planning is to design effective work flow as to make equipment
and workers more productive.
In response to the mentioned problem above, the researchers chose to make an improved
facility planning and design at Rodilla‟s Yema Cake production area. This project study proposes
to use Systematic Layout Planning (SLP) as the infrastructure for layout optimization and
entitled the study “Facilities Layout Improvement at Rodilla‟s YemaCake”. This study will
tackle on how the researcher came up with the design and effective facility layout that will help
eliminate the problems and improve the productivity inside the Rodilla‟s Yema Cake Factory.
Objectives of the Study
The main objective of the study is to design and develop an improved facility layout at
Rodilla‟s Yema Cake production area; thus this study aims to achieve the following specific
objectives:
1. To design an improved facility layout at Rodilla‟s Yema Cake.
2. To develop the improved facilities layout at Rodilla‟s Yema Cake.
3. To evaluate the improved facilities layout in terms of effectiveness, efficiency and cost.
Conceptual Framework
The project can be better understood through the guiding concepts as stated in (Input,
Process, and Output) model. The paradigm in Figure 1 shows the structure on how to conduct
and construct the proposed design.
Necessary processing time data would be gathered in this study. The current layout and
unnecessary movements would be carefully studied and considered inputs. The Input includes,
present work flow layout. The process comprises data gathering, time and motion study, design
of process layout, and process layout development. And the output: facilities layout improvement
at Rodilla‟s Yema Cake.
Existing facility layout

INPUT Present production process
Current production system
Data gathering and analysis

PROCESS Design of improved facilities layout
Development of the improved facilities layout
Evaluation
Facilities layout improvement at Rodilla‟s

OUTPUT Yema Cake
Figure 1. Conceptual Framework Paradigm

Scope and Limitations
This research only focuses in designing much better facility layout that would
improve the facility layout in the production area of yema cake at Rodilla‟s. It is only
concentrated in the existing layout of the workplace, the arrangements of machines, other
facilities and workers assigned, the sequence of operations, number of facilities and workers, takt
time, and the shifting operations of every worker, on which we would be used. All other stuffs
that are not related to the study would not be included. This project study only focuses on the
simulation of the proposed facility layout.
This research would tackle all different types of facility layout with their advantages
and disadvantages, especially the machine layout which it would be as the proposed facility
layout. The time and motion study, worker-machine process, line balancing and right-hand- left-
hand rule would also be discuss in this research to show the effectiveness of the proposed layout.
Significance of the Study
The proposed process facility layout provides significant contribution on Rodilla‟s Yema
Cake like a fully maximize lines improve the overall productivity of the team. The importance of
this after the implementation would be beneficial to the following:
Company and Management. Implementation of the proposed facility layout that would
improve the process flow cycle, the time in baking, the time in baking, the arrangement of
workers and machines, and the elimination of bottleneck in the operation. To attain of higher
productivity efficiency and competitiveness of the company.

Employees. They will have a comfortable working environment, much safer, and much
easier work. The proposed layout would make their work easier and lessen their fatigue, but in
the other hand they will have greater satisfaction and higher productivity.
Customers. They would be more satisfied that Rodilla‟s Yema Cake will meet their
expected taste and quality and ordered on time because of the improvement of proposed facility
layout.
Students. This research can be used as guide and reference for those students who will be
undertaking similar activities. It would capture their interest for further research and studies.
Researcher. They will have much benefit in this study in terms of verification and
application of the theories and concept with regards to their profession. They were able to apply
tools and techniques of an Industrial Engineer in the overall industry.
Definition of Terms
The following are words define operationally to easily help the readers to comprehend in
the study;
Facility Layout is thearrangement of equipment and machines at the production area of
Rodilla‟s Yema Cake.
Material Handling is a manual process of producing yema cakes by the workers at
Rodilla‟s Yema Cake to control the moving of materials.
Processing Time is the duration of time in each process of producing yema cake.
Process Improvement is the changes being made in the production area of Rodilla‟s
Yema Cake for the betterment of their process.
Production is the process of making Yema Cake.
Productivity is the rate of producing Yema Cake.
Acronyms
FLP- Facilities layout problem
JIT – Just in time
LB – Line balancing
PSI – Preference selection index
SLP- Systematic layout planning

Unit II
Review of Related Literature and Studies
This unit presents the literature and related studies which have direct bearing on facility
layout and design. It will discuss on how the facility layout and design can improve the work
flow in every production.
Related articles were compiled for the researchers‟ reference. These literatures provided
and additional information is necessary for the researcher in the conduct of the research process.
Facility Layout and Design
Facility layout and design is an important component of a business„s operation, both in
term of maximizing the effectiveness of the production process and meeting the needs of
employees. According to Prof. Serrano, A. (2015) the basic objective of layout is to ensure a
smooth flow of work, materials, and information through system, and basic meaning of facility is
the space in which a business „activities take place. Layout and design of the space impact
greatly how the work is done such as the flow of work, materia ls, and information through the
system. A good facility layout and design is the integrated of the need of people personnel and
customer, materials like raw material and in process, and machinery in such a way that they
create a single, well-functioning system.
According to the study of Quincena J.H.B., Granada, M.E.V., Llagas, K.J.R., Villaflor,
R.A. Jr. and Palero, M.I., authors of “Production on Layout Improvement through Facilities
Planning”, one of the problem that makes processing time too long was due to its present facility
layout, the machines are not place based on the sequence of operation that‟s why it took long
time to transfer parts from its next operation. The researchers also concluded that the
arrangement of machines is based on the design of the jacket, so the process will change if the
jacket design changed. In order to improve the process, the researchers suggested that every new
design of jackets they manufacture the J&C garments should arrange their machines to avoid
overtime and achieve their quota. (Quincena, Granada, Llagas, Villaflor, Palero, 2013)
Layout is an important component of any business because it can affect the process and
operator itself, facility should be designed to be suitable for everyone who is involved in the
operation to ensure smooth flow of work. Because of its relative performance, facility layout
probably is one of the most crucial elements affecting efficiency. An efficient layout can reduce
unnecessary material handling, help to keep cost low, and maintain product flow though the
facility.
Types of Layout.There are several alternative layout types that are appropriate for
different product mixes and production volume based on the book entitled “Niebel‟s Method
Standards, & Work Design” Thirteenth Edition International 2014 by Freivalds, A. and Niebel,
B.W.. Determination of the layout type is a major design because it impacts on so many other
aspects of the production system.
Process Layout. It is one of the main focuses of the researchers in this study; it is
otherwise called as functional layout or job shop layout. Process Layout is handiness for
inspection and supervision. In Industrial engineering, Process Layout is the ground plan of the
plant, which is fits by industrial engineers to get better the competence organizing tools
consistent with their purpose. In this layout, the major plan is to fix up or collect machinery or
equipment‟s of the similar role keen on one group or division. Process Layout is also called as
functional layout. Similar machines or similar operations are situated at one rest by mean of the
functions (Freivalds, Niebel, 2014). Process layout is facility configuration in which operation of
a similar nature of a function are group together. Improving process layout involves the
minimization of transportation cost, distance, or time. To accomplish this some firm use what is
known as a muter grid, where subjected information is summarized on a grid displaying various
combinations of department, work group, or machine part.
Advantage of process layout includes:
Flexibility. The firm has ability to handle a variety of processing requirement.
Cost. Sometimes, the general – purpose equipment utilized may be less costly to
purchase and less costly and easier to maintain than specialized equipment.
Motivation. Employees in this type of layout will probably be able to perform a variety of
task on multiple machines, as opposed to a boredom of performing a repetitive task on an
assembly line. A process layout also allows the employer to use some type of individual
incentive system.
System Protection. Since there are multiple machine available, process layout are not
particularly vulnerable to equipment failures.
Disadvantages of process layouts includes:
Utilization. Equipment utilization rates in process layout are frequently very low, because
machine usage is dependent upon a variety of output requirements.
Cost. If batch processing is used, in process inventory could be high. Low volume means
higher per –unit cost. More specialized attention is necessary for both products and customers.
Setups are more frequent, hence higher setup cost. Material handling is slower and more
efficient. The span of supervision is small due to job complexities (routing ,setup, etc.) so
supervisory cost are higher .Additionally , in this type of layout accounting , inventory control
and purchasing usually are highly involved.
Confusion. Constant changing schedules and routing makes joggling process requirements
more difficult.
Product Layout. It is the design of finished tangible items. Paced and outpaced are the
two types of lines that is used in products layout. Paced lines is machine like conveyor that is
used to move along the products continuously while unpaved line is more like a waiting line of
workers.
Product layout efficiency will be enhanced though the used of line balancing because it
will minimizes the amount of time that some workstations are idle, due to waiting parts from
certain process in order to accommodate large volume of products in a short time with a low unit
cost. (3G Elearning, 2015).
Fixed-position layout. It is a design area for heavy or large equipment. It is appropriate
for product that is too large or too heavy to move.
Combination layout. It is a design wherein two or more process layouts are combine
according to process requirements.
Cellular layout. It is a design area for a group of machine arrange according to its
process sequence.
Production Management
Production management is a system which concerned with the process of combination
and transformation of various resources into a product based on the book published by 3G
Elearning FZ LLC (2015). Production function is responsible in conversion of various resources
into desired quality of products. Production is a process of manufacturing goods. The production
systems are classified into Job shop, batch, and mass and continuous production system.
Job Shop Production is only producing ordered products in a specific time and costs.
Batch Production is only producing limited quantity of a product at regular intervals.
Mass Production is producing large number of products in a specific time, continuous
production is a sequence processing parts of a product before it turns into a finished products.
Operation Management. It is a system who facilitates the process of combination and
transformation of various resources into a product. Having an efficient system of production
planning and control helps better service to customers, fewer rush orders, better control of
inventory, and more effective use of equipment, reduced idle time, improved plant morale, good
public image and lower capital requirements.
Operation management are concerned with the various discipline such as design of goods
and services, quality of a product, design process and capacity, site selection, design layout,
human resources and design work, supply chain management, inventory decisions, scheduling
decisions and maintenance of the quality of a finished products.
Manufacturing is a process of converting a raw material to useful forms and eventually
into finished products made by hand or machinery and tools. Manufacturing systems
management is focused on converting product design into economical, environment friendly and
reusable product.
Time and Motion Studies
A time-motion study is a business efficiency technique combining the time study work of
Frederick Winslow Taylor with the motion study work of Frank and Lillian Gilbreth (Camilar-
Serrano, 2016). It is a major part of scientific management. A time motion study is used to
determine the amount of time required for a specific activity, work function, or mechanical
process can reduce and control costs, improve working conditions and environment, and
motivate people. Motion and time study is considered to be the backbone of industrial
engineering, industrial technology, and industrial management programs because the information
that time studies generate affects so many other areas, including cost estimating, production and
inventory control, plant layout, materials and processes, quality and safety.
Thus, as the name suggests “time motion study” is concerned primarily with increasing
performance by measuring and then minimizing the time taken to perform various operations
without compromising the quality of services.
Motion study offers a great potential for savings in any area of human effort. We can
reduce the cost by combining elements of one task with elements of another. It uses the
principles of motion economy to develop work stations that are friendly to the human body and
efficient in their operation. It must consider the operator‟s safety. It comes first before the setting
of time standards. Motion study is a detailed analysis of the work method in an effort to improve
it. It is for cost reduction, and time study is for cost control. Motion study is the creative activity
of motion and time study. It is design, while time study is measurement.
According to Mr. Eric B. Bermillo the author of “Production Efficiency Improvement
through Time and Motion Study” his evaluation on the findings and results of the study‟s
investigations yielded a reduced idle time of Machine Operators 1 and 2 for Go Life Angled
from 65% percent to only 25% percent. The researcher also evaluated the new process design‟s
implementable feasibility through a cost-benefit analysis to show potential savings generated
through the idle time reduction and transportation waste production output against the cost of
two (2) additional trimming machine tools. Furthermore the researcher‟s assumption and
objective is that: idle time percent can be converted productively through automated trimming
machinery, then both manpower and machine downtime can be converted productively; and; if
the trimming transportation problem can be minimized or eliminated, the overall production
improvement. The researcher also used the Time and Motion Study principles and concepts to
prove that a solution to the company‟s present problem can be reached using all IE basic tools in
project development and problem solving in order to achieve improvement of production
efficiency.
Flow Process Chart.Lontoc, et al. (2012), it helps in setting out the sequence of the flow
of a product or a procedure by recording all events under review using appropriate process chart
symbols. This tool is a graphical or symbolic representation of a process. Each step in the
process is represented by different symbols and contains a short description of the process step. It
covers symbols for operation, inspection, storage, delay and transportation.

