This document summarizes a study to improve the layout of Propper International's shoulder strap manufacturing process. The objectives were to minimize space utilization and haulage. The current layout and two alternative layouts were evaluated using a CRAFT (Cost of Routing of Flow in a Time period) analysis. Alternative 1, which relocated some operations, had the lowest cost. It is recommended to implement Alternative 1 to reduce hauling time and costs. A macro layout of the facility was also proposed to aid future planning.

1. “LAYOUT IMPROVEMENTS
TO THE SHOULDER STRAP
PROCESS”
PROPPER INTERNATIONAL,
CABO ROJO PUERTO RICO
Liz Antongiorgi Cruz - Industrial Engineering
Izamar González Marcucci – Industrial Engineering
University of Puerto Rico at Mayagüez

2. OBJECTIVES/ GOALS
1. Minimize space utilization
2. Minimize haulage of the daily production
3. Evaluate and analyze the flow of the product
4. Propose and evaluate multiple engineering design
alternatives and its implications
5. Create a cad of the Propper facility (macro)

3. Resources was utilized to aid our observations:
 Odometer- to generated distances
 Measurement tape- determine size of the machinery
To evaluate the current Shoulder Layout and the
alternatives use CRAFT method:
 Origin/Destination Matrix- represents the hauls
between operations
 Distance Matrix- rectilinear distances are calculated
from the midpoint of the operations, given that the
operator seats in this point
 Cost Matrix- assumed that all operators are paid the
same amount of money per unit
MATERIALS/RESOURCES

4. METHOLOGY / PROCEDURE
Our main goal was to reduce the hauling time inside the
department. This could be achieved by re-designing the
department layout. All precedence and sequence data
was obtained from the Operations Routing Sheet.

5. The Shoulder Strap Manufacturing Line has 21
processes and each features different machinery. The
following table describes the space required by each
machine:Process/Operation Description Measurements (inches)
O12 Prepare Elastic Ring 33 x 36
O14 Attach ID Label 46.5 x 30.5
O15 Fold & Attach Hook Tape 46.5 x 30.5
O16 Reinforce V-Strap 30.5 x 56.5
O17 Fold & Form V-Strap 46.5 x 30.5
O18 Attach Pile 46.5 x 30.5
O19 Thread Tape Buckle-Tack
26 x 28
27 x 29
O20 Thread Elastic Ring
All three operations are done on the same machine.
26.75 x 47
33.00 x 44
O21 Twist/Fold Web end & Bartack
O22 Fold Twice Webb & Bartack
O24 Pre-hole/Attach Snap Fastener 26 x 28
O25 Pre-hole/Attach Snap Fastener 23.5 x 48
O26 Attach Label to Webbing 30 x 48
O27 Close Shoulder Straps
21 x 59
29 x 47.5
20 x 60.5
O28 Turn/Insert Foam 38 x 48.25
O29 Close Shoulder STP/INS Webb
22.25 x 47.25
20 x 37.5
O30 Bartack 23.5 x 47
O31 Bartack & Fixed QS Buckle 31 x 47
O32 Prepare Sternum Strap
29.5 x 47.5
28 x 50.75
28 x 47.25
O34 Thread & Inspect 37 x 38
INSP Final Inspection 32 x 48.5

6. The following space requirements must also be taken into
account:
Description Measurements (inches)
Final Product Box
39 x 40
21.5 x 35.25
Yellow Product Cart 32 x 49
Work in Process 18.74 x 36.5
Desk 30 x 34.5
Non-Conforming Cart 4 x 23.25
Stand 20.5 x 28

7. RESULTS
 Macro view of the
facility detailing the
departments and
measurements of
each. Having this
design will aid the
company in future
modifications of the
layout and
organization of the
manufacturing area.

8. Actual Shoulder STR
Layout

9.  A total cost of haulage is calculated by multiplying O/D,
Cost and Rectilineal matrixes.
Final Matrix - Costs / Feet
cost to compared to
the cost of the
alternatives

10. Alternatives are
generated
interchanging
adjacent pairs of
machinery. Once
the cost of an
alternative
increases the
method is
stopped. The
best alternative is
then the
alternative that
yielded the
lowest haulage
cost.
Alternative # 1
Shoulder STR Layout -
CRAFT
Considering that
operations 19, 24
and 25 are actually
done outside the
department, this
was changed in
alternative # 1.

11.  Recalculate the
Rectilineal Matrix to
analyze the alternative #
1
Given that the cost of this alternative is
lower than the cost of the actual layout, the
alternative is the reference utilized to
generate the second alternative.

12. Alternative # 2
Shoulder STR Layout -
CRAFT
The second alternative
interchanged the machinery of
operations 27 & 26. These
interchanged is based in
minimize haulage between
these operations and the
operation 28.

13.  Recalculate the
Rectilineal Matrix to
analyze the alternative #
2
The cost of the alternative # 2
increases then the CRAFT method is
stopped.

14. RECOMMENDATIONS
 The best alternative is the alternative #1 that yielded
the lowest haulage cost. It is advised that the
operations 19, 24 and 25 be moved into de Shoulder
Strap department and have the optional storage
moved into the Belt department area.
 The macro will serve as a guide for future planning
and should be updated when new products arrive and
as departments change.
 Additionally, the company should take into
consideration that the hall standards are not in
compliance to standards and should be redesigned for
the safety of the operators.

15. REFERENCES
(1) Propper.com,. (2015). About Us. Recuperado
el 21 de febrero de 2015,
https://www.propper.com/about-us
(2) Tompkins, J.A., White J.A., Bozer, Y.A.
Frazelle, E.H., Tanchoco, J.M.A and Trevino, J.
(2010). Facilities Planning. Cuarta edición.
Wiley, New York.