Terra preta toilet

Manufacturing and Factory Planning Project

Group 5:1) Nguyen Minh Duc.2) Truong Thi Xuan Dao.3) Nguyen Thi Hong Nhung.4) Pham Dang Khoa5) Nguyen Phi Quoc Tuan.

An Introduction to

the

TERA PRETA TOILET

TERA PRETA TOILET

Terra-Preta Toilet is the toilet with the concept of ecological sanitation where human excreta and other bio wastes are transformed into pathogen-free, nutrient rich and organic matter rich hummus.

Source: http://www.tuhh.de/aww

POTENTIAL CUSTOMER

Any country in over the world where

- Problem with non-treated house water

- Problem with scarcity water

- Problem with sharing agricultural land re-source

Next

1. Define market and identify the first factory location

Define market

Define criteria

Evaluate five countries

Compare and recommend factory location

Amount of non treated house water returned to environment

Source: http://www.unwater.org/statistics.html

60%-80% Waste water in Asia and Africa flown untreated into rivers, lakes and coastal zones, threatening health, food security and access to safe drinking and bathing water.

0

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40

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80

90

Europe Africa North America Asia

Perc

en

tag

e

Region

Back

Map of Total World Population2009-2013

http://data.worldbank.org/indicator/SP.POP.TOTL/countries?display=map

Population Of Asia: 4,379,000,000 (4 billion) hosts 60% of the world’s population

Agricultural land (% of land area)2009-2013

http://data.worldbank.org/indicator/AG.LND.AGRI.ZS/countries?display=map

Agriculture accounts for around 70 per cents of global freshwater.

Asia supports about 60 percent of the global population on only about 23 percent of the world’s agricultural land.

Back

Forecast increased global water stress in 2025

Source: http://www.grida.no

Water stress is defined as having a high percentage of water withdrawal compared to total available water in area

Back

http://www.grida.no/

Conclusion

SOUTH ASIAis the most potential market whereas

has the large population, Agricultural

land and amount of non treated house

water returned to environment.

This Terra Preta Sanitation system will

offer South Asia the double benefit of

reducing water consumption and

sustainable source of soil fertilizer for

agriculture.Source:

http://www.southasianconcern.org

http://www.southasianconcern.org/


Define market

Define criteria



Define criteria


Define market

Define criteria



Criterion 1: Electricity priceNr. Country Electricity price

(US cents/Kwh)Rank

1 Brazil 34.2 5

2 Germany 34.1 4

3 Jordan 33 3

4 South Africa 16 2

5 Vietnam 10 1

0

10

20

30

40

Brazil Germany Jordan SouthAfrica

Vietnam

US

cen

ts/k

wh

Electricity price

Source: http://en.wikipedia.org/wiki/Electricity_pricing

Criterion 2. Employees

Nr. Criteria Brazil Germany JordanSouth

AfricaVietnam

1 Minimum wage for a 19-year old

worker or an apprentice

(US$/month)

299.6 1145.5 199.9 543.1 49.9

2Unemployed person(2013)* 1,940,000 1,998,000 884,400 4,340,000 1,310,000

3 Wage and salaried workers, total

(% of total employed)66.4% 88.3% 84.3% 84.5% 34.6%

Rank1 2 5 4 3

Source: World bank,*http://www.tradingeconomics.com

Criterion 3. Logistic

Nr. Criteria Brazil Germany Jordan

South Africa

Vietnam

1Road density (km of road per 100 sq. km of land area)

18.6 180.3 7.9 30.6 48

2 Roads, paved (% of total roads) 13.5% 100% 100% 17.3% 47.6%

3 Cost to export (US$ per container) 2,215 905 825 1,705 610

4Liner shipping connectivity index (maximum value in 2004 = 100)

38.5 90.6 22.8 36.8 48.7

Rank 5 1 4 3 2

Source: World bankback

Criterion 4. Supplier • The top countries are China, Mexico,

Turkey, Brazil, and Colombia.• China leads Asia market with a market

share of 60.2%• In South America, Brazil has the

highest market share of 54.5%• The major players in the industry are

Roca Sanitario SA (Spain), ToTo(Japan), American Standard (U.S.),Kohler Group (U.S.), Eczacibasi(Turkey), Duravit (Germany), Villeroy& Boch (Germany), and CeramicaAlthea (Italy).