The researchers used the flow process charts to analyze the flow of the process in the
production area of Rodilla‟s Yema Cake. The proponents can identify if there will be any
irregularity in the flow of the process.
Lean Concept
Lean enterprise is progressively more applied to manufacturing, service and non-profit
organization. Lean enterprise as of this date has been extended by combining lean production
idea to six sigma. Although, not all organization can apply this concept, but other which have
successfully applied these combined concepts have experienced noteworthy upgrade in their
performance in term of operation.
Bozarth & Handfield defined lean manufacturing as follows, which is essentially the
same to JIT: „Lean is a philosophy of production that emphasizes the minimization of the amount
of all the resources (including time) used in the various activities of the enterprise‟. The aim of
lean operation is to achieve a stable flow of products and services that could be delivered to
customer at the quality level and time they want in order to satisfy customers‟ needs. In addition,
lean operation could guarantee the production process to be more flexible when the demand is
uncertain.
According to Mayer, RR (2014) lean enterprise must be identify production and lean
thinking; and enumerate different types of waste and their banner of elimination: name
components of lean production system: and discuss new advances in lean production. In
addition, there is strong evidence that the concurrent implementation of internally- focused and
externally- focused lean practices yields greater performance benefits than selective lean
production implementation. Thus, this study contributes to the theory of lean production by
providing insights into the mediated and moderated effects of lean production on inventory
leanness and financial performance.
The researchers investigate the relationship between lean production, inventories and
performance. The empirical analysis is based on survey and secondary data from US
manufacturing firms. The effect of lean production on performance is partially mediated by
inventory leanness. The concurrent implementation of lean practice bundles yields greater
performance benefits.
Assembly Line Balancing
The Balancing of assembly lines is one of the most important problems among the other
problems of assembly lines like designing and managing. In today's highly competitive
manufacturing environment increasing system flexibility, reducing failure sensitivity, improving
system balance and productivity are crucial.
Parallel assembly lines provide some opportunities in improving these objectives
especially when the capacity of production system is insufficient. Unlike the traditional assembly
lines there are a few studies on balancing parallel assembly lines in the present literature. Parallel
assembly line balancing is a NP-hard problem similar to other assembly lines. In this paper, a
novel multiple-colony ant algorithm is developed for balancing bi-objective parallel assembly
lines.
Assembly lines are designed as flow oriented production systems which perform
operations on standardized products in a serial manner, that was according to Ozbakir, L.,
Baykasoglu, A., Gorkemli, B., Gorkemli, L., authors of “Multiple-colony ant algorithm for
parallel assembly line balancing problem” in Applied Soft Computing (Volume 11, Issue 3,
April 2011, Pages 3186–3198).
The researchers used assembly line balancing to increase such as minimizing wastes in
terms of waiting time, transportation and motion, reduce failure and improved system. The
researchers believe if the line is balanced it has smooth flow of work because it minimizes
wastes such as waiting, rework, transportation and unnecessary motion.
Just-in-time
Just-in-time (JIT) is „producing the necessary item in the necessary quantity at the
necessary time is an eternal diver of production and operations management‟. The ultimate
objective of JIT is to enhance flexibility of the whole system, which is one of the competitive
factors in future manufacturing and services systems.
Definition of JIT is quite consistent in many studies (or even textbooks) to the one
mentioned in previous section. For example Bozarth & Handfield defined JIT as: „A philosophy
of manufacturing based on planned elimination of all waste and on continuous improvement of
productivity. In the broad sense, it applies to all forms of manufacturing and to many service
industries as well‟. JIT requires elimination of waste which means that JIT systems could lead to
delivery of „perfect‟ products or services at the „exact‟ time they are required main purpose of
JIT systems is to identify and to eliminate as many kinds of wastes as possible through
improving production activities within a company.

A JIT system could be an „effective tool‟ for assisting a company to reduce cost and then
to obtain higher profits. JIT can be considered as one of the variants of production planning and
control systems, which are pivotal management tools for satisfying increasingly high client
demands and expectations in the business market, although traditional production planning and
control systems are „push‟ in nature, which means planning department decides the production
schedule and transmits to all production processes according to forecast of the demand of
market.
According to Furlan, A., Dal Pont, G., Vinelli, A., authors of “ Towards High
Performance Manufacturing”, in International Journal of Production Economics (Volume 133,
Issue 2, October 2011, Pages 489–495), the sequential nature of the improvement initiatives has
neglected the synergistic effects among practices and literature lacks research on
complementarily between internal and external bundles of practices. The aim of this paper is to
test the existence of complementarily among internal and external just-in-time bundles. The
researchers ran statistical analysis using the third round of High Performance Manufacturing
international research project data set and found that upstream and downstream JIT are
complements. This finding suggests the importance of managing the inter-dependencies both in
designing and implementing upstream and downstream JIT in order to maximize operational
performance. Various benefits, for example, inventory reduction, improved in operations
efficiency, and faster response, have been studied widely in previous research. Therefore,
successful implementation of JIT is vital to many companies. The main objective of this research
is to make use of a case study to present various issues surrounding implementation of JIT for an
automotive company. This case study also provides evidences for supporting the benefits of
employing JIT. The conclusion of this research indicates that JIT system is successful, and
operating JIT system can lead to many advantages to the case company.
The researchers therefore conclude that waste in time is a very important subject, for it
affects the productivity of every manufacturing organization. Reducing time waste is a never
ending process. Application of Just-In-Time system in the process workflow, a serious effort is
made to reduce not only moving and waiting time but also processing time. It is very important
to study carefully how time spent in the production process.
Material Handling
Material handling includes motion, time, place, quantity and space constraints. First,
material handling must ensure that parts, raw material, in-process materials, finished products
and supplies are moved periodically from the location to location. Second, as each operation
requires materials and supplies at a particular time, material handing ensures that no production
process or customer is hampered by either the early or late arrival of materials. Third, material
handling must ensure that materials are delivered to the correct place. Fourth, material handling
must ensure that materials are delivered at each location without damage and in the proper
quantity. Finally, material handling must consider storage space, both temporary and dormant.
A study conducted by the Material Handling Institute revealed that between 30 and 85
percent of the cost of bringing a product to market is associated with material handling.
Axiomatically, the best part is the least manually handled part. Whether the distances of the
moves are large or small, these moves should be scrutinized. There are five points that should be
considered for reducing the time spent in material handling, first is reducing time spent in
picking up material; use mechanized or automated equipment; make better use of existing
handling facilities; handle material with greater care; consider the application of bar coding for
inventory and related applications. A good example of the application of these five points is the
evolution of warehousing; the former stage center has become an automated distribution center.
Today, the automated warehouse uses computer control for material movement, as well as
information flow through data processing. In this type of automated warehouse, receiving,
transporting, storing, retrieving and controlling inventory are treated as an integrated function.
Companies become more interested in the manufacturing of material handling equipment
for the sustainability of their products (Shevtshenko, E., Bashkite, V., Maleki, M., Yan Wang,
authors of “Sustainable Design of Material Handling Equipment: A Win-win Approach for
Manufacturers and Customers” at Volume 18, No. 5 (2012). One possible approach to make
material handling equipment more sustainable is to make it re-configurable, reusable and
reliable. Those products are likely to be reused when customers‟ requirements change. More
sustainable material handling equipment can be much easier sold in the future, due to the
possibility to be reconfigured in accordance to the new customer requirements is high.

Unit III
Methods and Procedures
This unit discussed about research design, research environment, research procedures and
design concepts for better understanding of the study. It also includes the industrial engineering
tools and principles for the development of this study.
Research Design
This study used research and development to describe the improvement of new
arrangements of equipment in Rodilla‟s Yema cake. The researchers establish a new design of
facility layout, charts and diagrams that may serve as a prototype for this study. This study is
begun with the interview and observations in the research environment and through researches
found in books and studies. This study aims to improve the current facility layout of Rodilla‟s
Yema cake by eliminating unnecessary movements or motions using industrial engineering
analysis to figure out the best solutions to improve the current process and layout.
The researchers decided to achieve an efficient production flow by focusing on the
facility layout. Improving actual layout can be reduced until 30% through an effective facility
planning. Re-lay outing facility design could improve the performance of production line such as
decrease bottleneck rate, minimized material handling cost, reduces idle time, raise the efficiency
and utilization of labor, equipment and space.

