FACILITY DESIGN

PROJECT 3: SPACE REQUIREMENT

Lecturer : Anastasia Lidya Maukar S.T., M.Sc., M.MT.

Semester :V
Date : 28th February 2022

Member 1. Alivia Aulia Chairunnisa 004202000063

2. Andhyka Jeannataya Cikatania 004202000037

3. Ardia Bintang Fajar Kusuma 004202000029

4. Farel Abdurrahman 004202000002

5. Rizg Safa Lintang 004202000022

INDUSTRIAL ENGINEERING
PRESIDENT UNIVERSITY
Jababeka Education Park, Jl. Ki Hajar Dewantara, Kota Jababeka, Cikarang Baru,
Bekasi 17550 – Indonesia
Phone (021) 8910 9762-6, Fax (021) 8910 9768
Email: [email protected], http://www.president.ac.id
 ACKNOWLEDGEMENT
The authors would like to express their gratitude to God for his kindness and blessings, which
have enabled them to complete this "Module 3: Space Requirement" study. Without the
assistance of the other authors, the authors knew that this report would not be able to be
completed successfully. On this occasion, the authors would like to express their gratitude to
all who have already helped them complete this report.

1. Mrs. Anastasia Lidya Maukar, S.T., M.Sc., M.MT, as the lecturer of Facility Design
who guided the Authors in the process inside the classroom and outside the
classroom.
2. Authors’ families which already give author support can make this report very well.
3. IEN PU batch 2020 that cannot be said one by one. The friends which already support
and help authors to do this report.

The authors acknowledged that this writing report is far from ideal. As a result, the writers
humbly apologize for any errors made in this writing report or even in the writing process
itself. Authors are eager to hear from readers' criticisms and recommendations about the
mistakes made in this article so that they can write a better one in the future.

In the end, Authors also hope this report would help the readers who want to know more
about Product and Process Analysis - Facility Design.

Cikarang, February 2022

i|PROJECT 3 FACILITY DESIGN GROUP 13

 TABLE OF CONTENT

ACKNOWLEDGEMENT..........................................................................................................i
TABLE OF CONTENT.............................................................................................................ii
CHAPTER I...............................................................................................................................1
INTRODUCTION......................................................................................................................1
1.1. Background..................................................................................................................1
1.2. Objective......................................................................................................................1
CHAPTER II..............................................................................................................................2
METHODOLOGY.....................................................................................................................2
2.1. Collect Necessary Data And Information....................................................................2
2.2. Calculate The Storage Space Requirements................................................................3
2.3. Calculate Aggregation Of Material Requirement........................................................4
2.4. Calculate The Warehouse's Space Requirement.........................................................5
2.5. Calculate The Office Space Requirement...................................................................5
2.6. Calculate The Space Requirement Of Production Floor.............................................6
2.7. Calculate The Space Requirement Of Other Support Facilities..................................6
CHAPTER III.............................................................................................................................8
DATA COLLECTION...............................................................................................................8
3.1. Multi Product Process Chart (MPPC).........................................................................8
3.2. Number Of Machines And Operators..........................................................................8
3.3. Machine And Equipment List Dimension...................................................................9
4.1. 3.4. Number Of Personnel.........................................................................................12
CHAPTER IV..........................................................................................................................14
DATA Analysis........................................................................................................................14
4.1. Office Space Requirements.......................................................................................14
4.1.1. Office Room.......................................................................................................14
4.1.1.1. General Manager Room…………………………………………………….14
4.1.1.2. Secretary Room……………………………………………………………..15
4.1.1.3. Manager Room……………………………………………………………...15
4.1.1.4. Finance Department Room………………………………………………….16
4.1.1.5. Production Department Room………………………………………………16
4.1.1.6. Human Resource Department Room………………………………………...17
4.1.1.7. Quality Department Room…………………………………………………..17

ii | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 4.1.1.8. Warehouse Department Room………………………………………………18
4.1.1.9. Logistic Department Room………………………………………………….18
4.1.1.10.Sales And Marketing Departement………………...……………………….19
4.1.2. Office Facilities..................................................................................................19
4.1.2.1. Lobby………………………………………………………………………..19
4.1.2.2. Meeting Room……………………………………………………………….20
4.1.2.3. Pantry………………………………………………………………………..21
4.1.2.4. Restroom…………………………………………………………………….22
4.1.2.5. Janitor Room………………………………………………………………...22
4.1.2.6. Security Room……………………………………………………………….23
4.1.3. Space Requirement For Other Supporting Facilities.........................................24
4.1.3.1. Car Parking Lot……………………………………………………………...24
4.1.3.2. Motorcycle Parking Lot……………………………………………………..26
4.1.3.3. Truck Parking Lot…………………………………………………………...27
4.1.3.4. Canteen……………………………………………………………………....29
4.1.3.5. Musholla……………………………………………………………………..29
4.1.3.6. Shipping And Receiving Area……………………...………………………..30
4.2. Production Floor Space Requirement........................................................................30
4.2.1. Restroom Requirement For Production Floor....................................................31
4.2.2. Locker Room Requirement For Production Floor.............................................32
4.3. Space Requirement For Storage................................................................................32
4.4. Space Requirement For Warehouse……………..…………………………………46
CHAPTER V............................................................................................................................49
CONCLUSION........................................................................................................................49
REFERENCES.........................................................................................................................50
APPENDICES………………………………………………………………………………..52

iii | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 CHAPTER I
INTRODUCTION

1.1. Background

Determining the layout of an item or machine, it really requires efficiency in doing so.
Therefore, there is what is called the facility layout. This will simplify and streamline
working time and smooth production. Depends on the type of machine and the amount of
production each day

To support that need, we have to do its name space requirements. This is a method for
determining the placement of a specific and detailed place. Space requirements are places
or rooms to place a product that is stored in the warehouse, why use the space
requirements method because this will make it easier for us to find information on the
number of numbers needed for store items. Not only makes it easier but provides
efficiency in allocating the warehouse area, by using this method, alternative placements
that neatly place the shelves are achieved, which is expected to reduce the time employees
spend on products.
1.2. Objective

The objectives of this report are:

 To determine the space required for each in the production floor, warehouse, storage,
office, and supporting facilities (Parking lot and etc.)
 Calculate each Room for each element (production floor, warehouse, storage, office,
and supporting facilities (Parking lot and etc.)

1|PROJECT 3 FACILITY DESIGN GROUP 13

 CHAPTER II
METHODOLOGY

To finish and accomplish the objectives of this project, we will analyze several systematic
steps or organized strategies, referred to as methodology. The methodology outlined in this
chapter will be implemented and will have an effect on how the authors conduct the analysis.
The methodology described above will be expanded upon in the following chart.

Collect Necessary Data and Information

Calculate the Storage Space Requirements

Calculate Aggregation of Material Requirements

Calculate the Warehouse's Space Requirement

Calculate the Office Space Requirement

Calculate the Space Requirement of Production Floor

Calculate the Space Requirement of Other Support Facilities

2.1. Collect Necessary Data and Information

This session serves as the kick-off for the project's development. The author will
collect the data necessary to create space requirements in this section. The following
data is necessary by the author to determine the required space requirement:
1. Compile data on the materials and dimensions required to manufacture products,
including direct and indirect materials.
2. Gather data for the warehouse and storage area, including the appropriate shelves
and dimensions for the materials to be stored.

2|PROJECT 3 FACILITY DESIGN GROUP 13

3. Collect information about the machine and its dimensions to determine the area
required for the production floor.
4. Data collection of furniture/items with dimensions required in each office
division.
5. Data collection of determining and the requirement of office facilities and
supporting facilities required in the office and factory.