Nr. Country Rank*

1 Brazil 1

2 Germany 2

3 Vietnam 3

4 Jordan 4

5 South Africa 5

*Ranking ceramic sanitary ware production availability and Distance towards the China supplier

Source http://www.marketsandmarkets.com

Criterion 5. Distance to market

Nr. Country Distance to market (km) Rank

1 Brazil 14,526.33 5

2 Germany 6,222.22 3

3 Jordan 3,986.75 2

4 South Africa 8,415.75 4

5 Vietnam 3,543.52 1

0

5000

10000

15000

20000

km

Source : http://www.distancefromto.net

Criterion 6. Capital marketNr. Criteria

Brazil Germany JordanSouth Africa

Vietnam

1 Availability of financial services (1-7 best)

4.5 5.7 3.1 4.3 4.2

2

Ease of access to loans (1-7 best)3.4 3.2 2 2.9 3.3

3Legal rights index*(0-10 best) 6 7 3 7 10

Sum 13.9 15.9 8.1 14.2 17.5

Rank 4 2 5 3 1

Source: The Global Competitiveness Report 2013–2014

*Legal rights index: measures the degree to which collateral and bankruptcy laws protect borrowers’ and lenders’ rights and thus facilitate lending

Criterion 7. Communication

Nr. Criteria

Brazil Germany JordanSouth Africa

Vietnam

1

Int’l Internet bandwidth, kb/s per use 28 74.8 6.3 18.9 10

2

Secure Internet servers/million pop 54.2 1023.4 25.2 73.9 4.7

3 Accessibility of digital content[1 = not accessible at all; 7 = widely accessible]

4.9 6.1 5.4 4.8 5.3

4 Business-to-business Internet use[1 = not at all; 7 = extensively] |

5.5 5.9 5.3 5.6 5.7

Rank 3 1 4 2 5

Source : The Global Information Technology Report 2013

Criterion 8. Technology


South Africa

Vietnam

1 Availability of latest technologies[1 = not available; 7 = widely available]s

5.3 6.3 5.7 5.7 3.6

2 Quality of math & science education(1 = poor; 7 = excellent—among the best in the world)

2.6 4.7 4.7 2 4.1

3 Firm-level technology absorption[1 = not at all; 7 = aggressively absorb]

5.2 5.9 5.6 5.4 4

4 Capacity for innovation[1 =exclusively from licensing or imitating foreign companies; 7 =by conducting formal research and pioneering their own new products and processes]

3.7 5.7 3.3 3.5 3

Sum 16.8 22.6 19.3 16.6 14.7

Rank 3 1 2 4 5

Source : The Global Information Technology Report 2013

Criterion 9. Competitive regulations


South Africa

Vietnam

1 Tax regulations 16.8 19 7 0.4 8.5

2Tax rates 15.1 12.7 11.4 0.4 6

3 Policy instability 2.7 5.2 8.8 5.7 11.4

4Restrictive labor regulations 11.7 15.6 11.5 19.4 0.8

Sum 46.3 52.5 38.7 25.9 26.7

Rank 2 1 3 5 4

Per cent of responses of the most problematic factors for doing business

Source: The Global Competitiveness Report 2013–2014

Criterion 10. Political stability

Country Rank

Brazil 4

Germany 1

Vietnam 2

Jordan 5

South Africa 3

The index for Political Stability and Absence of Violence measures perceptions of the likelihood that the government will be destabilized or overthrown by unconstitutional or violent means, including

politically-motivated violence and terrorism.