The researchers used a research and development to describe the improvement of new
arrangement of equipment at Rodilla‟s Yema cake. The researcher gather data through interview,
observation, researches and principles found in books and other related studies.
Research Environme nt
This study was conducted in the production area of Rodilla‟s Yema cake located at Brgy.
Ilayang Wakas Tayabas, Quezon. The researchers gathered all the data to be used in the
improvement of facility layout at Rodilla‟s Yema Cake from field of observations, interviews of
the head of the operations and the employees, and other data provided by the process group
department. These would also serve as guide for the researchers to obtain the best design of
facility layout that would improve the process. The sources of information for the present and
proposed layout were differing from each other. The sources of data that were used in obtaining
the necessary information for the research study are the following:
In the observation of the proponents to the production area of Rodilla‟s Yema Cake in
minimum of twice a month to familiarize the actual procedure and the production process of
yema cakes, the researchers need to take note all the important things which are regarding the
activity in the environment of the production area. It is the process of observing come one
carefully in order to gain information. In this scenario, the researchers observed the actual
transaction of yema cakes inside and outside the production area. Truly then, the researcher
know the condition of their production area and process, what they need to do some
improvement.
Interview was conducted at the main office of Rodilla‟s Yema Cake; it was considered as
one if its research environments. In this case, interview is one of the mean points that the
researchers used in this proposed study.
Researchers read and gathered other information in the Internet Research using the Wi-Fi
of Enverga University to guide the researchers. The researchers were able to conduct an
intensive research regarding the production and distribution of Cakes. With this way, they are
able to gain related studies from different countries which are meet knowledge able to a
proposed study.
The researchers gathered their data by means library research using the books of Enverga
University, which would help the researchers to understand the ongoing study. Library technique
was conducted by the researchers in order to achieve the objectives of the study that they had
constructed at Rodilla‟s Yema Cake.
Procedures
This section provides details on how the study was conducted. In performing the project
study, the researcher first conducted data gathering to identify problems.
Data Gathering. Is an important aspect of any type of research study, it consists of
different means in collecting data needed. The important data in this study are the following: the
current facility layout, the problem and lapses encountered in production area, knowledge in
facility layout and design, knowledge in time and motion study. The following are the means of
data gathering that the researcher used.

Direct Observation. One way to gather data is to carefully observe the current situation
of the workplace in Rodilla‟sYema Cake.
Interview.Interviewing 4 operators and the supervisor helped the researchers to determine
problems in Rodilla‟sYema Cake. These interviews were necessary to gather data for the
development of the study.
Research.The researchers used two kinds of research using Internet research (it is the
most useful and easiest way to gather data and information needed) and Library research
(information such as concepts, techniques and methodologies of facility improvement can also
be obtained from the books).
Video-Camcorders.Recording every interview with the operators and the supervisor and
recording processes from raw materials to the finished product helped the researcher to easily
gather data.
Data Analysis. It is the action or process of observing something or someone in order to
gain information. The researchers conduct a regular observation in the Rodilla‟sYema cake to
determine all possible lapses and gaps in the production area.
The discussion between two or more people where in questions are being asked by the
interviewer to obtain the particulars or statements from the interviewee. The researchers
interviewed head of the operation and some workers from the different area of the production to
know their actual experience in the production line.
The researcher has used Why why analysis to understand the main reason of possible
defects and slow transportation after the collection of data. The researcher mapped the current
process using the process flow chart. Upon analysis of the problem the researcher validates all
the probable reasons to determine the root cause.
Design of Improved Facilities Layout. The researchers began with the project
discussion stage or the identification of the problem. After the researchers identify the problems
and lapses experienced in the facility and improved plans to define what the project would
provide; when would it be done; who would benefit; and what should be maintained.
After the researchers identified and classified the actual situation, the researcher tried to
improve the layout by using various IE tools to reach the objectives in design improvement
facility and machine layout using time and motion study and line balancing.
Development of Improved Facilities Layout. The researchers observed the facilities
and started to interview the head of production. The researcher identified the root cause of the
problem that they encounter during the production process. The researchers inspect all the
aspects on how to develop the productivity by elaborating the objective of the study. The
developed layouts were applied to achieve greater productivity. The researchers estimated the
proposed project in terms of functionality, effectiveness, efficiency and cost.
Evaluation. The researchers evaluated their recommended output by comparing the
actual and propose layout of the company. The evaluation of the study is necessary to determine
the functionality effectiveness, efficiency and cost of the proposed layout.
The researchers use five point Likert scale to qualify the numeric conclusions. The scale shown
in the table 1. The qualitative descriptions in the likert scale use are as follows: (5) strongly
agree, (4) agree, (3) neutral, (2) disagree, and (1) strongly disagree.
Table 1.
Modified Likert scale
Verbal Interpretation base

Numerical Rating Arithmetic Mean Rating
on Questionnaire
5 4.21-5.00 Strongly Agree
4 3.41-4.20 Agree
3 2.61-3.40 Neutral
2 1.81-2.60 Disagree
1 1.00-1.80 Strongly Disagree
The table 1 follows the Likert scale that contains the categories and its corresponding
ratings that used by the researcher in evaluating the improved facilities layout at Rodilla‟s Yema
Cake.
Design Concepts
In this project study, the selection of material is an important tool of successful facility
layout. The researcher considered the theories learned from facility planning and layout. In order
to perform this activity, there are methods and research that needs to be done. This step by step
process and action will give a detailed through understanding of what is needed to address the
problem. The methods used are discussed in the following:
Time and motion study. It is for the researchers to enhance work performance through
analysis and improvement of body and hand movement as well as determining the standard cost
of a particular work. Through the use of this tool, the researcher can identify the results of total
time and movements of the employees.
Line Balancing. Line Balancing is leveling the workload across all processes in a cell or
value stream to remove bottlenecks and excess capacity. A constraint slows the process down
and results if waiting for downstream operations and excess capacity results in waiting and
absorption of fixed costs. The researchers will use this to match the production rate after all
waste has been removed to takt time at each process of the value stream.
Work Station Design. Since the researchers‟ objective is to improve the facility layout,
workstation will contributes to productivity and the quality of the products and takes care of the
health and well-being of the workers. Conversely, the poorly designed workstation will result in
low productivity, quality problems and is likely to cause or contribute to the development of
health complaints or chronic occupational diseases.
Flow Process Chart. This is an analyzing process particularly in looking up to eliminate
sources of waste or delay. The flow process chart is a graphical and symbolic representation of
the processing activities performed on the work piece. The chart can selectively be used to show
what happens to selected people, materials or equipment.
Computer Aided Drafting. It is a software application for computer aided design (CAD)
and drafting. It aims to simplify the drawing of the proposed layout. The researchers used
computer aided drawing (CAD) to illustrate an improved facilities layout.
Cost- Benefit Analysis. It is a comparative assessment of all the benefits you anticipate
from the project and all the costs to introduce the projects, perform it, and support the changes
resulting from it. It is used for the researchers to estimate and total up the equivalent money
value of the benefits and costs to the community of projects to establish whether they are
worthwhile.
Relationship Activity Chart. It is a list of all departments on the relationship chart, it
also defines criteria for assigning closeness between relationships and it establishes relationships
value. It is used for the researchers to allow everyone to contribute something to the development
of the relationship chart it also minimizing unnecessary transportation in industrial facility
Travel Chart. It is a simple table where there are multiple movements between places. It
is a variation on the check sheet, indicating movements between places. It is a variation on the
check sheet for the researchers to indicate movements from and to any combination of a given
set of locations.
Unit IV
Results and Discussions
The information provided in this unit is based on the collected data. This collected data
are used to the effectiveness of the proposed project study. This unit also presents the step by
step method for the better understanding on how the proposed study will be incorporated in the
existing process.
Data Gathering
The researchers gather data in the production area of Rodilla’s Yema Cake, its present or
existing facility layout, present workflow diagram, and present flow process chart to come up
with the proposed facility layout design. To design an improved facility layout, the researchers
gathered all the relevant data regarding the company by interviewing the manager and workers,
and also by doing field observation in the production area.
The first step of Systematic Layout Planning requires gathering and analyzing data
required for the study. This must occur before any planning of relationships, space or
adjustments. The input variables for every SLP are P, Q, R, S and T. Product (P) is the material
that will be processed. For this study, the products are the yema cakes. Quantity (Q) is the
volume of each product to be processed. The volume in this study refers to the output of each
product. It relies on the total time used to build a unit of product. Routing (R) is the path a
product travels to be processed. The routing (R) in this study is obtained from the company’s
process specific document(PSD) for yema cakes. Time(T) refers to the overall time required to
complete processing. Data collection of the cycle time for each process is done by time studies.
Existing Set-Up.The production area produces four different types of cake with flavors
original yema, chocolate, mocha and ube. A flowchart is used toa type of diagram that represents
an algorithm, workflow or process, showing the steps as boxes of various kinds, and their order
by connecting them with arrows. This diagrammatic representation illustrates a solution model to
a given problem.
Flowcharts are used in analyzing, designing, documenting or managing a process or
program in various fields. This production area uses various types of machines like egg mixers,
flour mixers, icing mixers, and big and small ovens. It operates eight hours a day, six times a
week. The workers compensation is paid based on the policy of Rodilla’s Yema Cake. The yema
cake production was composed of 12 processes which are operated by 25-30 workers.
In analyzing processes, particular actions along the way are often significant, especially if
you are looking to eliminate sources of waste (ormuda, as the Japanese call it). The chart can
selectively be used to show what happens to selected people, materials or equipment.
The 12 processes on how the production area of Rodilla’s operates are: 1.) Receiving of raw
materials. 2.) Storing of raw materials into storage or stock room. 3.) Issuing of materials to
production. 4.) Pre mixing. 5.) First baking. 6.) Second mixing. 7.) Second baking. 8.) Cooling.
9.) Slicing. 10.) Icing and cheesing. 11.) Packing. 12.) Loading of finished products.
Start
Receiving of raw materials
Storing of raw materials into storage or stock room
Issuing of materials to production
Pre-mixing
First baking
Second mixing
Second baking
No Yes
Let it cool Does the
dough cool? Slicing
Icing and cheesing
Packing
Loading of finished
End
Figure 2.Present flow process chart

Present Flow Diagram. Industrial Engineering tools help the researchers to elaborate the
problems in the production area of Rodilla’s Yema Cake and also help to establish a better
design of the facility layout. Figure 3 shows how the actual process of producing yema cakes. It
also shows the arrangement of facilities and the spaces between each machine. There were 11
ovens, 2 mixers for flour and sugar mixing, 6 big mixers for making chiffon cake, 8 mixers for
icing, 6 racks and 7 tables in the finishing area.
Figure 3.Present flow diagram
Process begins with incoming material at the production area. However this process is not
included in the scope of this case study. After that, the pre mixing assembly is performed by the
operator in the lower building of the production. After that they have to transfer the mixed
ingredient to the next process which is chiffon making. The chiffon making process will take
about 6 minutes in each mixer of dough. Upon completion, operator has to transfer the mixed
dough into the oven section; this will take about 30 minutes in each batch of cakes per oven.
After the baking of cakes in the oven it proceeds to the next process which is cooling. When the
cakes are cool enough operator transfer them to the finishing section located at a different
building above the baking section. This process requires the usage of racks. Therefore long
travelling distance and time occurs when the operator has to wait for the cakes to cool and
travelling occurs to-and-from from the ovens to the finishing section.
After the transferring of cakes to the finishing sections, cakes are going to 3 same
assemblies of slicing, icing and cheesing. The processes are being done in three different
assembly tables all at the same time before it is transferred to another table which is boxing.
Present Relationship Diagram.Figure 4 shows the actual layout or location of the
different departments in the production area of yema cakes. These departments are the icing
section, storage area, washing area, mixing areas, oven section, racks area, icing and slicing area,
boxing and packing area.
Figure 4.Present relationship diagram