2.2. Calculate the Storage Space Requirements

This session will require information to calculate space requirements. Additionally,
information regarding direct and indirect materials for storage is required. The
following sections detail the requirements for the steps involved in calculating direct
and indirect materials:
 Requirements for both materials:
 Lead time is equal to two weeks or ten days.
 Arrived materials are immediately placed in storage.
 Requirements for direct materials:
 Unit demand per hour.
 Material requirements as a function of lead time.
 Demand is taken from the route sheet in Project 2.
Below are the steps of storage for direct material and indirect material.
1. Make the calculation of direct material requirements.
1.1 Make the list of materials.
1.2 Establish the shelf requirements, including the capacity, dimensions,
quantity, and amount of space required to store the direct material.
1.3 Calculate the requirements units per week (Rw).
Demand Width of Material Dms .
Rw = ×
Length of material Dims . Width of Finised ∏ .
Length of Finished ∏ .
(2-1)
1.4 Calculate the requirements unit per lead time (Rlt).
R¿ =Rw × Lead time (2-2)

1.5 Assume actual requirements with the roundup of Rlt.

2. Make the calculation of indirect material requirements.
2.1 Make the list of materials.

3|PROJECT 3 FACILITY DESIGN GROUP 13

 2.2 Determine the material dimensions.
2.3 Determine the material requirement (units/product).
2.4 Determine the requirements unit per lead time.
2.5 Determine the requirements box per lead time.
2.6 Calculate the materials requirements needed.
3. Calculate the storage for direct and indirect materials, Since the shelf will have
several racks, The rack's vertical capacity calculation will take the thickness of
the material into account. Below is the formula.
3.1 Calculate the vertical stacks.
Vertical ¿ Round ¿
(2-3)
3.2 Calculate horizontal stack.

Horizontal ¿ Round ( Length of the Material )

Length of Rack (2-4)

3.3 Calculate the number of items.

No . of Item=Vertical ¿ Horizontal ¿ (2-5)
3.4 Calculate the number of racks.

No . of Rack=Round ( ActualNoRequirement
. of Item ) (2-6)

3.5 Calculate the area.

Area=Length of Rack × Width of Rack (2-7)

3.6 Calculate the allowance.

Allowance= Area× Assumed Allowance (2-8)

3.7 Calculate the total area.

Total Area= Area+ Allowance (2-9)

3.8 Sum all of the Total Rack of each material, assume the roundup of no. of
rack.
3.9 Calculate the Item Capacity (Ic).
I c =H c × V c (2-10)

3.10 Calculate amount of Rack.

R¿ (2-11)
Amount of Rack=
Ic

2.3. Calculate Aggregation of Material Requirement

4|PROJECT 3 FACILITY DESIGN GROUP 13

Aggregation of materials, both direct and indirect, will be conducted at this stage.
Numerous steps are required to calculate the aggregation of materials; the procedure
detailed below demonstrates how to calculate the aggregation.
1. Classify each part according to the raw materials used.
2. Calculate the Material Requirement based on the previous material
requirement.
3. Round up the material required to the nearest whole number to make it an
actual requirement.
4. Add up all of the actual material requirements for each product component in
relation to their raw materials.

2.4. Calculate the Warehouse's Space Requirement

A warehouse is a component of a company's logistics system that stores raw
materials, semi-finished products, finished products, and spare parts. It also serves as
a repository for information about the status, condition, and disposition of stored
goods (Proxisgroup, 2020). In companies relating to the distribution of goods, the
warehouse plays a critical role in ensuring the smooth operation of the business, as it
serves as a storage facility for the goods that the company will distribute.
Additionally, we ought to estimate the number of boxes stored in the warehouse for
this project. Below is the step on how to estimate the number of boxes:
1. Compile information on the number of products that will be stored in the
warehouse.
2. Determine the product's dimensions.
3. Determine the model and size of the box that will be used to store the product.
4. Calculate the number of racks required for a single shelf by considering the
vertical and horizontal stacks.
5. Calculate the warehouse allowances.
6. Determine the warehouse's total area. Below is the formula to calculate the
warehouse's total area.
Total of Area= Area+200 % Allowance (2-11)

2.5. Calculate the Office Space Requirement

5|PROJECT 3 FACILITY DESIGN GROUP 13

At this stage, the author will determine the office's space requirements. This
calculation will determine the amount of space required for each office's work
department as determined in Project 2. The following steps must be taken to
determine the office space requirement:
1. Compile all necessary room data for the office.
2. Determine the items/furniture needed in each room.
3. Count the number of each item/furniture.
4. Determine each room's total area; a formula for determining the total area is
included below.
(2-12)
Area=length× width
(2-13)
Total of Area=Total Area+ 200 % Allowance

2.6. Calculate the Space Requirement of Production Floor

To determine the production floor's space requirements, the author will use the
number of machines data from the Routing and MPPC project 2. Additionally, the
following steps will be followed when performing this calculation.
1. Obtain information from the department regarding the number of machines
and their dimensions.
2. Calculate the area in each department.
(2-14)
Area=length× width
3. Calculate allowance for each department.
Allowance= Area × Assumed Allowance (2-15)

4. Calculate the total area per machine.

Total Area per Machine=Total Area + Assumed Allowance (2-16)

5. Calculate the total space in each department.

Total of Area=Total Area+ Assumed Allowance +Total Area per Machine (2-17)

2.7. Calculate the Space Requirement of Other Support Facilities

A supporting facility directly or indirectly supports all of the company's activities and
all of its employees. Based on (Tompkins, White, Bozer, & Tanchoco, 2010),
employee parking, locker rooms, restrooms, food services, drinking fountains, and
health services are all included in the planning of personnel requirements. The author
will use the parking lot, cafeteria, musholla, lastly shipping and receiving area as the

6|PROJECT 3 FACILITY DESIGN GROUP 13

supporting facility in this project. According to (Tompkins, White, Bozer, &
Tanchoco, 2010), The canteen's space requirements should be determined by the
maximum number of employees who can eat in the canteen at any given time. They
also state the following is the procedure that must be followed when creating parking
lots:
1. Determine the number of automobiles parked according to their type.
2. Calculate the required space for each automobile.
3. Determine the available parking space.
4. Develop alternate parking layouts to accommodate alternate parking patterns.
5. Choose the layout that maximizes space utilization and employee
convenience.

7|PROJECT 3 FACILITY DESIGN GROUP 13

 CHAPTER III
DATA COLLECTION

3.1. Multi Product Process Chart (MPPC)

Multi Product Process Chart (MPPC) is a diagram that illustrated the manufacturing that
illustrated the manufacturing process steps to be reviews by that the materials required in
it including raw materials and addition materials. MPPC maps can moreover be valuable
as an outline related to the working steps of each item at a certain handle time so that
data is obtained almost the closeness of the method of each item with others. Besides
that, other functions of the MPPC incorporate to calculate the number of theoretical
machines, for the purposes of making each component, deciding the number of machines
per unit and the number workers. The MPPC will be shown in Appendix 3.1.

3.2. Number of Machines and Operators

After performing the MPPC, next calculate the number of machines and operators. There
are two calculations of number of machines. The calculation divided to theoretical and
actual number of machines. The different of theoretical and actual calculation is based on
the source of data. We can calculate the theoretical data by looking the MPPC, and the
actual is based on rounded up of theoretical data of MPPC.

Table 3.1. Number of Machines and Operators

Number of Machine and Operator
Process Layout
Department Total Operator
Theoretical Machine Actual Machine
Pre-Fabrication & Fabrication
Cut off Saw 1.17 2 2
Planner 0.97 1 1
Circular Saw 12.82 13 13
Jointer 6.30 7 7
Disc. Sand 15.02 16 16
Drill Press 11.15 12 12
Assembly

8|PROJECT 3 FACILITY DESIGN GROUP 13

 Disc. Sand 4.75 5 5
Bench I/Table 15.34 16 16
Bench II/Table 8.81 9 9
Bench
4.42 5 5
III/Table
Spray Booth 2.25 3 3
Total 83.02 89 89

3.3. Machine and Equipment List Dimension

Table 3.2. until Table 3.7 shows the size of each machine and equipment used in making
the train per part (engine, gondola, and box car). The dimension will show in inches.
Table 3.2. Material Specification of Engine
Specification (inches) Number of
Material
Material Name Parts per
Number Length Width Thickness
Production
Rough Lumber 3 144 2 0.75 1
3/4"
Finished Rod - 72 - 1.5 1
Stick ᴓ 1.5
Finished Rod - 72 - 0.75 1
Stick ᴓ 0.75
Rough Lumber 1 144 2 0.25 4
1/4"
Rough Lumber 2 144 2.5 0.5 1
1/2"
Finished Rod - 72 - 1 8
Stick ᴓ 1