Define market

Define criteria



Data Comparison

Criteria/country Weight Brazil Germany JordanSouth

AfricaVietnam

Electric supply price 0.15 5 4 3 2 1

Employees 0.15 4 5 2 3 1

Logistics 0.15 5 1 4 3 2

Supplier 0.1 1 2 5 4 3

Distance to market 0.1 5 3 2 4 1

Capital market 0.1 4 2 5 3 1

Communication 0.1 2 1 5 3 4

Technology agglomeration0.05 3 1 2 4 5

Competitive influencing

regulations0.05 2 1 3 5 4

Political stability 0.05 3 1 5 4 2

Total 3.7 2.5 3.7 3.10 2.05

(5=low to 1=high)

Location Recommendation

Lowest

electricity

price

Lowest

Minimum

wage for a

19-year old

worker

(US$/month

)

Nearest

distance

to market

Competitive

capital

market

High political

stability

Good logistics

2. Design of the process chain, equipment and workstation

Develop bill of material & required processes

Cluster the processes into work stations & Workstation’s value creation


1. Ceramic sanitary

2. Plastic container

8. Side cover

6. Airtight

9. Emptying pipe

7. Stirrer

11. Anti-slip wooden flat

3. Handle

4. Additive lid

5. Toilet cover

Select the degree of automation for each process step and the required equipment

Process Describe stepProcess

timeInformat

ionPower

Degree of automatio

nEquipment

AAssemble air-tight & stirrer intocontainer

67 Human Human Manual Silicon gun

B Join container to ceramic body 111 Human Human Manual Silicon gun

C Install right-side handle 67 Human Human Manual Silicon gun

D Glue emptying pipes 67 Human Human Manual Silicon gun

E Screw additive lid & toilet lid 44 Human Human Manual Srew driver

F Screw side covers 167 Human Human Manual Srew driver

G Glue sprayer fixture 17 Human Human Manual Silicon gun

H Inspecting 67 Human Human Manual NA

I Packing 122 Human Machine ManualTapping machineTrapping machine

K Cutting anti-slip (wood/metal) 113 Human Machine AutomaticAuto-cutting machine

L Deburing anti-slip (wood/metal) 73 Human Machine AutomaticAuto-deburing machine

M Glue anti-slip upon side covers 133 Human Human Manual Silicon gun

Bondit Silicon addhesive gunSource: http://www.workshopsuppliessales.co.uk

Screw driverSource: http://msgirardsonlineclassroom.pbworks.com

Equipment

Mental cutting machineSource: 1190x450x680

http://www.diytrade.com

Mental deburring machineSource: 1500x800x600http://www.stet.ch

Tapping machineSource: 1000x500http://www.sharpstrapping.com

Strapping machineSource: 1000x500http://www.signode.com

Wood cutting machineSource: 700 x 700 x 850

www.tradekorea.com

Wood deburring machineSource: 2400x900x870http://turanlar.com

http://www.workshopsuppliessales.co.uk/

http://msgirardsonlineclassroom.pbworks.com/

http://www.diytrade.com/

http://www.stet.ch/

http://www.sharpstrapping.com/

http://www.signode.com/

https://www.google.com.vn/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&docid=rHgJvJ9rkXSq2M&tbnid=mp_-8YzW0YI4OM:&ved=0CAQQjB0&url=http://www.tradekorea.com/products/ruler.html&ei=EXSIUqPPM4rIkQXfmIGoBw&psig=AFQjCNGefV036umzIkuI3Q_sKvE_Qasi0Q&ust=1384760602155055

http://turanlar.com/

2. Design of the process chain, equipment and workstation


Cluster the processes into work stations & Workstation’s value

creation

Determine workstation

Initial Demand = 5000 products/year.