Present Facility Layout.The existing layout of the production area of Rodilla’s Yema
Cake is given in Figure 2 below. In this layout, the dimensions of the area and the existing
assemblies or process sections are shown.
Figure 5.Present facility layout
Present Standard Time. Standard provides information essential for the successful
operation of an organization. To calculate standard time for each operation, time study is
conducted in the production area. To do this, the researcher selects one operator from each
operation. Then, each operation is taken for at least three cycles to get better results. Once time
study is made by collecting raw data the performance rating is given to each operator and actual
time is calculated for particular operation.
Standard Time determination is the observed time (OT) of the given element is
determined by taking the mean of 5observations. The sample size, n, is then calculated to show
its sufficiency. Normal Time (NT) is found by multiplying the observed time by the average
rating.
By using one of the oldest used rating systems, the Westinghouse rating system
considering four factors in evaluating the performance of the operator: skill (as proficiency at
following a given method), effort (is representative of the speed with which skill is applied, and
can be controlled to a high degree by the operator), conditions (referred to in this performance
rating procedure affect the operator and not the operation, and they include temperature,
ventilation, light, and noise.), and consistency (as being in conformity with a set of rules,
guidelines or policies), the researchers determined the value of the rating factor.
Normal Time = Observed Time*Average Rating
The rating used here is 119% for the overall rating factor of all the operators:
Skill B2 +0.18
Effort B1 +0.10
Condition D 0.0
Consistency C +0.01
Algebraic Sum: +0.19
Performance Factor: 1.19
Standard Time= Normal Time/ (1- Allowances)
Allowances for this project are: Personal needs 5%, Unavoidable delay 1%, Basic Fatigue
4 %, Total = 10%
Actual Computation:
Observed Time: 3032.4 seconds (small) 3017.4 seconds (big)
Normal Time: 3032.4*1.19 = 3608.56 3017.4 *1.19 = 3590.71
Standard Time: (3608.56) (1+.10) = 3969.42 (3590.71) (1+.10) = 3949.78

Table 2.
Present time study for small cakes
Activity : Yema Cake Production ( Small )
Date : 2016
Operator: BSIE
Circle appropriate Method & type :
Method: Present Proposed
Remarks
Event Description Trial 1 Trial 2 Trial 3 Trial 4 Trial 5 Average Time

(sec) (sec) (sec) (sec) (sec) (sec)
Mixing the Flour 67 65 63 66 64 65
Transferring of mixed flour 32 29 31 28 30 30
Making of chiffon cake 390 390 390 390 390 390
Baking of chiffon cake in the 1830 1830 1830 1830 1830 1830
oven
Transferring of baked chiffon 115 125 122 120 118 120
cake racks
Cooling of cakes in the racks 480 480 480 480 480 480
Transferring of racks to the 58 122 60 59 61 72

finishing section
Slicing of cakes ( small Yema 4 4 4 4 4 4
Cake )
Icing of cakes 22 23 21 19 20 21
Cheesing of cakes 10 8 6 9 7 8
Transferring of cakes 5 4 6 6 4 5
Boxing of cakes 9 7 7 6 8 7.4
Arranging of finished cakes 2 2 2 2 2 2
for the delivery
Total 3024 3089 3022 3019 3018 3034.4

Table 3.
Present time study for big cakes
Activity : Yema Cake Production ( Big )
Date : 2016
Operator: BSIE

Remarks

(sec) (sec) (sec) (sec) ((sec) (sec)
oven

cake racks

finishing section
Slicing of cakes ( big Yema 2 2 2 2 2 2

Cake )
Icing of cakes 23 17 21 19 20 20
Boxing of cakes 9 7 7 6 8 7.4

for the delivery
Total 3023 3015 3015 3018 3016 3017.4

Table 4.
Summation of the present time study for small and big cakes
`Location: Rodillas Yema Cake `Location: Rodillas Yema Cake
Activity :Yema Cake Production (small) Activity :Yema Cake Production (big)
Date: 2016 Date: 2016

Operator: BSIE Operator: BSIE
Circle appropriate Method & type : Circle appropriate Method & type :
Method: Present Proposed Method: Present Proposed
Remarks: Remarks:
Event Description Time Event Description Time

(sec) (sec)
Mixing the flour 65 Mixing the flour 65
Transferring of mixed flour 30 Transferring of mixed flour 30
Making of chiffon cake 390 Making of chiffon cake 390
Baking of chiffon cake in the oven 1830 Baking of chiffon cake in the oven 1830
Transferring of baked chiffon cake to 120 Transferring of baked chiffon 120

the racks cake to the racks
Cooling of cakes in the racks 480 Cooling of cakes in the racks 480
Transferring of racks to the finishing 72 Transferring of racks to the 60

section finishing section
Slicing of cakes( small Yema Cake ) 4 Slicing of cakes( big Yema Cake ) 2
Icing of cakes 21 Icing of cakes 20
Cheesing of cakes 8 Cheesing of cakes 6
Transferring of cakes 5 Transferring of cakes 5
Boxing the cakes 7.4 Boxing the cakes 7.4
Arranging of finished cakes for the 2 Arranging of finished cakes for 2

delivery the delivery
Table 5.
Present time study data
Description Time
Small Cakes Big Cakes
Observed time (sec/unit) 3034.4 3017.4
Standard time (sec/unit) 3969.42 3949.78
Working hours 28800 28800
Output 500-700 500-700
Total travel time 227 215
From the data gathered, the total time of processing for a single cake is 3034.4 seconds
for a small cake and 3017.4 for a big cake. With the standard working days per month of 22
days, the output yields 11000-15400 small and big yema cakes per month. It can be seen that the
travelling time is high due to frequent travelling between 2 buildings. The travelling time is
about 210-230 seconds which is higher than the assembly and cueing time.
Present Flow Process Chart.A facility layout is an arrangement of everything needed
for production of goods or delivery of services. It means planning for the locations of all
machines, utilities, employee workstations, material storage area, aisles, offices and storage
rooms. This is for the flow patterns of materials and people around, into and within buildings.
In the production of yema cake, operation starts by mixing different ingredients from
different areas in the production. The flow process chart illustrates the delayed process in making
yema cake including all activities such as the operations, transportations, delays and storage.
This helps the researchers in setting out the sequence of the flow of a product by recording all
events under review using appropriate process chart symbols.

`Location: Rodillas Yema Cake Summary

Activity :Yema Cake Production (small) Event Present Proposed Savings
No. Time No. Time
(sec) (sec)
Date: 2016 Operation 7 2327.4
Operator: BSIE Transport 4 227
Circle appropriate Method & type : Delay 1 480

Storage 0 0
Inspection 0 0
Total 13 3034.4
Remarks:
Total Distance 21 meters
Process Description Symbol Time Distance Method
(sec) (meter) Recommendation
Mixing the flour 65
Transferring of mixed 30 1.5

flour
Making of chiffon 390
cake
Baking of chiffon cake 1830
in the oven
Transferring of baked 120 12.5
chiffon cake to the
racks
Cooling of cakes in the 480
racks
Transferring of racks 72 6
to the finishing section
Slicing of cakes( Small 4
Yema Cake )
Icing of cakes 21
Cheesing of cakes 8
Transferring of cakes 5 1
Boxing the cakes 7.4
Arranging of finished 2
cakes for the delivery
Figure 6.Present flow process chart for small cakes

`Location: Rodillas Yema Cake Summary

Activity :Yema Cake Production (big) Event Present Proposed Savings
No Time No Time
(sec) (sec)
Date: 2016 Operation 7 2322.4
Operator: BSIE Transport 4 215
Circle appropriate Method & type : Delay 1 480
Method: Present Proposed Storage 0 0
Inspection 0 0
Total 13 3017.4
Remarks: Total distance 21 meters
Mixing the flour 65

flour
cake
in the oven
chiffon cake to the
racks
racks
Slicing of cakes(Big 2
Yema Cake )
Icing of cakes 20
Cheesing of cakes 6
Boxing the cakes 7.4
Figure 7.Present flow process chart for big cakes

In getting the data of the flow process chart, the researcher used the standard time of each
operation computed in the time study table. The transportation distances was got from measuring
the distance of each station to the next station based on the sequence of the process while the
transportation time is computed by taking up the average of the 5 trials of the observed time
collected by the researcher. The total flow time of producing yema cake is computed.
Data Analysis
The results of the interview and observation in the production area, the researchers found
out that the common problem that the production area of Rodilla’s Yema Cake usually
encountered is long processing time between each processes because of their distances from each
other. To be able to understand the roots of the problem, and how will it be prevented, the
researchers use of various root cause analysis tools as shown in the following figures.
Table 6.
Whys Analysis – Causes of the problem in Rodilla’s Yema Cake
Why’s Because
Why Rodilla’s cannot produce yema cake in There having a hard time in the production of
time? yema cake.
Why Rodilla’s having a hard time in the There is a long transportation of each
production of yema cake? operations/stations.
Why was there a long transportation of each The production area has a poor production
operations/stations? system.
Why the production area has a poor production The operations are not in proper arrangement?
system?
Why was there a improper arrangement? Because the production area has a poor facility
layout.
In Table 5, the causes of the error in production of yema cake were shown using the 5
whys analysis. From the last reason, the answer to the problem was found out to redesign of an
improve facility layout of the production area.
Figure 8.Ishikawa Diagram
Validation of Root Cause

Table 7.
Validation of Root Cause Using Why’s Analysis
Primary causes Secondary causes Validation of root cause
Rodilla’s cannot produce yema There having a hard time in the Not a true cause
cake in time production of yema cake
Rodilla’s having a hard time in the There is a long transportation of Not a true cause
production of yema cake each operations/stations
Rodilla's has a long transportation The production area has a poor Not a true cause
of each operations/stations production system
The production area of Rodilla's The operations are not in proper Not a true cause
has a poor production system arrangement
The operation in production area The production area has a poor True cause
of Rodilla's has a improper facility layout.
arrangement
Table 8.
Validation of Root Cause Using Ishikawa Diagram
Primary causes Secondary causes Validation of root cause

Over Fatigue Not a true cause
Not properly trained Not a true cause
Man
Not flexible Not a true cause
Unnecessary movements Not a true cause
Overused True cause
Machine Under maintenance Not a true cause
Poor production yield Not a true cause
Delayed cooling of cakes Not a true cause
Line balancing True cause
Method
Material handling Not a true cause
Transferring of cake True cause
Far location of storage Not a true cause
Undersupply of raw materials Not a true cause
Material
Mixing of ingredients Not a true cause
Poor quality of eggs Not a true cause
Weather condition Not a true cause
Poor lighting Not a true cause
Environment
Facility Layout True cause
Getting hit by other operators Not a true cause
Design of Improved Facility Layout
Activity Relationship Chart.In this stage, the identification of the relationships between
resources is discussed. The resources are the various processes involved in the manufacturing of
the product. The information regarding where a product is received from and the destination of
the product upon completion is gathered.
The results are tabulated in an activity relationship chart. The relationship chart displays
which entities are related to others and it also rates the importance of the closeness between
them. This makes the chart the most effective tool for layout planning and is the best way of
planning the arrangement of a plant layout having little flow of materials. The quantitative
descriptions used in activity relationship chart are as follows: (A) absolutely necessary, (E)
especially important, (I) Important, (O) ordinary closeness, (U) unimportant, and (X)
undesirable.
Figure 9.Activity relationship chart
Space Relationship Diagram. The space relationship diagram is a visual display of the
activity relationship chart. Each entity on the chart is translated to a symbol to be placed on the
diagram and then lines are connected to show the value of the relationship. Figure 10 shows the
space relationship diagram of the production area of Rodilla’s Yema Cake. The numbers and
types of lines are used to distinguish the importance between each process are as follows; (A)
four straight lines, (E) three straight lines, (I) two straight lines, (O) one straight lines, (U) no
line, (X) zigzag line.