Table 3.3 Part Specification of Engine

Number of Part Specification

Part Raw
parts per Thickness Length Width
Name Material
9|PROJECT 3 FACILITY DESIGN GROUP 13
 prod (inches) (inches) (inches)
110
Rough
Chassis 1 0.75 9.5 2
lumber ¾”
Engine
Finished Rod
120 Boiler 1 1.5 4.5 0
Stick ᴓ1.5
Finished Rod
121 Stack 1 0.75 1.5 0
Stick ᴓ0.75
131 Side Rough
2 0.25 2.5 2
cab lumber ¼”
133 Front Rough
1 0.25 2 1.5
cab lumber ¼”
135 Roof Rough
1 0.5 3 2.5
cab lumber ½”
141 Side Rough
2 0.25 2 1.5
Tender lumber ¼”
144 Back Rough
1 0.25 1.5 1.5
Tender lumber ¼”
150 Finished Rod
8 1 0.5 0
Wheel Stick ᴓ1

Table 3.4 Material Specification for Gondola

Specification (inches) Number of

Material
Material Name Parts per
Number Length Width Thickness
Production
Rough Lumber 3/4" 3 144 2 0.75 1
Rough Lumber 1/4" 1 144 2 0.25 4
Finished Rod Stick ᴓ 1 - 72 - 1 6

10 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 Table 3.5 Part Specification of Gondola

Number of Part Specification

Raw
Part Name parts per Thickness Length Width
Material
prod (inches) (inches) (inches)
210
Rough
Chassis 1 0.75 6 2
lumber ¾”
Gondola
Finished
150 Wheel 8 1 0.5 0 Rod Stick
ᴓ1
231 Side Rough
2 0.25 6 1
gondola lumber ¼”
233 End Rough
2 0.25 1.5 1
Gondola lumber ¼”

Table 3.6 Material Specification for Box Car

Specification (inches) Number of

Material
Material Name Parts per
Number Length Width Thickness
Production
Rough Lumber 2" 4 144 6 2 1

Rough Lumber 1/2" 2 144 2.5 0.5 1

Finished Rod Stick ᴓ 1 - 72 - 1 6

Table 3.7 Part Specification of Box Car

Part Specification
Part Number of Raw
Thickness Length Width
Name parts per prod Material
(inches) (inches) (inches)
330 Body Rough
1 2 6 2
box car lumber 2”
340 Roof Rough
1 0.5 6 2.5

11 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 box car lumber ½”
350 Finished
Wheel 6 1 0.5 0 Rod Stick
box car ᴓ1

3.4. Number of Personnel

After calculating the number of machines and operators, next calculation is determined
the number of personnel in the company. The number of personnel employed in the
company are 141 people. Table 3.8 will show the detailed number of each position based
on organization structure.
Table 3.8. Number of Personnel
Position Number of Personnel
General Manager 1
Secretary 1
Total 2
Manager of Finance 1
Staff of Finance Treasure 2
Staff of Accounting 2
Total 5
Manager of Production 1
Operator 89
Total 90
Manager of Human Resource 1
Staff of Human Resource 2
Total 3
Manager of Quality 1
Staff of Quality Control 2
Staff of Quality Assurance 2
Total 5
Manager of Warehouse 1
Staff of Warehouse 3
Total 4

12 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 Manager of Logistic 1
Staff of Logistic 3
Total 4
Manager of Sales and Marketing 1
Staff of Marketing 3
Staff of Sales 3
Total 7
Material Handling 0
Maintenance Engineer 3

Security Officer 6/3 shift

Canteen 6/3 shift

Janitor Staff 6/3 shift

Total 21

Total Employee 141

13 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 CHAPTER IV
DATA ANALYSIS

4.1. Office Space Requirements

Space necessities had been set to create paintings surroundings uniformity and
performance. Office area making plans is the system of arranging fixtures and workplace
sports to match collectively effectively and permitting highest quality use of area.

4.1.1. Office Room

The office space is a very important area, where it is a closed room and has many
different sizes and types for each office. The office space usually has an area for each
division to support a dynamic and structured work ecosystem. The following is an
example of the type of area in the office that is in the table below which is separated
from each a rea in the division.

4.1.1.1. General Manager Room

Table 4.1. General Manager Room Space requirement
Length/ Total
Qt Width Area Roundin Allowance
Item Diameter Area
y (m) (m2) g (200%)
(m) (m2)
Table 1 1.2 0.6 0.72 0.72    
Chair 1 0.65 0.65 0.4225 0.42    
Desk 1 1.8 0.8 1.44 1.44    
Sofa (Single) 2 0.9 0.9 1.62 1.62    
Sofa (Triple) 1 1.97 0.94 1.8518 1.85    
Trash bin 1 0.25 0.25 0.0625 0.06    

Bookshelf 1 1.6 0.28 0.448 0.45    

Total 6.5648 6.56 13.12 19.68

As you can see in the Table 4.1. it's a calculation from the Space CEO Room. In the table
items it is clear that there are more rooms than other divisions. To get the above
calculation use multiplying length and width, and then sums all of the area are multiplied

14 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 with the Allowance (200%), Allowance with 200% the result is 13.12 m2 and for total
area is 19.68 m2

4.1.1.2. Secretary Room

Table 4.2. Secretary Room Space Requirement
Total
Length/ Width Area Allowance
Item Qty Rounding Area
Diameter (m) (m) (m2) (200%)
(m2)
Chair 1 0.61 0.57 0.3477 0.35    
Desk 1 1.2 0.6 0.72 0.72    
Trash
1 0.2 0.2 0.04 0.04    
bin
Total 1.11 2.22 3.33

As you can see in the Table 4.2. that is the total calculation from the secretary's room, it
is clear that the item and quantity differences from other rooms are different, due to the
difference from the position received. To get the above calculation use multiplying
length and width, and then sums all of the area are multiplied with the Allowance
(200%), Allowance with 200% the result is 2.22 m2 and for total area is 3.33 m2.

4.1.1.3. Manager Room

Table 4.3. Manager Room Space Requirement
Length/ Total
Qt Width Area Roundin Allowance
Item Diameter Area
y (m) (m2) g (200%)
(m) (m2)
Table 1 1.2 0.6 0.72 0.72    
Chair 1 0.6 0.59 0.354 0.35    
Desk 1 1 0.6 0.6 0.6    
Sofa (Single) 1 0.9 0.9 0.81 0.81    
Sofa (Triple) 1 1.97 0.94 1.8518 1.85    
Trash bin 1 0.25 0.25 0.0625 0.06    
Bookshelf 1 1.6 0.28 0.448 0.45    
Total 4.8463 4.84 9.68 14.52

15 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 As you can see in Table 4.3. that is the total of calculations from the Manager Room. In
the table there are items, quantities, and to get the above calculation use multiplying
length and width, and then sums all of the area are multiplied with the Allowance
(200%), Allowance with 200% the result is 9.68 m2 and for total area is 14.52 m2.

4.1.1.4. Finance Department Room

Table 4.4. Finance Department Room Space Requirement
Total
Length/ Width Area Allowance
Item Qty Rounding Area
Diameter (m) (m) (m2) (200%)
(m2)
Chair 5 0.61 0.57 1.7385 1.74    
Desk 5 1.2 0.6 3.6 3.6    
Board 1 1 0.05 0.05 0.05    
Trash
1 0.2 0.2 0.04 0.04    
bin
Total 5.4285 5.43 10.86 16.29

As you can see in Table 4.4. that is the total of calculations from the Finance
Department Room. In the table there are items, quantities, and to get the above
calculation use multiplying length and width, and then sums all of the area are multiplied
with the Allowance (200%), Allowance with 200% the result is 10.86 m2 and for total
area is 16.29 m2

4.1.1.5. Production Department Room

Table 4.5. Production Department Room Space Requirement
Length/ Total
Qt Width Allowance
Item Diameter Area (m2) Rounding Area
y (m) (200%)
(m) (m2)
Chair 1 0.61 0.57 0.3477 0.35    
Desk 1 1.2 0.6 0.72 0.72    
Board 1 1 0.05 0.05 0.05    
Trash bin 1 0.2 0.2 0.04 0.04    

16 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 Total 1.1577 1.16 2.32 3.48

As you can see in Table 4.5. that is the total of calculations from the Production
Department Room. In the table there are items, quantities, and to get the above
calculation use multiplying length and width, and then sums all of the area are multiplied
with the Allowance (200%), Allowance with 200% the result is 2.32 m2 and for total area
is 3.48 m2

4.1.1.6. Human Resource Department Room

The total space of the Human Resource Department room will be shown in Table 4.6 in
this calculation consists of items needed in the room along with dimension and quantity
in each item. Based on the data, the author calculates the area with equation (2-12) until
equation (2-13). From the table, it can be concluded that the total area needed for Human
Resource Department room is 11.49 m2.