Additional demand: 20680 x 2 = 41360

Demand per day = (41360+5000)/303= 153 products/day

Max time /one product = (8 hour/day x 3,600 sec/hour)/ 150

products/day = 188 sec/one product

Month Sale forecast (products) Actual sale tolerance

1 2,400 +/10%

2 3,600 +/10%

3 2,900 +/10%

4 2,700 +/10%

5 4,100 +/10%

6 3,100 +/10%

Total 20,680 (+ 10%)

Cluster the processes into work stations

Work stations regarding its value creation

Value creation Workstation 1

Describe step

- Assembling Air-tight + stirrer into container- Join container to ceramic body

Product

- Raw material: Container, airtight, stirrer, ceramic sanitary- Finish good: Main body- Spec: Main body with full airtight and stirrer, no leak and clean

Process- Assembling process- Gluing process

Equipment

- Silicon gun- Recycle bin- Electric supply

Organization- Material supplied by pallet- Finish good moved by manual conveyor belt system

Human- 1 operator- Operator with qualified to do assembling and glueing process

Work stations regarding its value creation

Value creation Workstation 2

Describe step

- Install right-side handle- Screw additive lid & toilet lid- Glue two emptying pipe

Product

- Raw material: Main body, handle, additive lid, toilet lid, pipe, screw, bold, nuts and washers, rubber sealing

- Finish good: Toilet without side cover- Spec: toilet must be seal tight, no water leaked

Process- Gluing process- Assembling process

Equipment

- Silicon gun- Screw-driver- Recycle bin- Electric supply


Human- 1 Operator- Operator with qualified to do assembling and gluing process

Work stations regarding its value creationValue creation Workstation 3

Describe step- Screwing two side cover- Glue sprayer fixture

Product

- Raw material: Toilet without side cover,- 2 x cover with anti-slip, scew, sprayer fixture- Finish good:Toilet- Spec: Toilet with full 5 screws for each side of cover and sprayer fixture

Process- Screwing process- -Gluing process

Equipment

- Screw-driver- Silicon gun- Recycle bin- Electric supply


Human- 1 operator- Operator with qualified to do screwing and glueing process


Describe step- Inspecting- Packing

Product

- Raw material: Toilet, unfold carton Box, washing cloth, packing tape, label, plastic band for packing

- Finish good: Finish Toilet- Spec: Clean Toilet, packed carton properly with full label

Process - Inspecting process

Equipment

- Silicon gun- Tapping machine- Trapping machine- Recycle bin- Electric supply

Organization

- Toilet moved by manual conveyor belt system from the previous station- Material supplied by pallet- Finish good moved by manual forklift truck

Human- 1 operator- Operator with qualified to do inspecting & packing process


Describe step

- Cutting anti-slip (wood/metal)- Deburing anti-slip (wood/metal)- Glue anti-slip- upon side covers

Product

- Raw material: 2m long rod- Finish good: Cover with anti-slip- Spec: Cover with enough 17pcs rod

Process

- Cutting process- Deburring process- Glueing process

Equipment

- Automatic cutting machine: parameter set by human- Edge deburring machine: parameter set by human- Silicon gun- Bin for burring material- Recycle Bin- Electric supply

Organization- Material supplied every 4 hours- Finish good store in pallets and moved by forklift

Human

- 2 operator- Operator with qualified using automatic cutting & deburring machine, be able

to do gluing process

3. Design of factory layout

Material flow in factory

Define floor space required for workstation

Layout planning and selection

- Ceramic

- Airtight

- Stirrer

- Container

- Handle

- Pipes

- Additive lid

- Toilet lid

- Sprayer fixture

1 2 3 4

5

- Material rod

- Packing stuff

- Side covers with anti-slip

Buffer

OUT


Flat rod preparation

Material flow matrix (Kg)

WS Buff 5 1 2 3 4 Out

In 3.5 25.6 1 0.1 0.2

Buffer 7.5

5 7.5

1 25.6

2 26.6

3 34.2

4 34.6

Component Unit Weight (kg)Ceramic Piece 20

Airtight Piece 0.1Stirrer Piece 0.5

Container Piece 5Handle Piece 0.1Pipe Piece 0.1

Additive lid Piece 0.2Toilet lid Piece 0.5Sprayer fixture Piece 0.1

Packing stuff Batch 0.2

Material rod Rod 0.5

Side cover Piece 2

1 2

3Buff5

3.5

In 25.6

7.5 7.5

4Out 34.6

25.6

26

.6


WS Machine Over head factor Space (m2)