Figure 10.Space relationship diagram
Absolutely necessary relationship occurs between the assembly line of slicing/icing and
boxing. Locating them close together is absolutely necessary as the products share these 2
processes. Rework process, which requires travelling to and fro among these 2 processes, is also
the highest. Especially important relationship occurs among mixing process, baking and oven
and cooling as these processes occur back to back and are also shared between products.
Block Diagram. This shows the new actual layout or location of the different
departments in the production area of yema cakes. These departments are the icing section,
storage area, washing area, mixing areas, oven section, racks area, icing and slicing area, boxing
and packing area.

Figure 11.Block diagram
Standard Time. Standard provides information essential for the successful operation of
an organization. To calculate standard time for each operation, time study is conducted in the
production area. To do this, the researcher selects one operator from each operation. Then, each
operation is taken for at least three cycles to get better results. Once time study is made by
collecting raw data the performance rating is given to each operator and actual time is calculated
for particular operation.
The researchers then make a new time table to test the proposed facility layout that has
been implemented at the production area of Rodilla’s Yema Cake. The data is shown in the
figure below.
Table 9.
Proposed time study for small cakes
Activity : Yema Cake Production ( Small )
Date : 2016
Operator: BSIE

Type : Material WorkerMachine
Remarks

(sec) (sec) (sec) (sec) (sec) (sec)
oven

cake racks

finishing section
Slicing of cakes (small Yema 4 4 4 4 4 4

Cake)
Icing of cakes 18 16 20 16 20 18
Boxing of cakes 6 8 7 6 8 7

for the delivery
Total 2758 2762 2760 2757 2763 2760

Table 10.
Proposed time study for big cakes
Activity : Yema Cake Production ( BIg )

Date : 2016
Operator: BSIE
Type : Material Worker Machine
Event Description Trial 1 Trial 2 Trial 3 Trial 4 Trial 5 Average
(sec) (sec) (sec) (sec) (sec) Time (sec)
Transferring of mixed 7 8 8 8 9 8
flour
Baking of chiffon cake 1830 1830 1830 1830 1830 1830

in the oven
Transferring of baked 60 60 60 60 60 60
chiffon cake racks
Cooling of cakes in the 435 431 433 437 439 435
racks
Transferring of racks to 13 15 17 15 15 15
the finishing section
Slicing of cakes ( big 2 2 2 2 2 2
Yema Cake )
Icing of cakes 17 15 16 17 15 16
Boxing of cakes 7 6 8 6 8 7
Arranging of finished 2 2 2 2 2 2
Total 2745 2743 2752 2751 2751 2748
`Location:Rodillas Ye ma Cake Summary
Activity :Yema Cake Production Event Present Proposed Saved

(small) time
No Time No Time (sec)
(sec) (sec)
Date: 2016 Operation 7 2327.4 8 2241 86.4
Operator: BSIE Transport 4 227 4 84 143
Circle appropriate Method & type : Delay 1 480 1 435 45
Method: Present Proposed Storage 0 0 0 0 0
Inspection 0 0 0 0 0
Total 13 3034.4 13 2760 274.4
Remarks: Total distance 21 meters
Mixing the flour 65

flour
cake
in the oven
chiffon cake to the
racks
racks
Yema Cake )
Icing of cakes 18
Cheesing of cakes 7
Boxing the cakes 7
Figure 12.Proposed flow process chart for small cakes

`Location:RodillasYema Cake Summary
Activity :Yema Cake Production (big) Event Present Proposed Saved

time
No Time No Time (sec)
(sec) (sec)
Date: 2016 Operation 7 2322.4 8 2229 93.4
Operator: BSIE Transport 4 215 4 84 131
Circle appropriate Method & type : Delay 1 480 1 435 45
Storage 0 0 0 0 0
Inspection 0 0 0 0 0
Total 13 3017.4 13 2748 269.4

Remarks:
Total distance 21 meters
Mixing the flour 60

flour
cake
in the oven
chiffon cake to the
racks
racks
Yema Cake )
Icing of cakes 16
Cheesing of cakes 4
Boxing the cakes 7
Figure 13.Proposed flow process chart for big cakes

Development
The proposed layout is based on the activity relationship chart and the theme of reducing
travelled distance. Altering the positions between several departments will ensure smooth flow
of materials as well as it will reduce total travelled distance throughout the production unit.
Proposed flow diagram.In this diagram, the machines were arranged according to the
flow of the process. The machines that are related to each other were put up together in the same
line to minimize the long transportation and long processing time. Same as the present flow
diagram, the black arrow starts from the mixing area of flour and sugar to the boxing section. As
shown in the figure 6, the layout is much more systematic and organized than the present layout
because the operators will not have longer distance to transfer their part to the next operation.
Figure 14.Proposed flow diagram

Proposed Facility Layout.In order to arrive at the proposed facility layout, the
researchers analyze the gathered data and the present arrangement of the facility because those
knowledge will be the basis of the design of new facility layout that will improve the process in
producing yema cakes, minimize its processing, increase their production per day w/o overtime,
improve their flow time and saves costs.
Figure 15.Proposed facility layout
In the proposed layout assembly tables in the finishing section are arranged in line
according to the sequence of their process. This was done because the tables were not in
sequence based on their processes and the operators are having an unspecific direction all over
the area.
The purpose of this proposed facility layout is to decrease time travel and to have a
standardized production system process at Rodilla’s. In creating the facility layout of Rodilla’s
Yema Cake, the researcher use process layout type as the basis because through the study of
literature on the various types of facility layout, the researchers learned that flow processing type
of manufacturing such as baking, the process layout would be suited in producing yema cakes.
Designing the proposed facility layout is the arrangement of the assembly lines.
Evaluation
In order to evaluate whether the propose facility layout is efficient and effective,
applicable and cost saving this part will compare the present and proposed layout. Also, this will
show how the proposed layout overcomes the present layout.
Table 11.
Comparison of Total Time between the Present and Proposed Layout of Small Yema Cakes
Process Description Time (sec)
Present Proposed Saved time
Mixing the flour 65 65 0
Transferring of mixed flour 30 8 22
Making of chiffon cake 390 308 82
Baking of chiffon cake in the oven 1830 1830 0
Transferring of baked chiffon cake to the 120 60 60

racks
Cooling of cakes in the racks 480 435 45
Transferring of racks to the finishing 72 15 57

section
Slicing of cakes( small Yema Cake ) 4 4 0
Icing of cakes 21 18 3
Cheesing of cakes 8 7 1
Transferring of cakes 5 1 4
Boxing the cakes 7.4 7 0.4
Arranging of finished cakes for the 2 2 0

delivery
TOTAL 3034.4 2760 274.4
Table 12.
Comparison of Total Time between the Present and Proposed Layout of Big Yema Cakes
Process Description Time (sec)
Present Proposed Saved time
Mixing the flour 65 60 5
Transferring of mixed flour 30 8 22
Making of chiffon cake 390 308 82
Baking of chiffon cake in the oven 1830 1830 0
Transferring of baked chiffon cake 120 60 60

to the racks
Cooling of cakes in the racks 480 435 45
Transferring of racks to the 60 15 45

finishing section
Slicing of cakes( big Yema Cake ) 2 2 0
Icing of cakes 20 16 4
Cheesing of cakes 6 4 2
Transferring of cakes 5 1 4
Boxing the cakes 7.4 7 0.4
Arranging of finished cakes for the 2 2 0

delivery
TOTAL 3017.4 2748 269.4
According to the result, the time required to produce a single yema cake was reduced to 5
minutes compared to the present time.
2000 Comparison of Present and Proposed Time of Small Cakes

1800
1600
1400
1200
1000
800
Present
600 Proposed
400
200
Figure 16.Graphical representation of the compared present and proposed time study
2000 Comparison of Present and Proposed Time for Big Cakes

1800
1600
1400
1200
1000
800
Present
600 Proposed
400
200
Figure 17.Graphical representation of the compared present and proposed time study
This happens because of the new systematic arrangement of each machines and
operations from a proposed facility layout. The figure above shows the graph to see the actual
differences between the time in each operation of the present and proposed layout.
Survey Result
In the post survey that the researchers had prepared, the data collection is based on self-
completion schemas, which the selected target group or the workers of Rodilla’s has received by
letter.
In this survey the researchers collected a fairly answers from a large amount of persons,
within a relatively short time span, and a relatively limited economic range. The respondents get
the possibility to answer the questionnaire when they feel like it and can find the time and space.
In this manner, the respondents can use more time to think about difficult or complex questions
when it is required, in order to provide the best answers.
Table 13.
Survey Result
Items 5 4 3 2 1 Total
Effectiveness
1. Usefulness of the improved layout 30 0 0 0 0 30