Table 4.6. Human Resource Department Room Space Requirement

Length /
Width Allowance Total
Item Qty diameter Area (m2)
(m) (200%) Area (m2)
(m)
Chair 3 0.62 0.49 0.91    
Board 1 1 0.05 0.05    
Desk 3 1.2 0.6 2.16    
Book Shelf 2 0.8 0.4 0.64    
Trash bin 1 0.31 0.22 0.07    
Total 3.83 7.66 11.49

4.1.1.7. Quality Department Room

The total space of the Quality Department room will be shown in Table 4.7 in this
calculation consists of items needed in the room along with dimension and quantity in
each item. Based on the data, the author calculates the area with equation (2-12) until
equation (2-13). From the table, it can be concluded that the total area needed for Human
Resource Department room is 17.84 m2.
Table 4.7. Quality Department Room Space Requirement

17 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 Length /
Width Allowance Total
Item Qty diameter Area (m2)
(m) (200%) Area (m2)
(m)
Chair 5 0.62 0.49 1.52    
Board 1 1 0.05 0.05    
Desk 5 1.2 0.6 3.60    
Book Shelf 2 0.8 0.4 0.64    
Trash bin 2 0.31 0.22 0.14    
Total 5.95 11.89 17.84

4.1.1.8. Warehouse Department Room

The total space of the Warehouse Department room will be shown in Table 4.8 in this
calculation consists of items needed in the room along with dimension and quantity in
each item. Based on the data, the author calculates the area with equation (2-12) until
equation (2-13). From the table, it can be concluded that the total area needed for
Warehouse Department room is 14.76 m2.

Table 4.8. Warehouse Department Room

Length /
Width Allowance Total
Item Qty diameter Area (m2)
(m) (200%) Area (m2)
(m)
Chair 4 0.62 0.49 1.22    
Board 1 1 0.05 0.05    
Desk 4 1.2 0.6 2.88    
Book Shelf 2 0.8 0.4 0.64    
Trash bin 2 0.31 0.22 0.14    
Total 4.92 9.84 14.76

4.1.1.9. Logistic Department Room

The total space of the Logistic Department room will be shown in Table 4.9 in this
calculation consists of items needed in the room along with dimension and quantity in
each item. Based on the data, the author calculates the area with equation (2-12) until
equation (2-13). From the table, it can be concluded that the total area needed for
Logistic Department room is 14.76 m2.

18 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 Table 4.9. Logistic Department Room Space Requirement
Length /
Width Allowance Total
Item Qty diameter Area (m2)
(m) (200%) Area (m2)
(m)
Chair 4 0.62 0.49 1.22    
Board 1 1 0.05 0.05    
Desk 4 1.2 0.6 2.88    
Book Shelf 2 0.8 0.4 0.64    
Trash bin 2 0.31 0.22 0.14    
Total 4.92 9.84 14.76

4.1.1.10.Sales and Marketing Department Room

The total space of the Sales and Marketing Department room will be shown in Table 4.10
in this calculation consists of items needed in the room along with dimension and
quantity in each item. Based on the data, the author calculates the area with equation (2-
12) until equation (2-13). From the table, it can be concluded that the total area needed
for sales department room is 23.98 m2.
Table 4.10. Sales and Marketing Department Room Space Requirement
Length /
Width Allowance Total
Item Qty diameter Area (m)
(m) (200%) Area (m)
(m)
Chair 7 0.62 0.49 2.13    
Board 1 1 0.05 0.05    
Desk 7 1.2 0.6 5.04    
Book Shelf 2 0.8 0.4 0.64    
Trash bin 2 0.31 0.22 0.14    
Total 7.99 15.99 23.98

4.1.2. Office Facilities

Beside the office room, office has their other supporting facilities inside them, the
supporting facilities are lobby, meeting room, pantry, restrooms, janitor rooms, and
security rooms. In the next section will explain about the extent of that.

4.1.2.1. Lobby
The office lobby is the first place where the guests and the employees enter the office.
The lobby must be designed as good as possible because it will be the first impression
from the guest to the company. The layout, design, ambience of the lobby will bring out

19 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
that first impression. The lobby takes and important part in the workplace because can
fostering a positive work environment. In the Table 4.11. will determine the lobby size,
and the area of item listed inside the lobby.
Table 4.11. Lobby Space Requirement
Lobby
Length /
Area Allowance Total
Item Qty diameter Width (m)
(m2) (200%) Area (m2)
(m)
Chair 1 0.62 0.49 0.30    
Table 1 1.17 0.45 0.53    
Desk 1 1.2 0.6 0.72    
Sofa (single) 1 0.95 0.89 0.85    
Sofa (Triple) 1 2.85 0.89 2.54    
Television 1 0.53 0.92 0.49    
Total 5.42 10.84 16.26
Based on the Table 4.11., we know that the total space in the Lobby. There are many
items along with quantity that should be stored in lobby rooms. The section of area
comes from multiplying the length with the width of items. At the end the total we add
the allowances 200%. Allowance 200% is enough for the number of people in it and the
result is 10.84 m2. So, the total area of the lobby is 16.26 m2.

4.1.2.2. Meeting Room

The meeting room is the most important place in the office. The meeting room is used to
meeting for all the employees and the guests with the scheduled appointments. In order
to determine the total area of the meeting area, the area of each item is listed on the table
below.
Table 4.12. Meeting Room Space Requirement
Meeting Room
Length /
Width Allowance Total
Item Qty diameter Area (m2)
(m) (200%) Area (m2)
(m)
Chair 12 0.62 0.49 3.65    
Board 1 1 0.05 0.05    

20 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
Meeting Table 1 4.5 1.5 6.75    
Projector 1 1.57 0.05 0.08    
Trash bin 1 0.31 0.22 0.07    
Total 10.60 26.50 37.10

From the table 4.12., we can know the total space in the meeting room. The listed item in
the table 4.12. is based on the requirement of meeting room. The column of area is
achieved from the column length with the column width. After multiplying those two
columns, we need to multiply with allowance 200%. The result is 37.10 m2 after sum the
total area with the allowance 200%.

4.1.2.3. Pantry
Pantry is a room where beverages, food, and sometimes dishes, household cleaning
chemicals, linens, or provisions are stored. Food and beverage pantries serve in an
ancillary capacity to the kitchen. The total area of a pantry is determined below in the
Table 4.13.
Table 4.13. Pantry Space Requirement
Pantry
Length /
Width Allowance Total
Item Qty diameter Area (m2)
(m) (200%) Area (m2)
(m)
Table 1 1.17 0.45 0.53    
Chair 4 0.62 0.49 1.22    
Sink 1 0.64 0.51 0.33    
Shelf 1 0.8 0.4 0.32    
Trash bin 2 0.31 0.22 0.14    
Total 2.52 5.05 7.57

Table 4.13 explained about the space requirement of the pantry. There are some items
need to store in pantry’s room. The length column needed to multiply with width
column, the result is in the area column. The total of area column per item is 2.52 m2.
Beside that we need to add the allowances in to 200%, so the total space requirement for
the pantry is 7.57 m2.