In 24 pallet 3 floors, (1.5*2) 24*1.2 28.8

Out 2 pallet *(1.5*2) 3*2 6

1 Conveyor 1.5*0.5 0.75*3.8*1.2 3.42

2 Conveyor 1.5*0.5 0.75*3.8*1.2 3.42

3 Conveyor 1.5*0.5 0.75*3.8*1.2 3.42

4 Conveyor 1*0.5 + tap machine 1*0.5 + trap machine 1*0.5 1.5*3.8*1.2 6.84

5Wood cutting 0.7*0.7 + wood deburring 2.4*0.9Steel cutting 1.2*0.5 + steel deburring 1.5*0.8

4.45*3.8*1.2 20.292

Buffer 300 side cover (2pcs = 500*700*250 ) 150*0.5.0.7/6*1.2 10.5


- Over head factor for machine area follow product structure area: 3.8- Over head factor for production control and services area: 1.2

Internal supply strategy

ComponentQty per finish

productSupply 2 times/day

(75pcs)Qty Pallet

Ceramic 1 75 10

Container 1 75 5Side cover 2 150 3

Toilet lid 1 75 1

Packing stuff1

75 1

Material rod 4 300 1Airtight 1 75 1Stirrer 1 75

1Handle 1 75Additive lid 1 75

Pipe 2 1501

Sprayer fixture1

75

Total 24


92 m2 91 m2 93 m2

1 2

3Buff5

3.5

In 25.6

7.5 7.5

4Out 34.6

25.6

26

.6


LAYOUT 1

LAYOUT 2

LAYOUT 3



Material flow matrix (Kg)


In 3.5 25.6 1 0.1 0.2

Buff 7.5

5 7.5

1 25.6

2 26.6

3 34.2

4 34.6

Cost matrix ($) - Layout 2

WS Buff 5 1 2 3 4 Out Total

In 17 70 5 1 1 95

Buff 23 23

5 35 35

1 59 59

2 61 61

3 118 118

4 52 52

TOTAL 442

Distance matrix (m) – Layout 2


In 4.95 2.75 5.05 7.35 6.2

Buff 3

5 4.7

1 2.3

2 2.3

3 3.45

4 1.5

Layout selection criteria:

+ Small space required

+ Small cost moving and handling

+ Suitable arrangement between WS

COST = WEIGHT * DISTANCE * UNIT COST

UNITCOST= 1$/DISTANCE



In 6 7 8.15 9.3 12.05

Buff 3

5 4.7

1 2.3

2 2.3

3 2.65

4 4.7


WS Buff 5 1 2 3 4 Out Total

In 21 179 8 1 2 212

Buff 23 23

5 35 35

1 59 59

2 61 61

3 91 91

4 163 163

TOTAL 643


Buff 5 1 2 3 4 Out Total

17 70 5 1 1 95

23 23

35 35

59 59

61 61

118 118

52 52

TOTAL 442


Buff 5 1 2 3 4 Out Total

16 157 8 1 2 185

11 11

31 31

59 59

61 61

118 118

190 190

TOTAL 655



In 4.95 2.75 5.05 7.35 6.2

Buff 3

5 4.7

1 2.3

2 2.3

3 3.45

4 1.5



In 4.45 6.15 8.45 10.75 11.1

Buff 1.4

5 4.15

1 2.3

2 2.3

3 3.45

4 5.5

92 m2 91 m2 93 m2

4. Suppliers strategy

Delivery intervals

Organization chart

Minimal throughput-time and bottleneck work station

Customer order : 5,000 pieces per year

Sale forecast for the first half a year product quantities: (+/- 10%)

Variations demand:

- Toilet lid colour: white plastics (47%), green plastics (12%), blue plastics

(23 %), natural wood (18 %)