2. Improved layout is effective in maximizing the
capacity of the business 18 10 2 0 0 30
3. Reduce of unnecessary movements 19 9 2 0 0 30
Efficiency
4. Suitability of the improved layout for everyone 20 8 2 0 0 30
5. Synchronized with the previous and next previous and

next process 24 5 1 0 0 30
6. Enhanced present time due to improved layout 23 7 0 0 0 30
Cost
7. Less losses incurred as a result of the layout 30 0 0 0 0 30
8. Enhanced quality of the product have not been

sacrificed 24 4 2 0 0 30
9. Savings due to reduction of process time 30 0 0 0 0 30
After the questionnaire is completed, each item may be analyzed separately or in some
cases item responses may be summed to create a score for a group of items. Hence, Likert scales
are often called summative scales. Used mainly in training course evaluations and market
surveys, Likert scales usually have five potential choices (strongly agree, agree, neutral,
disagree, strongly disagree) but sometimes go up to ten or more. The final average score
represents overall level of accomplishment or attitude toward the subject matter.
Table 14.
Result of the survey based on Likert Scale
Criteria SA (5) A (4) N (3) D (2) SD (1) Total
F W % F W % F W % F W% F W% F M
Usefulness of 30 150 100 0 0 0 0 0 0 0 0 0 0 0 0 30 5 Strongly
the improved Agree
layout
Improved 18 90 60 10 40 33 2 6 7 0 0 0 0 0 0 30 4.5 Strongly
layout is Agree
effective in
maximizing
the capacity of
the business
Reduce of 19 95 63 9 36 30 2 6 7 0 0 0 0 0 0 30 4.6 Strongly
unnecessary Agree
movements
Suitability of 20 100 67 8 32 27 2 6 7 0 0 0 0 0 0 30 4.6 Strongly
the improved Agree
layout for
everyone
Synchronized 24 120 80 5 20 17 1 3 3 0 0 0 0 0 0 30 4.8 Strongly
with the Agree
previous and
next previous
and next
process
Enhanced 23 115 77 7 28 23 0 0 0 0 0 0 0 0 0 30 4.8 Strongly
present time Agree
due to
improved
layout
Less losses 30 150 100 0 0 0 0 0 0 0 0 0 0 0 0 30 5 Strongly
incurred as a Agree
result of the
layout
Enhanced 24 120 80 4 16 13 2 6 7 0 0 0 0 0 0 30 4.7 Strongly

quality of the Agree
product have
not been
sacrificed
Savings due to 30 150 100 0 0 0 0 0 0 0 0 0 0 0 0 30 5 Strongly
reduction of Agree
process time
Average 4.7 Strongly
weighted mean Agree
Cost Benefit Analysis
Table 15.
Cost benefit analysis
Criteria Present Proposed Saved
Estimated Daily Total Walk Time 0.418 hour/day 0.163 hour/day 0.25 hour/day
Estimated Daily Total Cost Php 14.63/day Php 5.705 /day Php 8.75 /day
Estimated Monthly Total Cost Php 321.86/month Php 125.51/month Php
192.5/month
Estimated Annually Total Cost Php Php Php
3862.32/annual 1506.12/annual 2310/annual
In the cost benefits of the time saved, using the same flow process chart, the
Rodilla’sYema Cake would have a projected savings of 0.25 hour per day, yearly with 61%
efficiency.
Estimated Daily Total Walk Time Saved = Present – proposed
= 0.418 -0.163
= 0.25 hour/day
% efficiency= x100% = 0.610 or 61%
In the cost benefits of the worker, using the same flow process chart, the Rodilla’s Yema
Cake would have a projected savings of Php 8.75 per day, or Php 192.5 per month, or Php 2310
per year, with a yearly efficiency of 59.8%.
Estimated Daily Total Savings Cost = Present – proposed
= 14.63-5.705
= Php 8.75 /day
% efficiency= x100% = 0.598 or 59.8%
Estimated Monthly Total Savings Cost = Present – proposed
= 321.86-125.51
= Php 192.5/month
% efficiency= x100% = 0.598 or 59.8%
Estimated Annually Total Savings Cost = Present – proposed

= 3862.32-1506.12
= Php 2310/annual
% efficiency= x100% = 0.598 or 59.8%
Summary of Findings
All in all, if the results were being summarized, the effectiveness and efficiency of the
proposed facility layout was a great success and help to Rodilla’s Yema Cake. The sum of total
savings of the workers and the total time savings of the outgoing goods has a big effect on the
annual savings of the Rodilla’s Yema Cake. As shown in table 12, an amount of Php 2310is
projected to be saved through the improvement efforts studied by the researchers.

Unit V
Conclusions and Recommendations
This unit dealt with the conclusion and recommendation of the researchers concern in the
facility layout of the Production area of Yema Cake. This unit includes all the important
information that was found in the study. It shows the generalizations and answers to the
objectives stated at the beginning of the study. Furthermore, it also includes a suggestion or
proposed answers for the problems encountered during the study.
Conclusions
To develop a proposed solution, design of an effective new facility layout to the problems
encountered of the Production area of Yema Cake, the following conclusions were established:
1. The researchers designed an improved facility layout at the production area of Rodilla’s
Yema Cake. The improved layout such as new arrangements of machines and working
areas helped to decrease the distance and time consumption during the process or
operations of producing yema cakes, these results in an increase in the productivity.
2. The researchers developed the improved facilities layout at Rodilla’s Yema that helped
the Production area to increase their output per day and helped them to minimize their
processing time in slicing and icing cakes, saves cost, saves energy, minimize errors, and
deliver their products to the franchisers on time.
3. The researchers evaluated the improved facility layout in terms of effectiveness,
efficiency and cost using time and motion study principles the researchers determined the
wastes such a long transportation of materials and products and idle time that should be
lessen or eliminated in the whole process to decrease the flow of processing the product.
Recommendations
In conducting this study, the researchers have proposed the following suggestions for the
improvement based on the findings and conclusions derived:
1. The researchers recommend to the next researchers to conduct study on the design and
layout of next process. Continuously improve the process in to produce more cost down
activity for the company.
2. The developed process layout and must be monitored and act on the items that Facilities
planning and design requires the use of different tools and techniques, in order for it to
operate at low cost and provide fast delivery but not sacrificing the quality being
produced. It also defines layout as an integral part of a Lean Manufacturing strategy.
3. Sustaining the implementation of proposed layout in the company will be a good start to
improve production line productivity. The company should arrange their product or its
flow in a way that the efficiency and productivity will not suffer.
References
Prof AngelitaOngCamilar-Serrano. (2016) Facilities Planning and Management.Intramuros
Manila: Unlimited Books Library Services and Publishing Inc.
Prof AngelitaOngCamilar-Serrano. (2016) Productivity and Quality Management.Intramuros
Manila: Unlimited Books Library Services and Publishing Inc.
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3g E-learning fzllc.(2015) Production and Operations Management Basics. UAE: 3G Elearning
FZ LLC
Frievalds, Niebel et al. (2014) Process Layout. NY: McGraw-Hill
Lontoc, et al. (2012) Facility Layout
Miranda, Joshua. (2011) “Facilities Layout and Design”
Bermillo, E.B. et al. (2013) Production Efficiency Improvement through Time and Motion Study
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System at the Red system Company Inc.
Quicena, J.H.B., Granada, M.E.V., Llagas K.J.R., VillaflorJr, R.A., Palero, M.I. (March 2013)
Production Layout Improvement through Facilities Planning
Maniya, K.D., Bhatt M.G. (2011) An alternative multiple attribute decision making methodology
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Hofer C., Eroglu C., Hofer A.R. (2012) The effect of lean product of financial performance: The
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Ozbakir, L., Baykasoglu A., Gorkeml L. (2011) Multiple Colony ant algorithm for parallel
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International Journal of Production Economics
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Handling Equipment: A Win-win Approach for Manufacturers and Customer
K, Alexander (2013) Facility Management: Theory and Practices. Retrieved from
https://scholar.google.com.ph/scholar?hl=en&as_sdt=0,5&q=facilities+management+refe
rence
B, Atkins, A Brooks (2011) Total Facilities Management. Retrieved from
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Ramazan Şahin (April 2011) A simulated annealing algorithm for solving the bi-objective facility
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ArashShahin, Mehdi Poormostafa (Nov 2011) Facility Layout Simulation and Optimization:
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Erik Sundin , Mats Björkman, Mats Eklund, Jörgen Eklund, Inga-Lill Engkvist (June 2011)
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Appendices
Appendix A
Project Study Gantt Chart
JUNE JULY AUG UST SEPTEMB ER OCTOB ER NOVEMB ER DECEMB ER

Activity
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
1. Data gathering
through:
a. Brainstorming
b. Conduct survey
c. Acquiring data
from respective
organization.
2. Formulation of
Running tile
3. Preparation of
Units 1 to 3 of the
Study
4. Proposal defense
5. Submission of
Final Proposal paper
6. Data gathering
and analysis
7. Design of
improved production
process
8. Development of
the facility layout
9. Implementation of
the improved facility
layout and design
10. Evaluation
11. Continuation and
Completion of the
manuscript
12. Final defense
13. Submission of
hardbound.
Appendix B
Result of Interviews & Observations
This appendix contains samples of all the participant interviews. When the researcher
began the interview process, the line of questions concerning the production process and the
material-transition process were viewed as separate entities. After, the first four interviews with
the workers of Rodilla’s Yema Cake from different areas of production, the supervisor toured the
researcher around the production area which in fact flowed into the follow-up interviews with
her. Separate conclusions concerning production process and the material-transition process were
derived from the data.
1st PARTICIPANTS DATA
WORKERS FROM PACKING AND ICING/SLICING INTERVIEW
The interview was held in the main office of Rodilla’s Yema Cake, July 12, 2016. The
researcher's time with them was limited to 30 minutes by their schedule. The interview
proceeded on a very structured path defined by the preliminary question set used by the
interviewer to assure coverage of the topics of importance to the researcher. The interview got
off to a bumpy start, as Participant 1 agreed to record the session.
When will you usually start the production?
The production usually starts at 5:30 in the morning every day except for Sunday. We are
here by 5 o’clock to prepare things. Some of us start by 5 sharp, those are the workers
assigned in the mixing and baking.

How many workers are working in the production for ordinary days?
We are 25 to 30 people working here together. We are divided into 2 wherein boys are on
the mixing and baking area and girls are in the icing, slicing and packing.
During peak season like Christmas and New Year, How many workers work here?
During peak season we hire extras and we most likely are 35-40 workers doing the
production.
Is your work here comfortable and stress free during the production?
Yes. But there is a time we stand and work too long, that’s when we have plenty of
orders from the customers. But that’s just once in a blue moon now because if we have
too much order we hire extra workers.
Is the ventilation in your work place good enough so you can work productively?
Yes. We are air-conditioned in the girl’s area. The boys’ area wherein there are ovens and
racks also has good ventilation because they have 2 big electric fans there.
What part of your job is the most tiring and uneasy?
I worked here 3 years already and I am used to my job so well. If there is something
uneasy for me it is when we transfer cakes from icing to slicing to packing because we
have to carry each cake from one table to another.
Is there anything aside from transferring cakes uneasy in your job?
I don’t think there is anything else. My job as a packer and sometimes slicer, it is the only
thing that is uneasy for me.

2nd PARTICIPANT DATA
WORKER FROM MIXING AND BAKING INTERVIEW
The interview was held in the main office of Rodilla’s Yema Cake, July 12, 2016. The
researcher's time with them was limited to 30 minutes by their schedule. The interview
interviewer to assure coverage of the topics of importance to the researcher. Participant 2 gave
very tight concise answers to the questions and kept the discussion on track to an on time
conclusion.
When will you usually start the production?
The production in our area usually starts at 5:00 in the morning every day except for
Sunday. We are the first step in the production so we cannot be delayed or else the whole
production will be delayed too.
How many workers are working in your area for ordinary days?
We are 12 to 15 people working here together. We are divided into 2, mixing and baking.
Is your work here comfortable and stress free during the production?
Yes it’s fine. We worked here for years already and we got used to the daily routine. We
are well divided for each task so we don’t exert too much force in our jobs.
Is the ventilation in your work place good enough so you can work productively?
Yes. We have two big electric fans to somehow eliminate the heat coming from the seven
big ovens.
What part of your job is the most tiring and uneasy?
For me as a mixer, I think probably the most uneasy one is when I get the sacks of flour,
sugar and baking powder in their area to the mixing room. I carry them manually.
Though it is not that far but it is still not that easy.
Is there anything aside from transferring cakes uneasy in your job?
I don’t think there is anything else. In my job as a mixer the only thing that makes my job
uneasy for me is the transferring of ingredients to the mixing room.
3rd PARTICIPANT DATA
SUPERVISOR INTERVIEW
The interview was held in the production area of Rodilla’s Yema Cake, July 12, 2016.
The researcher's time with them was limited to 30 minutes by their schedule. The interview
interviewer to assure coverage of the topics of importance to the researcher. Participant 3 gave
very tight concise answers to the questions and kept the discussion on track to an on time
conclusion as she toured as in the whole production area.
What is the hardest part in the production?
The hardest part in the production is the transferring of materials (in-process goods and
raw materials) from one place to another. Though we use racks, we still can’t avoid to
sometimes carrying things manually.