21 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 4.1.2.4. Restroom
Restroom in the office is provide for all the people in the office. Restroom is one of the
most important facility in the company. We must determine how many male and female
employees. Assume the employees are 60% male and 40% female. Basically, the number
of toilets that needed are 2, because there are only 52 employees in the office. The
calculation of the space requirement in the restroom is explained in the Table 4.14.
Table 4.14. Restroom Space Requirement
Restroom
Male
Length / Allowance Total Area
Item Qty Width (m) Area (m2)
diameter (m) (200%) (m2)
Trash bin 2 0.31 0.22 0.14    
Closet 3 0.73 0.35 0.77    
Sink 5 0.64 0.51 1.63    
Urinals 3 0.47 0.35 0.49    
Total 3.03 6.06 9.09
Female
Length / Allowance Total Area
Item Qty Width (m) Area (m2)
diameter (m) (200%) (m2)
Trash bin 2 0.31 0.22 0.14    
Closet 3 0.73 0.35 0.77    
Sink 5 0.64 0.51 1.63    
Total 2.53 5.07 7.60
Total Area   16.69

In the Table 4.14. explained about the space requirement for the restroom. But there are 2
sections, male and female. The total area for the male and female restroom is 16.69 m2
after adding with the 200% allowances.

4.1.2.5. Janitor Room

Janitor is the room for the helper in the office to maintain the conditions of office to keep
it clean. Janitors also on duty when there are some items in the office not functions well.

22 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 This room normally located near the pantry rooms. Table 4.15. shows the area needed to
conduct the janitor room.
Table 4.15. Janitor Room Space Requirement
Janitor Station
Length / Allowance Total Area
Item Qty Width (m) Area (m2)
diameter (m) (200%) (m2)
Chair 2 0.62 0.49 0.61    
Table 1 1.17 0.45 0.53    
Shelf 1 0.8 0.4 0.32    
Total 1.45 2.91 4.36

Table 4.15. shows the space requirement of pantry room. The total area of pantry room
comes from the sum of total area with the 200% allowances. The result is 4.36 m2.

4.1.2.6. Security Room

Security room in every office always located in every gate of the office. Security room is
a small building where a person stands and decides whether to let that person through.
Security room also can be defined as the guard place to keep the office and the
employees safe. Table 4.16 shows the space requirement for the security room.
Table 4.16. Security Room Space Requirement
Security
Length / Allowance Total
Item Qty Width (m) Area (m2)
diameter (m) (200%) Area (m2)
Chair 2 0.62 0.49 0.61    
Desk 1 1.2 0.6 0.72    
Television 1 0.53 0.92 0.49    
Total 1.82 3.63 5.45
Table 4.16. provided an information of the dimension every item needed to be stored
inside the security room. The total area of the security room can be calculated by sum the
total area per item with the allowances 200%. The number shows 5.45 m2 for the total
area of security room.
Table 4.17. Summary of Office Requirement
Room Area + Allowances

23 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 Office Room 140,15 m2
Office Facilities 183,76 m2
Total 323,91 m2

4.1.3. Space Requirement for Other Supporting Facilities

This section calculates the support facilities required for factories and offices. The
calculation is based on criteria specified by multiple parties. The support facility consists
of a parking lot, canteen, musholla, shipping and receiving area. And will be explained in
detail the calculation of the required space of the support facility.

4.1.3.1. Car Parking Lot

Parking area is provided for the employee who use vehicle to go to company, so in this
section is the calculation of car parking lot, we assume the employee who use car is 30%
of the total employee, so the employee who use car is about 43 employees, and we
assume the size of the car as the standard car is 2.5 m x 5 m, and the layout of the
parking area uses 90° double loaded, because with this pattern there will be more
capacity for parking and the parking area is consist of 2 rows. So, after see the size of the
car we have to considering the aisle size, because the area parking is use angle 90° so we
use the aisle is 7 m, and In Table 4.18., we can see that the total parking for standard car
is 7.740,00 m2.

24 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 Table 4.18. Car Parking Lot
Car Parking Lot
Potentia
Angl Modul Park
Stall Stall W Numbe l Aisl Park Total Total
Transportatio e of e Lengt Allowanc
Widt Lengt Configuratio r of Amount e Width Area (I Area
n Type Park Width h e (200%)
h (m) h (m) n Row of (m) (m) m2) (m2)
(°) (m) (m)
Vehicle
107.5 2580.0 7740.0
Standard Car 2.50 5.00 W2 90.00 2.00 17.00 43.00 7.00 24.00 5160.00
0 0 0

Figure 4.1. Car Parking Lot

25 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 4.1.3.2. Motorcycle Parking Lot
So, in this section is the calculation of motorcycle parking lot, we assume the employee who use motorcycle is 30% of the total employee,
so the employee who use car is about 59 employees, and we assume the size of the motorcycle is 0.76 m x 1.82 m, and the layout of the
parking area uses 90° double loaded, because with this pattern there will be more capacity for parking and the parking area is consist of 2
rows.
So, after see the size of the motorcycle we have to considering the aisle size, because the area parking is use angle 90° so we use the aisle is
3 m, and In Table 4.19., we can see that the total parking for motorcycle is 1080.64 m2.
Table 4.19. Motorcycle Parking Lot
Motorcycle Parking Lot
Potentia
Angl Modul Aisl Park Park
Stall Stall W Numbe l Total Total
Transportatio e of e e Lengt Widt Allowanc
Widt Lengt Configuratio r of Amount Area Area
n Type Park Width (feet h h e (200%)
h (m) h (m) n Row of (I m2) (m2)
(°) (feet) ) (m) (m)
Vehicle
432.2 1296,7
Motor Cycle 0.76 1.82 W2 90.00 2.00 6.64 59.00 3.00 9.64 44.84 864,52
6 7
26 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 Figure 4.2. Motorcycle Parking Lot
4.1.3.3. Truck Parking Lot
Truck parking lots are provided for the loading and unloading of raw material and finished goods using trucks. We assume that the number
of trucks we used is 3. and we assume the size of the truck is 4.14 m x 14.60 m, and the layout of the parking area uses 90° double loaded,
because with this pattern there will be more capacity for parking and the parking area is consist of 2 rows.
So, after see the size of the truck we have to considering the aisle size, because the area parking is use angle 90° so we use the aisle is 20 m,
and In Table 4.20., we can see that the total parking for truck is 2.034,40 m2.

27 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 Table 4.20. Truck Parking Lot
Truck Parking Lot
Potentia
Angl Modul Park Park
Stall Stall W Numbe l Aisle Total Total
Transportatio e of e Lengt Widt Allowanc
Widt Lengt Configuratio r of Amount Area Area
n Type Park Width h h e (200%)
h (m) h (m) n Row of (m) (m2) (m2)
(°) (m) (m) (m)
Vehicle
20.0 678.1 2034,4
Truck 4.14 14.60 W2 90.00 1.00 34.60 3.00 54.60 12.42 1356,26
0 3 0

28 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
Figure 4.3. Truck Parking Lot

29 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 4.1.3.4. Canteen
The company has 141 employees, so we divide the total of employees into 2 shifts to
lunch breaks, 11.30 am -12.00 am hours (shift 1) and 11.50 am -12.10 am (shift2). The
canteen contains 13 table, 26 chairs, 3 trash bin and 4 sink. Table with dimension 2,385
m × 0,7 m, chair with dimension 2,385 m × 0,3 m. The total area for the canteen is
around 41.21 m2. The space allowances are 61.82. So, the total space requirement for
Canteen is = 123.63 m2.
Table 4.21. Canteen
Canteen
Length /
Allowance Total Area
Item Qty diameter Width (m) Area (m2)
(200%) (m2)
(m)
Table 13 2.385 0.7 21.70 43.41 65.11
Chair 26 2.385 0.3 18.60 37.21 55.81
Trash Bin 3 0.28 0.28 0.24 0.47 0.71
Sink 4 0.44 0.38 0.67 1.34 2.01
Total 41.21 82.42 123.63

4.1.3.5. Musholla
Musholla is Muslim prayer room, the musholla contains prayer Rug, water faucets, and
cabinets. The total area for the musholla is around 51.05 m2. The space allowances are
102.10 m2. So, the total space requirement for musholla is 199.50 m2. The calculations
shown in the table 4.22. show the calculation of Musholla.
Table 4.22. Musholla
Musholla
Length /
Width Area Allowance Total
Item Qty diameter
(m) (m2) (200%) Area (m2)
(m)
Prayer Rug 50 0.76 1.22 46.36 97.27 185.44
Water Faucets for Wudhu 10 1 0.4 4.00 8.00 12.00
Cabinet 2 0.8 0.43 0.69 1.38 2.06
Total 51.05 102.10 199.50