- The material of the flat rods: wood (35%), stainless steel (10%), plastics

(55%)

Average each month: 3900 products

1st month: 2400

products

2ndmonth: 3600 products 3rd month: 2900 products

5th month: 4100 products 4th month: 2700 products 6thmonth: 3100 products

Schedule for production running

Variations demand for 6 months

Rod Sum

Lid White (W) Green(G) Blue (B) Natural (N)

6 month 5902 869 1665 1303 9738

1month 984 145 277 217 1623

Rod Sum


6 month 972 248 476 372 2068

1month 162 41 79 62 345

Rod Sum


6 month 5346 1365 2616 2047 11374

1month 891 227 436 341 1896

Wood (W)

Steel (S)

Plastic(P)

Detail weekly production planning for the

first month

Rod type Lid color

White 500 200 284

Green 145

Blue 150 127

Natural 100 117

White 162

Green 41

Blue 79

Natural 62

White 200 500 191

Green 100 127

Blue 156 180 100

Natural 100 100 141

Total

quantity

Wood 1624

Steel 344

Plastic 1896

PRODUCT/WEEK1ST 2ND 3RD 4TH 5TH(2DAY

S)

Delivery intervals

Supply strategy for 1 month

(26 days)

Ceramic sanarity (piece)

Plastic containers

(piece)

Side covers(piece)

Handle(piece)

Air-tight (piece)

Stirrer (piece)

Prayer fixture(piece)

Delivery frequency 1 time/2 day 1 time/2 day 1 time/2 day 1 time/month

Dependent demand per month

3,900 3,900 7,800 3,900 3,900 3,900 3,900

Stock supplied per time 300 300 600 3,900 3,900 3,900 3,900

Supply for 1 month

(26 days)

Wooden rods(bar)

Stell rods(bar)

Toilet lid + additive lid(piece)

Plastic rods(piece)

White Green Blue Natural White Green Blue Natural

Delivery frequency

1 time/month 1 time/month 1 time/month 1 time/month

Dependent demand per month

5,063 1,076 2,056 418 800 627 900 230 440 345

Stock supplied per time

5,063 1,076 2,056 418 800 627 900 230 440 345

Rod Lid

White

Green

Blue

Natural 100

White 162

Green 41

Blue 79

Natural 62

White

Green 100

Blue 156

Natural 100

Order 1 5000

Order 2 2400+10% 166 124 32 60 47

Order 3 3600+10% 50 35 57 50 38 9 19 15 53 102 80

Order 4 2900+10%

Order 5 2700+10%

Order 6 4100+10%

Order 7 3100+10%

Product type/Day1 2 3 4 5

Wood

6 7 8

500

9 10

Steel

500

Plastic 200

209

434 110 210

Detail production planning per day


Delivery intervals

Organization chart


General Manager

1 person

Head of office

1 person

HR + Admin

1 person

Purchasing + Shipping

1 person

Business + Planning

1 person

Account + IT

1 person

Head of production

1 person

Warehouse

2 person

Finished good

2 person

Production

8 person

Maintenance

1 person

Organization chart


Delivery intervals

Organization chart


Bottleneck work station: WS 3 (184s)Minimal throughput-time: 718 sImprovement: Use well-trained people for decrease process time at WS3


Factory's principle summaryProduct Tera Preta ToiletMarket South AsiaFactory location Viet NamTactical planning Material outsourcingProduction strategy Push systemType of planning Production leveling Flow principles One piece flow Production technology Assembling and packing

Number of workstation 5Type of layout Product layoutFactory structure FunctionalFactory area size 90 m2Employee 20 peopleImproving tool 5S Methodology & quality policyNumber of shift 1 shift/day

Generally, the project is technical feasible, socially and economically

acceptable. Hence the project is worth implementing.

SUMMARY

http://reportformfp-project.blogspot.com/

http://reportformfp-project.blogspot.com/

Terra preta toilet

Engineering

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