What is the main reason that usually causes delays in the production?
The waiting of cakes to get cooked in the oven and the waiting of cakes to get cool before
the icing process.
Thus this causes idle time for the workers?
Sometimes, but sometimes not because we do other things like assembling the boxes
while waiting for the cakes to cool down.
Do you face any uneasiness in the production area aside from the things that are mentioned
before?
Not really, no. There’s nothing more because we are just a small business here in Quezon
so we got used to do a lot of things here in the production area manually. Besides it’s a food
manufacturing business so we don’t let machines do all the works. Deliciousness in our yema
cakes still comes from the hands of our workers.
Interviewees:
1. Mixer:
2. Baker:
3. Slicer/Icing Personnel:
4. Packer:
5. Supervisor:
Appendix C
Result of Surveys
This appendix contains the sample of the post survey form. When the researcher finished
the implementation of the proposed layout a post survey form was given to the workers, the line
of questions concerning the production process and the material-transition process were viewed
as separate entities.
Demographic Profile
Name (Optional): ____________________________________________________

Gender : Female Male
Directions: Please rate each item using the following scale:

5 – Strongly Agree 4 – Agree 3 – Neutral 2 – Disagree 1 – Strongly Disagree
Items 5 4 3 2 1
Effectiveness
1. Usefulness of the improved layout
2. Improved layout is effective in maximizing the capacity of

the business
3. Reduce of unnecessary movements

Efficiency
4. Suitability of the improved layout for everyone
5. Synchronized with the previous and next previous and next
process
6. Enhanced present time due to improved layout
Cost
7. Less losses incurred as a result of the layout

8. Enhanced quality of the product have not been sacrificed
9. Savings due to reduction of process time
Items 5 4 3 2 1 Total
Effectiveness
1. Usefulness of the improved layout 30 0 0 0 0 30
2. Improved layout is effective in maximizing the 18 10 2 0 0 30

capacity of the business
3. Reduce of unnecessary movements 19 9 2 0 0 30
Efficiency
4. Suitability of the improved layout for everyone 20 8 2 0 0 30
5. Synchronized with the previous and next previous and 24 5 1 0 0 30

next process
6. Enhanced present time due to improved layout 23 7 0 0 0 30
Cost
7. Less losses incurred as a result of the layout 30 0 0 0 0 30
8. Enhanced quality of the product have not been 24 4 2 0 0 30

sacrificed
9. Savings due to reduction of process time 30 0 0 0 0 30
Computation of average weighted mean in likert scale

1. Usefulness of the improved layout
( ) ( ) ( ) ( ) ( )
2. Improved layout is effective in maximizing the capacity of the business

( ) ( ) ( ) ( ) ( )
3. Reduce of unnecessary movements

( ) ( ) ( ) ( ) ( )
4. Suitability of the improved layout for everyone

( ) ( ) ( ) ( ) ( )
5. Synchronized with the previous and next previous and next process
( ) ( ) ( ) ( ) ( )
6. Enhanced present time due to improved layout

( ) ( ) ( ) ( ) ( )
7. Less losses incurred as a result of the layout

( ) ( ) ( ) ( ) ( )
8. Enhanced quality of the product have not been sacrificed

( ) ( ) ( ) ( ) ( )
9. Savings due to reduction of process time

( ) ( ) ( ) ( ) ( )
Appendix D
Cost Benefit Analysis
Criteria Present Proposed Saved
Estimated Daily Total Walk Time 0.418 hour/day 0.163 hour/day 0.25 hour/day
Saved
Estimated Daily Total Savings php 14.63/day php 5.705 /day php 8.75 /day
Cost
Estimated Monthly Total Savings php 321.86/month php 125.51/month php
Cost 192.5month
Estimated Annually Total Savings Php Php Php
Cost 3862.32/annual 1506.12/annual 2310/annual
Saved
Estimated Daily Total Walk Time Saved = Total Time Saved per Unit x Unit per batch
= 131 seconds/batch x 7 batches/day
= 917 seconds/day
= 15.28 minutes/day
= 0.25 hour/day
Estimated Daily Total Savings Cost = Average Daily Walk Time Saved x Direct Labor
Cost
= 0.25 hour/day x Php 35/hour
= php 8.75 /day
Estimated Monthly Total Savings Cost = Daily Total Savings Cost x 22 days/month
= 8.75/day x 22 days
= php 192.5month
Estimated Annually Total Savings Cost = Monthly Total Savings Cost x 12 month
= PHp 227.5/month x 12 months
= Php 2310/annual
Present
= 215seconds/batch x 7 batches/day
= 1505 seconds/day
= 25.08 minutes/day
= 0.418 hour/day
Cost
= 0.418hour/day x Php 35/hour
= php 14.63/day
= 14.63/day x 22days
= php 321.86/month
= Php 3862.32/annual
Proposed
= 84seconds/batch x 7 batches/day
= 588 seconds/day
= 9.8 minutes/day
= 0.163 hour/day
Cost
= 0.163 hour/day x Php 35/hour
= php 5.705 /day
= 5.705 /day x 22days
= php 125.51/month
= Php 1506.12/annual
92
Curriculum Vitae
Yvonne R. Casas
Carillo St. Brgy. Parang
Pagbilao, Quezon
Contact No. 09060084216
Email Address : yvonnecasas28@yahoo.com.ph
PERSONAL INFORMATION: TRAININGS/SEMINARS ATTENDED:
Birthdate: February 28, 1995 1. 10th IEshikawa Seminar held at Henry

Birthplace: San Andres Quezon Lee Irwin Theater, Ateneo de Manila
Age: 21 yrs. old University last Nov. 21, 2015 with the
Civil Status: Single theme“Nexus: X Marks the Spot-
Name of Father: Casius P. Casas Converging Minds Across the Years.
Name of Mother: Nida R. Casas 2. 10th IEshikawa Seminar held at Henry
Citizenship: Filipino Lee Irwin Theater, Ateneo de Manila
Religion: Roman Catholic University last Nov. 21, 2015: themed “
Sex: Female Nexus: X Marks the Spot-
Language Spoken: Tagalog and English Converging Minds Across the Years.
3. Sports FIEsta 2015 held at University
EDUCATIONAL ATTAINMENT: of Philippines Los Baños, last Oct.30,
2015
Tertiary: Bachelor of Science in 4. 12th PIIE National Student Congress
Industrial Engineering held at Mapua Institute of Technology
MSEUF- Lucena Gymnasium, Manila last Feb. 7, 2015
5. Sports FIEsta 2014 held at Colegio De
Secondary: Casa Del Ñino Jesus de San Juan De Letran- Calamba,last Oct.
Pagbilao 25, 2015
Pagbilao, Quezon 6. FCG Scholar Seminar held at Veterans
Distinction Memorial Hospital last January 3, 2016
S.Y. 2007-2012 7. 11th IEshikawa Seminar held at Henry
Lee Irwin Theater, Ateneo de Manila
Primary: Pagbilao West Elementary University last Nov.12 , 2016 with the
School theme “ PARALLAX: Shifting Focus
S.Y. 2001-2007
ORGANIZATION: CHARACTER REFERENCES:

Name of Organization: PIIE-NSC
Position: Ambassador for Communication Engr. James Louie R. Meneses.
Inclusive Dates: 2016-present CIE-AAE – Lucena City,
09494247437
Name of Organization: PIIE-SC
Position: Member Engr. Ferdinand Christian M. Catapangan
Inclusive Dates: 2015-2016 REE, RME- Pagbilao, Quezon
09463305737
SKILLS:
Communication Skills: both oral and written Violeta Guevarra Rafa
Management leadership skills: work independently, Teacher in Casa Del Ñino Jesus de Pagbilao
organized in work load 09394623177
Technical Skills: microsoft skill
I hereby certify that the above information is true and correct to the best of my knowledge and belief.
YVONNE R. CASAS
Signature over printed name
93

Rodriguez Subdivision, Brgy. Balubal
Sariaya, Quezon
Phone Number: 09212210676
Email Address: aeron_jaztine@yahoo.com.ph
PERSONAL DATA
SKILLS
Birthdate: November 04 1995 Can perform multitasking
Birthplace: Sariaya, Quezon Can apply knowledge about Industrial
Age: 20 Engineering Tools
Civil Status: Single Good Leadership
Name of Father: JuanitoAbuel Fast Learner
Name of Mother: Elma Abuel Computer Literate
Citizenship: Filipino
Religion: Catholic TRAINING/S EMINARS ATTENDED
Sex: Male 1. Leadership Empowerment Seminar Manuel
Language Spoken: Filipino, English S. Enverga University Foundation 2014
2. 6th Southern Tagalog Industrial Engineering
EDUCATIONAL BACKGROUND: Seminar
3. University of Philippines, Los Baños,
Tertiary:
Laguna 2014
th
Bachelor of Science in Industrial 4. 5 PIIE Regional Congress Seminar
Engineering University of Philippines, Los Baños,
Laguna 2015
Manuel S. Enverga University 5. 12th PIIE National Congress Seminar Mapua
Foundation, University Site, Institute of Technology, ManilA2015
Lucena City 6. 10th IEshikawa Workshop and Seminar
2012 until present
Ateneo de Manila University, Loyola
Heights, Quezon City, Manila 2015
Secondary:
Sariaya Institute Inc.
Sariaya Quezon CHARACTER REFERENCE:
2008 - 2012
Engr. James Louie R. Meneses, 09494247437
Primary: Professor,Manuel S. Enverga University
Foundation
Central Main Elementary School University Site, Lucena City
Sariaya Quezon
2002 – 2008 Dr. Guillermo M. Rago Jr., 710 - 3151
Dean of the College of Engineering and
ORGANIZATIONS Technical Department,
PHILIPPINE INSTITUTE OF INDUSTRIAL Manuel S. Enverga University Foundation
ENGINEERS – University Site, Lucena City
MSEUF STUDENT CHAPTER
Assistant Vice President - Internal Engr. Agnes Aviles 09228620376
A.Y. 2015 - 2016 Professor,Manuel S. Enverga University
Foundation
University Site, Lucena City
AARON JUSTINE E. ABUEL