30 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 4.1.3.6. Shipping and Receiving Area
In this section, we calculate the loading and unloading area of the company. Assume that
the number of trucks that can be in the loading and unloading area is three because the
staging area has three levels. We also designed the truck area to be 4.14 x 14.60 = 60.444
m2. There are 3 areas, so the total area is 181 m 2, and adding 200% allowance gives the
total area 544 m2. The total area for shipping and receiving area is 1.894 m2.
Table 4.23. Shipping and Receiving Area
Shipping and Receiving Area
Number of Total Area Allowance Total Area
Name of Part
Item (m2) (200%) (m2)
Truck Area 3 181 363 544
Staging Area 3 450 900 1,350
Total Area 1,894

4.2. Production Floor Space Requirement

Table 4.24. Production Floor Space Requirement

Space Requirement for Production Floor
Allowances
Dimension
No. of Space Total Total
Department Area
Machine L W Area/Machine Space
200%
(m) (m)
Cut off Saw 2 0,26 0,53 0,14 0,27 0,41 0,81
Planner 1 0,29 0,16 0,04 0,09 0,13 0,27
Circular Saw 13 0,02 0,04 0,00 0,00 0,00 0,01
Jointer 7 1,10 0,48 0,53 1,06 1,58 3,17
Disc. Sand 16 0,91 0,13 0,11 0,23 0,34 0,69
Drill Press 12 0,69 0,43 0,30 0,59 0,89 1,78
Disc. Sand
5
(Assembly) 0,91 0,13 0,11 0,23 0,34 0,69
Bench
I/Table 16 203,2
(Assembly) 0,10 0 20,65 41,29 61,94 123,87
Bench
II/Table 9 203,2
(Assembly) 0,10 0 20,65 41,29 61,94 123,87
Bench
III/Table 5 203,2
(Assembly) 0,10 0 20,65 41,29 61,94 123,87

31 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
Spray Booth 100,0
3
(Assembly) 0,15 0 15,00 30,00 45,00 90,00

Based on the table 4.24. we can see that the companies use 200% allowances to make the
operator ease working in the production floor. The allowances determined by considering
the aisle for material handling process and also the working area of the operators. The
total space of the production floor needs around 469,01 m2.

4.2.1. Restroom Requirement for Production Floor

Table 4.25. Restroom Requirement for Production Floor

Restroom Requirement for Production Floor
Male

Item Qty Length (m) Width (m) Area Allowance (200%) Total Area

Closet 3 0,70 0,43 0,90 1,81 2,71

Sink 5 0,42 0,42 0,88 1,76 2,65
Urinal
6 0,35 0,34 0,71 1,43 2,14
s
Total 7,50
Female

Item Qty Length (m) Width (m) Area Allowance (200%) Total Area

Closet 4 0,70 0,43 1,20 2,41 3,612

Sink 4 0,42 0,42 0,71 1,41 2,1168
Total 5,7288
Total Area 13,23

The total operator works in the production floor is 89 operators. For the restroom
requirement in the production floor, the assumption for the female 40% and male 60%.
Which is the number of females being 35 and the male is 54. This assumption also based
on the standard because the company has 35 females, the company need to provide 4
sink and 4 closet. Every sink use for 9 operators, for the minimum number of closets is 3
but 4 closets will be put to balance to the total of sink. For male restrooms, if the total

32 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
operator 54, so the total sinks will be 5, and for the closet is 3and we put 6 urinals in the
restrooms.

4.2.2. Locker Room Requirement for Production Floor

Table 4.26. Locker Room Requirement for Production Floor

Locker Room Requirement for Production Floor
Male
Qt Length Width Allowance Total
Item Area
y (m) (m) (200%) Area
Locker 11 0,90 0,40 3,96 7,92 11,88
Space for 1
54 1 1 54 108 162
Person
Total 173,88
Female
Qt Length Width Allowance Total
Item Area
y (m) (m) (200%) Area
Locker 7 0,90 0,40 2,52 5,04 7,56
Space for 1
35 1 1 35 70 105
Person
Total 112,56
Total Area 286,44

Based on table 4.26., it can be seen that the locker room at the production. The room is
built as a place to put operator’s personal things to make their things save. This room
should be near the production floor and will be divided into male and female. The type of
locker room is divided into 2, male and female. Same as the restroom. We assume the
value of female workers is 40% and the value of male is 60%. So, the total area is 286.44
m2.

4.3. Space Requirement for Storage

There are two materials in making train (engine, gondola, and box car). That’s two
materials are direct material and indirect material. The materials will be stored in the

33 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
storage area. The lead time (LT) is 2 weeks (10 days). Table 4.27 shows the materials
specification both direct and indirect materials.

Table 4.27 Direct Material Specification

Material Dimension
No Material Code Material
L W T/Ø

Rough Lumber 1/4"(3 per

1 RLB 1 144 2 3/(5/4)
5/4" thickness)

Rough Lumber 1/2"(4 per

2 RLB 2 5/4" 144 2,5 4/(5/4)
thickness)
Rough Lumber 3/4"(3 per
4/4"
3 RLB 3 144 2 3/(4/4)
thickness)
thickness)

Rough Lumber 2" (3 per 10/4"

4 RLB 4 144 6 3/(10/4)
thickness)

5 FRS 1 Finished Rod Stick ᴓ 1.5 72 - 1,5

6 FRS 2 Finished Rod Stick ᴓ 0.75 72 - 0,75

7 FRS 3 Finished Rod Stick ᴓ 1 72 - 1

Table 4.27 shows the indirect materials that will be used for making each part of train
(e.g., Engine, Gondola. Box Car). The indirect material and the decision. The dimension
must be calculated first for the packaging.

34 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 Table 4.28 Calculation Direct Material

Calculation of Direct Material Requirements

Finished Product
Material Dimension
Dimensions
Part Qt Demand Req Req
No Part Name
Code W T/Ø L W T/Ø y (Units/Day) (Units/Day) (Units/LT)
L (m)
(m) (m) (m) (m) (m)

Chassis
1 110 0,24 0,05 0,02 3,66 0,05 0,05 1 96,74 6,38 63,82
Engine

2 120 Boiler 0,11 0,00 0,04 1,83 0,00 0,04 1 95,77 5,99 59,86

3 121 Stack 0,04 0,00 0,02 1,83 0,00 0,02 1 273,43 5,70 56,96

4 131 Side Cab 0,06 0,05 0,01 3,66 0,05 0,01 2 95,77 1,66 16,63

5 133 Front Cab 0,05 0,04 0,01 3,66 0,05 0,01 1 95,78 1,00 9,98

6 135 Roof Cab 0,08 0,06 0,01 3,66 0,06 0,01 1 187,74 3,91 39,11

35 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 7 141 Side Tender 0,05 0,04 0,01 3,66 0,05 0,01 2 191,57 2,00 19,95

8 144 Back Tender 0,04 0,04 0,01 3,66 0,05 0,01 1 95,78 0,75 7,48

Wheels
9 150 0,01 0,00 0,03 1,83 0,05 0,03 8 743,43 5,16 51,63
Engine
Chassis
10 210 0,15 0,05 0,02 3,66 0,05 0,02 1 135,33 5,64 56,39
Gondola

Side
11 231 0,15 0,03 0,01 3,66 0,05 0,01 2 270,69 5,64 56,39
Gondola

12 233 End Gondola 0,04 0,03 0,01 3,66 0,05 0,01 2 270,69 1,41 14,10

Wheel
13 240 0,01 0,00 0,03 1,83 0,00 0,03 6 787,88 5,47 54,71
Gondola
Body Box
14 330 0,15 0,05 0,05 3,66 0,15 0,05 1 94,54 1,31 13,13
Car
Roof Box
15 340 0,15 0,06 0,01 3,66 0,06 0,01 1 90,81 3,78 37,84
Car
Wheel Box
16 350 0,01 0,00 0,03 1,83 1,83 0,00 6 539,39 3,75 37,46
Car

The direct material that needs per week already calculated in previous project. We will calculate the required material per lead time. From table
4.28, the required per weeks is 2 weeks. From the data, the required material per lead time for engine chassis is 6,38 and then for the required
material per lead time is 63,82 and it comes from 6,38 multiplied by 10 (lead time).

