Automated Production System Facility Plan and Safety Design

Faculty: Engineering and Applied Science Industrial System Engineer(ISE) - University of Regina

Project Team: Zhihao Zhang; Riyad UI Islam Shuvo; Victor Ray Sacedor.

Academic Supervisor: Dr. Sharfuddin Khan

Presentation Date: March 28th, 2025

Summary

The objective of this project is to design a facility layout and automate the existing PET bottle production line for the company Estevan Plastic Products Ltd.(EPP). This company is the leading production company which manufacturing Pet plastic bottle for food and beverage in SK, Canada. The company is found around 2 years and continued growth. This project aims to address the underlying issues the company is currently facing regarding productivity, safety and efficiency as they move their production line from Estevan to Saskatoon.

Problem Statement

As it stands, EPP is not able to meet their customers' demand due to the inefficiency in their current production system requiring manual labour in between each process which ultimately reduces their productivity to an estimated 60% to 70%.

Main Content

This project based on the industrial system engineering background to help them solving the problem. To propose a feasible solution, the team collaborates with EPP to design a new facility layout that satisfies the conditions: utilizes the allocated space, cost-efficient, open for future expansions, and operates with an over 95% productivity via simulation while addressing potential hazards of working in a warehouse. Finally, after the optimized design is chosen, the production reaches up to 3.4 times more than current system, and with increasing revenue up to 2.6 times. The net margin increase around 70%, which is the confident growth for a start-up company with future long term growth. This project also provide recommendation and support future development in lean process within 10 years.

Figure & Table

Figure 2 Process Flow Chart of EPPs Production System

Table 1 ALDEP Relationship Table of Facility Department

New Facility Layout

Figure Design Option 5

Figure 14 Simulation of Option 5

Resource

Video

1. Loading Preform

2. Injection Machine

Presentation and Report

Automated Production System Facility Plan and Safety Design Powerpoint

Automated Production System Facility Plan and Safety Design Poster

Automated Production System Facility Plan and Safety Design Report

Contact Information

Riyad Ul Islam: Shuvo:rsk624@uregina.ca

Ray Victor Sacedor: vcs797@uregina.ca

Zhihao (Alexander) Zhang: zzs297@uregina.ca

Dr. Sharfuddin. Khan: sharfuddin.khan@uregina.ca

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