94
SHARMAINE V. COMINTAN
247 U. Camacho St. Brgy. 4,
Quezon,Quezon
CP # 09254737265
E-mail: sharmaine_comintan@yahoo.com
PERSONAL DATA:
Resourceful and willingness to learn new concepts
Birth Date : November 28,1995 and apply them to yield s uccessful results
Birth Place : Gumaca Quezon
Age : 20 TRAININGS/SEMINARS ATTENDED:
Civil Status : Single
Name of Father : Vicente V.Comintan On the Job Training
Name of Mother : Lesaida V. Comintan PETER PAUL CORPORATION
Citizenship : Filipino Production Office Staff
Religion : Roman Catholic Brgy.Pahinga Candelaria Quezon
Sex : Female
Language Spoken : Tagalog and English 6 th PIIE Regional Congress “Limitless:
Unlocking Possibilities with Product Design
EDUCATIONAL BACKGROUND: January 30, 2016
Tertiary: BACHELOR OF SCIENCE IN 12 th PIIE National Student Congress

INDUSTRIAL ENGINEERING February 7, 2015
Manuel S. Enverga University Foundation
5 th PIIE Regional Congress “IntensifIEd
Secondary: Thingking:Decision Making Under Risk and
Name of School: Cometa National High School Uncertainty”
Annex Quezon,QuezonDate January 17, 2015
Graduated: 2011-2012
6 th Southern Tagalog Industrial Engineering
Primary: Seminar
Name of School: Quezon Elementary School September 13, 2014
Quezon,Quezon
Date Graduated: 2007-2008 CHARACTER REFERENCES:
ORGANIZATION: Engr. James Louie R. Meneses, 09494247437

Professor,Manuel S. Enverga University
Name of Organization: Philippine Foundation
Institute of Industrial Engineers University Site, Lucena City
Position: Active Member
Inclusive Dates: 2014-Present Dr. Guillermo M. Rago Jr., 710 - 3151
Dean of the College of Engineering and
Name of Organization: CFC Youth for Technical Department,
Christ Manuel S. Enverga University Foundation
Position: Member University Site, Lucena City
Inclusive Dates: 2009-Present
SKILLS:
Engr. Agnes Aviles 09228620376
Good Communication skills both written Professor,Manuel S. Enverga
and verbal University Foundation University
Can easily adapt to a working environment Site, Lucena City
SHARMAINE V.COMINTAN
95
ARMANDO F. ANADING III

St, Jude phase 2B Blk17 lot14-15 Mayao
Lucena City
0942-832-7772
microanading@gmail.com
PERSONAL DATA:
Birthdate: February, 1, 1996 Work independently, Organized work load
Birthplace: Sta. Rosa Laguna
Age: 20
Civil Status: Single TRAININGS/SEMINARS ATTENDED:
Name of Father: Rodante L. Anading 1. 10 TH IEshikawa seminar held at
Name of Mother: Fely F. Anading Henry Lee Theater, Ateneo de
Citizenship: Filipino Manila University last
Religion: Christian November 21, 2015: Themed
Sex: Male “Nexus: X Marks the spot-
Language Spoken: Filipino, English converging minds Across the year
2. Sports FIEsta 2015 held at
EDUCATIONAL BACKGROUND: University of the Philippines Los
Baños , Last October 25,2015
Tertiary: BACHELOR OF SCIENCE IN 3. 12 th PIIE National Congress held at
INDUSTRIAL ENGINEERING Mapuá Institute of Technology
Manuel S. Enverga University Foundation Gymnasium, Manila Last February
7,2015
Secondary: 4. Sport FIEsta 2014 held at Colegio
Name of School: Manuel S. Enverga University De san Juan De Letran – Calamba,
Foundation Last January 3, 2014
Awards Received: GLEE CLUB Membership
Award/ Boy Scout of the
Philippines COMMUNITY SERVICES:
Date Graduated: 2012 Christmas Gift Giving for
Homeless
Primary: Feeding program
Name of School: ELVIRA RAZON Tree Planting
ARANNILA ELEMENTARY
SCHOOL CHARACTER REFERENCES:
Awards Received: Boy Scout of the Philippines ENGR. James Meneses
Date Graduated: 2008 Proffessor at Manuel S. Enverga
University Faundation
Lucena City
ORGANIZATION: 0949 424 7437
Name of Organization:
Philippine Institute of Industrial Engineering ENGR. Gervin Espinosa
Position: Member Proffessor at Manuel S. Enverga
Inclusive Dates: 2015-2016 University Faundation
Lucena City
SKILLS:
Computer literate (Microsoft Word, Microsoft Power Dr. Guillermo M. Rago, Jr.
Point), Dean, College of Engineering and
Welding, Ability to learn systems and procedures in a
workplace.
ARMANDO F. ANADING III

96
JOY E. PANALIGAN
ZONE 11, Poblacion Sta Elena
Camarines Norte
Contact No. : 0939-808-2091
E-mail: joy_panaligan28@ymail.com
PERSONAL DATA: Can easily adapt to given work

Birthdate: May 1, 1996
Birthplace: Lopez, Quezon TRAININGS/SEMINARS ATTENDED:
Age: 19y/o
Civil Status: Single 1. 6 th PIIE Regional Congress
Name of Father: John C. Panaligan Theme: “Limitless: Unlocking Possibilities
Name of Mother: Yolanda E. Panaligan with Product Design”
Citizenship: Filipino 2. 10 th IEshikawa
Religion: Roman Catholic Theme: “Nexus: X Marks the Spot –
Sex: Female Converging Minds Across the Years”
Language Spoken: Filipino, English
3. Leadership Empowerment Seminar 2015
EDUCATIONAL BACKGROUND: Theme: “Empowering Leaders of the 21st
Century, Brewing Sustainability to the Future
Tertiary: Society”
BACHELOR OF SCIENCE IN INDUSTRIAL 4. 23 rd International Conference on
ENGINEERING Production Research
Name of School: Manuel S. Enverga University Marriot Hotel Manila Pasay City
Foundation 5. 12 th PIIE National Student Congress
Awards Received: Dean’s Lister, A.Y 2015-2016 (1st 6. 5 th PIIE Regional Congress
semester) Theme: “IntensifIEd Thinking: Decision
Dean’s Lister, A.Y 2016-2017 (1st Making under Risk and Uncertainty”
semester) 7. 6 th Southern Tagalog Industrial
Secondary:
Engineering Seminar
Name of School: St. Peter’s School Calauag Inc.
Theme: “Fast Forward: Reconstructing our
Awards Received: Academic Performance Award &
National Identity Through Industrial
Arts and Culture Award
Date Graduated: March 2012 Evolution”
8. “Certification for Industrial Engineers”
Primary:
Name of School: Seventh-Day Adventist School
CHARACTER REFERENCES:
Awards Received: Class Salutatorian & Academic
Dr. Guillermo M. Rago, Jr.
Award
Dean, College of Engineering & Technical
Date Graduated: March 2008
Dep’t
MSEUF, Lucena City
ORGANIZATION: Contact No. : 710-31-51
Engr. Agnes L. Aviles, PIE

Name of Organization: Philippine Institute of
Adviser, PIIE-SC
Industrial Engineers – Student Chapter (PIIE-SC)
MSEUF, Lucena City
Position: Vice-President External Affairs
Contact No. : 0922-862-0376
Inclusive Dates: September2014 - June2017
SKILLS: Engr. James Louie R. Meneses, CIE, AAE

Adviser, PIIE-SC
Computer Literate
MSEUF, Lucena City
With good communication skills in English and
Contact No. : 0949-424-7437
Filipino
JOY EVANGELISTA PANALIGAN


Facilities Layout Improvement at Rodilla's Yema Cake

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Facilities Layout Improvement at Rodilla's Yema Cake

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FACILITIES IMPROVEM ENT

Facilities Layout Improvement at Rodilla’s Yema Cake

Presented to the Faculty of the

College of Engineering and Technical Department

Manuel S. Enverga University Foundation

In partial fulfillment of the

Requirements for the Degree of

Bachelor of Science in Industrial Engineering

Aaron Justine E. Abuel

Armando F. Anading III

In partial fulfillment of the requirements for the degree of Bachelor of Science in

Industrial Engineering program. This project entitled “Facilities Layout Improvement at

for oral examination.

Engr. James Louie R. Meneses, CIE, AAIE

Dr. Guillermo M. Rago Jr. Ed. D CE

Engr. Gervin S. Espinosa Engr. Luzviminda Sinapilo

May 2017 Guillermo M. Rago Jr. Ed. D CE

encouragement they have given them.

energy and strength every day.

and acknowledgement to the following:

university, and letting me come to achieve a higher education.

spent time and effort for this study.

have done to make this research possible. Thank you!!!

giving me strength and inspire me to reach and chase my dreams;

be ngarag when the deadline is tomorrow’’.

sharing knowledge that we could use in our study.

continuously inspired me and given me strength.

Aaron Justine E. Abuel

Background of the Study………………………………..……………………………….13

Objectives of the Study………………………………..…………………………………14

Scope and Limitations……………………………………………………………………16

Significance of the Study………………………………………………………………...16

Unit II - Review Of Related Literature and Studies.………………………...…………………..19

Unit III - Methods and Procedure….……………………………………...……………………..32

Unit IV – Results and Discussion……….……………..……………...………………………..41

Design of Improved Facility Layout…………………………………………..…………54

Unit V - Conclusions and Recommendations…………………..…………………………...…72

A. Project Study Gantt Chart……………………………….……………..……..77

B. Result of Interviews & Observations……………………………………......78

D. Cost Benefit Analysis……………………………..….………………………86

Table No. Title Page No.

1 Modified Likert scale………………………………………………………...…..38

2 Present time study for small cakes…………………………………………..…...48

3 Present time study for big cakes……………………………...………………….49

5 Present time study data ………………………………………………….………51

6 Whys Analysis – Causes of the problem in Rodilla’s Yema Cake………………54

7 Validation of Root Cause Using Why’s Analysis………………………………..55

8 Validation of Root Cause Using Ishikawa Diagram……….…………………….56

9 Proposed time study for small cakes……………………….…………………….60

10 Proposed time study for big cakes……………………….………………………61

14 Result of the survey based on Likert Scale………………………………………71

15 Cost benefit analysis…………………………………………….……………….72

FIgure No. Title Page No.

1 Conceptual Framework Paradigm ..….…………………………………………..16

2 Present flow process chart ……..………………………….……………...……..43

3 Present flow diagram ……………………………...…………………...………..44

4 Present relationship diagram ………………………..……..…………………….45

5 Present facility layout ……………………...…………………..………………..46

6 Present flow process chart for small cakes …………………………..…….……52

7 Present flow process chart for big cakes ……………………………………..….53

9 Activity relationship chart………………………………………………………..57

10 Space relationship diagram………………………………………………………58