Below is the list of the indirect material.

36 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 4.29 Calculation Indirect Material

Calculation of Indirect Material Requirements LT 10

Material Box Dimension
Dimension (m) Material Material Actual (m)
Cod Material Req Details
No. Material Req Req Req
e (Units/Prod) (Pcs/Box)
L W T (Units/LT) (Box/LT) (Box/LT) L W T
Drive
1 DN 0,04 0,00 - 20 62200 4,98 5 0,80 0,50 0,40 12.500
Nail
Washer
2 WF 0,30 0,30 0,04 20 62200 4,98 5 0,80 0,50 0,40 12.500
Flat
Hook
3 HS 0,06 0,01 0,00 5 15550 4,86 5 0,80 0,50 0,40 3.200
Screw
Wood
4 WH 0,04 0,00 - 20 62200 4,98 5 0,80 0,50 0,40 12.500
Head
5 S String 7,00 0,10 - 1 3110 4,78 5 0,80 0,50 0,40 650
6 C Carton 0,45 0,35 0,30 1 3110 4,78 5 2,00 1,00 1,00 650
Carton
7 CL 0,45 0,35 0,30 1 3110 4,78 5 2,00 1,00 1,00 650
Linier
8 L Label 0,06 0,03 - 1 3110 4,78 5 0,80 0,50 0,40 650
Gamed
9 GT 100,00 0,05 - 1 3110 4,78 5 0,80 0,50 0,40 650
Tape
10 LQ Lacquer 0,26 0,19 0,38 3110
5 Litters/Gallon. 2 for Engine, 1,5 for Gondola, 1,5 for Box
Lacquer 1
11 LQT 0,26 0,19 0,38 622 Car
Thinner
12 G Glue 0,25 0,25 0,38 1 3110 600 g. 300 for Engine, 150 for Gondola, 1,5for Gondola
Sand
13 SP 0,23 0,28 - 1 3110 4,78 5 0,8 0,5 0,4 650
Paper
14 SD Sand Disc 0,11 0,11   1 3110 4,78 5 0,8 0,5 0,4 650

37 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 Table 4.30 Aggregation of Direct Material Requirements

Aggregation of Direct Material Requirements

Material Dimension
Material Part Req. Actual Req. Total Requirement
No Material Name Part Name
Code Code (unit/LT) (unit/LT) (unit/L)
L (m) W (m) T/Ø (m)

131 Side Cab 3,33 4,00

133 Front Cab 2,00 2,00

Rough Lumber
1 RLB 1 1/4"(3 per 3,6576 0,0508 3/(5/4) 141 Side Tender 3,99 4,00 27,00
5/4" thickness)

Back
144 1,50 2,00
Tender

Side
231 11,28 12,00
Gondola
End
233 2,82 3,00
Gondola

38 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 Rough Lumber 135 Roof Cab 7,82 8,00
2 RLB 2 1/2"(4 per 5/4" 3,6576 0,0635 4/(5/4) 16,00
thickness) Roof Box
340 7,57 8,00
Car
Rough Lumber Chassis
110 12,76 13,00
3/4"(3 per 4/4" Engine
3 RLB 3 3,6576 0,0508 3/(4/4) 25,00
thickness) Chassis
thickness) 210 11,28 12,00
Gondola
Rough Lumber 2"
Body Box
4 RLB 3 (3 per 10/4" 3,6576 0,1524 3/(10/4) 330 2,63 3,00 3,00
Car
thickness)
Finished Rod Stick
5 FRS 1 1,8288 - 1,5 120 Boiler 11,97 12,00 12,00
ᴓ 1.5
Finished Rod Stick
6 FRS 2 1,8288 - 0,75 121 Stack 11,39 12,00 12,00
ᴓ 0.75
Wheel
150 10,33 11,00
Engine
Finished Rod Stick Wheel
7 FRS 3 1,8288 - 1 250 10,94 11,00 30,00
ᴓ1 Gondola
Wheel Box
350 7,49 8,00
Car
Total 125,00

Table 4.31 Storage Space for Direct Material

39 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 Storage Space Requirement Calculation for Direct Material
Rack Dimension
No. (m) Total
Material Material Actual Req Vertical Horizontal No. of Total Area Allowances
No of Area
Code Name (units/LT) Stacks Stacks Rack Rack (m^2) (200%)
Item L W H (m^2)

Rough
Lumber
1 RLB 1 1/4"(3 per 27 21 0,20 4,20 6,43
5/4"
thickness)
Rough
Lumber
2 RLB 2 1/2"(4 per 16 10 0,20 2,00 8,00
5/4"
thickness)
0,80 0,50 0,40 38,00 0,40 0,80 1,20
Rough
Lumber
3/4"(3 per
3 RLB 3 25 7 0,20 1,40 17,86
4/4"
thickness)
thickness)
Rough
Lumber 2"
4 RLB 4 3 3 0,20 0,60 5,00
(3 per 10/4"
thickness)
Finished
5 FRS 1 Rod Stick ᴓ 12 5 0,40 2,00 6,00
1.5 0,80 0,50 0,40 19,00 0,40 0,80 1,20
6 FRS 2 Finished 12 11 0,40 4,40 2,73

40 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 Rod Stick ᴓ
0.75
Finished
7 FRS 3 Rod Stick ᴓ 30 8 0,40 3,20 9,38
1
Total Area 2,40

  m  

0,8
Length 31,50
0

0,5
Width 19,69
0
0,4
Thickness 15,75
0

There are some indirect materials that are still unknown, and for the amount we will assumed. The requirements of indirect material will be
shown in next table. Then the material required per lead time is calculated by the material pr product times the lead time (2 weeks) and the
demand for the engine is 92. After we find the results of aggregation, the next step is determining the requirement of shelf like dimensions,
capacity, space requirement and the total of the shelf that we need to store the direct material. For the shelf it will be put on the racks, and it is
assumed one rack store is one type of the direct material.
The calculation of the vertical capacity of the rack will consider the thickness of the material.

Height of Rack
Vertical Cap of Rack= ' (4-1)
Materia l s Thickness

41 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 0.4 /3
Vertical Cap of Rack=
0.05

Vertical Cap of Rack=3 Units

Based on the calculation it is known that the rack for Rough Lumber could keep 3 units. The next calculation is for the length capacity of the
rack.
Length of Rack
Horizontal Cap of Rack= (4-2)
Materia l ' s Length

0. 8
Horizontal Cap of Rack=
0.24

Horizontal Cap of Rack=4 Units

The allowances that will be use is 200% included material handling, aisle and material movement.

Sheld Area=Length × width× shelf required (4-3)

Allowance=SHelf Area×%Allowances (4-4)

Total Area=Shelf Area + Allowances (4-5)

The calculation will be done for each shelves and each materials. The details result of calculation will be summarized in the table below

Table 4.32 Indirect Material Specifications

42 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 Calculation of Indirect Material Requirements LT 10
Material Dimension Material
Material Material Actual Box Dimension (m)
Cod (m) Req Details
No. Material Req Req Req
e (Units/Prod (Pcs/Box)
L W T (Units/LT) (Box/LT) (Box/LT) L W T
)
Drive
1 DN 0,04 0,00 - 20 62200 4,98 5 0,80 0,50 0,40 12.500
Nail
Washer
2 WF 0,30 0,30 0,04 20 62200 4,98 5 0,80 0,50 0,40 12.500
Flat
Hook
3 HS 0,06 0,01 0,00 5 15550 4,86 5 0,80 0,50 0,40 3.200
Screw
Wood
4 WH 0,04 0,00 - 20 62200 4,98 5 0,80 0,50 0,40 12.500
Head
5 S String 7,00 0,10 - 1 3110 4,78 5 0,80 0,50 0,40 650
6 C Carton 0,45 0,35 0,30 1 3110 4,78 5 2,00 1,00 1,00 650
Carton
7 CL 0,45 0,35 0,30 1 3110 4,78 5 2,00 1,00 1,00 650
Linier
8 L Label 0,06 0,03 - 1 3110 4,78 5 0,80 0,50 0,40 650
Gamed
9 GT 100,00 0,05 - 1 3110 4,78 5 0,80 0,50 0,40 650
Tape
10 LQ Lacquer 0,26 0,19 0,38 3110
5 Litters/Gallon. 2 for Engine, 1,5 for Gondola, 1,5 for Box
Lacquer 1
11 LQT 0,26 0,19 0,38 622 Car
Thinner
12 G Glue 0,25 0,25 0,38 1 3110 600 g. 300 for Engine, 150 for Gondola, 1,5for Gondola
Sand
13 SP 0,23 0,28 - 1 3110 4,78 5 0,8 0,5 0,4 650
Paper
14 SD Sand Disc 0,11 0,11   1 3110 4,78 5 0,8 0,5 0,4 650

43 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 Table 4.33 Material Dimension of Indirect Material

Material Dimension
Material
No Material Qty
Code L W T/Ø

1 DN Drive Nail 0,04 0,00 - 20

2 WF Washer Flat 0,30 0,30 0,04 20
3 HS Hook Screw 0,06 0,01 0,00 5
4 WH Wood Head 0,04 0,00 - 20
5 S String 7,00 0,10 - 1
6 C Carton 0,45 0,35 0,30 1
7 CL Carton Linier 0,45 0,35 0,30 1
8 L Label 0,06 0,03 - 1
9 GT Gamed Tape 100,00 0,05 - 1
10 LQ Lacquer 0,26 0,19 0,38 1
Lacquer
11 LQT 0,26 0,19 0,38 0
Thinner
12 G Glue 0,25 0,25 0,38 1
13 SP Sand Paper 0,23 0,28 - 1
14 SD Sand Disc 0,11 0,11 0,00 1

44 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 Table 4.34 Storage Space Requirements of Indirect Material

Storage Space Requirement Calculation for Indirect Material

Actual No. Rack Dimension No. Total
Material Material Vertical Horizontal (m) Total Area Allowance
No Req of of Area
Code Name Stacks Stacks Rack (m^2)
(units/LT) Item L W H Rack 200% (m^2)
Drive
1 DN 5 13 20 260 0,02
Nail
Washer
2 WF 5 13 3 39 0,13
Flat
Hook
3 HS 5 13 15 195 0,03
Screw
Wood
4 WH 5 13 21 273 0,02
Head
5 S String 5 13 2 26 0,19
6 C Carton 5 5 2 10 0,80 0,50 0,40 0,50 2,00 0,80 1,60 2,40
Carton
7 CL 5 5 2 10 0,50
Linier
8 L Label 5 13 4 52 0,10
Gamed
9 GT 5 13 2 26 0,19
Tape
Sand
10 SP 5 13 3 39 0,13
Paper
Sand
11 SD 5 13 7 91 0,05
Disc
12 LQ Lacquer 1 5 3 15 0,07
Lacquer
13 LQT 1 5 3 15 0,80 0,50 0,40 0,07 1,00 0,40 0,80 1,20
Thinner
14 G Glue 1 5 3 15 0,07

45 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 Table 4.35. Total Storage Space Requirements

Storage Space Requirement

Facility Area (m2) Allowance 200% Total
Direct Material 107,60 215,20 322,80
Indirect
1,20 2,40 3,60
Material
Total 326,40

Based on the table above, the storage consists of two type there are for direct material
and indirect material with allowances 200% the total needed for the storage is 326,40 m2.

4.4 Space Requirement for Warehouse

Warehouse is a building for storing goods. Warehouses are used by manufacturers,
importers, exporters, wholesalers, transport businesses, customs, etc. To calculating the
total area of warehouse there are several things that need to be calculated, such as type of
product, quantity, type of shipping and docking, and Requirement. To move the goods in
to warehouse the packaging needs to passed the quality control. The dimension of EGGG
packaging is 0.25m x 0.24m x 0.10m. The dimension of EBB packaging is 0.25m x
0.16m x 0.10m. The dimension of EBG is 0.25m x 0.08m x 0.10m. Table 4.36. shows
the calculation looking for the space requirement of warehouse.
The Shelf Capacity is calculated by determine the length, width, and height of the box
dimension of the shelf. The calculation of the capacity shelf for Engine, Gondola and
Box Car.

Length of Rack (4-6)

Length Capacity= =6
Length of Box

Width of Rack
Width Capacity= =1 (4-7)
Width of Box

Height of Rack
Thickness Cap acity= =1
Thickness of the material (4-8)

Total Cap=6 ×1 ×1=6 box

We assume we decide to use same type of rack with 3 levels of shelves

(4-9)
46 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 Height of Rack
Number of Rack= =0,89 ≈ 1
box
No . of × No . of Shelf
shelf

The area shelf can be calculated as the formula below

Area of Shelf =Length ×width ×no . of rack (4-10)

Area of Shelf =4 ×1 ×3=12 m

47 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 Table 4.36 Space Requirement of Warehouse

Warehouse Space Requirement Calculation LT 5 days

Dimension of Single Box
Dimension of Shelf (m) Allowances
(m) No. of Horizontal Shelf No. of Total Area
Product No. of Rack/Shelf Vertical Stacks Area (m^2)
Box/Rack stacks Capacity Shelf (m^2)
L W H H L W 200%
EGGG 0,25 0,24 0,10 0,80 0,5 0,4 8,00 2,00 8,00 4,00 32,00 3 0,60 1,20 9,00
EBB 0,25 0,16 0,10 0,80 0,5 0,4 8,00 3,00 8,00 5,00 48,00 3 0,60 1,20 9,00
EBG 0,25 0,08 0,10 0,80 0,5 0,4 8,00 5,00 8,00 10,00 80,00 3 0,60 1,20 9,00
Total 27,00

In the warehouse determine the single box as packaging the finished good product. Every packaging will be put in the master box. So, the total of single box for engine is 6. The calculation of shelf dimension also the
same with the collection of the master box that can filled into one shelf.

(4-11)
Total Area= Area+( Area ×200 %)

Total Area=27 , 0 0 m ²

48 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 CHAPTER V
CONCLUSION

In Project 3, we have some basic information like raw material demand, material and
machine dimension, number of employees, number of allowances and list of departments,
that we can use to calculate the office space requirement, other supporting office facilities,
production floor, storage, and warehouse calculation. We add the 200% allowances in every
total area of the calculation to increase the productivity off employees.

After conducting the calculation of space requirement for every element that needed in the
company, the total space requirement could be summarized. The space requirements will be
shown on the tables below.
Table 5.1. Total Space Requirement
No Room Area
1 Office Space Requirement 323,91 m2
2 Other Supporting Facilities 13288,30 m2
3 Storage 326,40 m2
4 Warehouse 13,50 m2
5 Green Area 5.510,62 m2
6 Production Floor 4403,14 m2
Total 23.879,37 m2

So the total area needed is 23.879,37 m2

49 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 REFERENCES

Proxisgroup. (2020, November 28). Apa itu Warehouse? Retrieved from Proxisgroup:
https://proxsisgroup.com/pq/apa-itu-warehouse/
Tompkins, J. A., White, J. A., Bozer, Y. A., & Tanchoco, J. M. (2010). Facilities Planning
4th Edition. Wiley.

50 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 APPENDICES

Appendix 4.1 MPPC of Engine

51 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
Appendix 4.2 MPPC of Gondola

52 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
Appendix 4.3 MPPC of Box Car

53 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
Appendix 4.4 3D Views of Single Box
0.07 m2

0.23 m2

Appendix 4.5 3D Views of

Master Box

1.47 m2

1.15 m2

0.20 m2

54 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
Appendix 4.5 Thinner and Glue Rack
0,4 m2 0,5 m2

0,6 m2

55 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
 Appendix 4.6 Picking Up Box

4 m2

1 m2

4 m2 0.4 m2

56 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
Appendix 4.7 Storage Rack
0,4 m2 0,5 m2

0,8 m2

57 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3
Appendix 4.8 Rough Lumber Rack

0.8 m2

0,5 m2

58 | P R O J E C T 3 F A C I L I T Y D E S I G N G R O U P 1 3