An-Najah National University

Faculty of Engineering and Information Technology

Industrial Engineering Department

Jadallah factory

Facility Planning and Design

Prepared by:
Ahmad Tayseer Hala Habash
Izz kabi shahd Hussein
Supervisor:
Dr. Muawia Ramadan
Table of Content
Abstract.......................................................................................................................................... 3
Chapter 1 ....................................................................................................................................... 4
1.1 Introduction........................................................................................................................................ 5
1.2 Problem Statement ............................................................................................................................ 6
1.3 Project Objectives .............................................................................................................................. 7
Chapter 2 ....................................................................................................................................... 8
2.1 Operation analysis: ............................................................................................................................ 9
2.2 Material: ...........................................................................................................................................13
2.3 Material handling ............................................................................................................................15
2.4 Tolerance ..........................................................................................................................................16

Table of Figure
Figure 1 Logo of Jadallah factory ................................................................................................................... 7
Figure 2 Machine 2 ........................................................................................................................................ 9
Figure 3 Machine 1 ........................................................................................................................................ 9
Figure 4 Machine 3 ........................................................................................................................................ 9
Figure 5 Machine 4 ......................................................................................................................................11
Figure 6 Machine 5 ......................................................................................................................................11
Figure 7 Machine 8 ......................................................................................................................................11
Figure 8 Machine 6 ......................................................................................................................................11
Figure 9 plastic material (HDPE) ..................................................................................................................13
Figure 10 PET plastic material......................................................................................................................14
Figure 11The current layout of Jadallah factory (second floor) .................................................................17
Figure 12 The current layout of Jadallah factory (First floor) ......................................................................18
Abstract

Jadallah Factory for Tahini and Halawa is a new establishment that was founded in 2019.
The factory is situated in the Industrial Zone in Nablus and occupies a two-story building
with an area of 400 m² for each floor. The factory has several machines that are responsible
for the production of tahini, including a sesame washer, a dryer, a coarse mill, three fine
mills, and four roasters. Additionally, there are six to seven workers that operate the
machines around the clock.

Our project aims to improve the factory's design and layout by analyzing its current
production processes and identifying future requirements to enhance efficiency and
effectiveness in achieving the organizational goals. During our visit to the factory, we
identified several problems that impact the production speed and profitability of the
factory. These issues include a manual and labor-intensive production process, an
insufficient number of workers, slow and outdated machinery, and incomplete production
lines.

To address these challenges, our project's goals are to minimize delays and bottlenecks in
the production system, maintain operational flexibility, ensure optimal utilization of
resources, provide design flexibility to adapt to future requirements, and establish effective
supervision and production control. By achieving these goals, we aim to enhance the
factory's production capacity, increase profitability, and ensure its sustainability.
Chapter 1
1.1 Introduction

Tahini is a versatile and popular food product that is widely used in many cuisines,
especially in Middle Eastern and Mediterranean cuisine. It is a paste made from sesame
seeds that are soaked in water and crushed to separate the bran from the kernels. The
resulting kernels are then toasted and ground to produce a smooth, oily paste. It can also
be prepared with untoasted seeds, which is called "raw tahini."

Due to the high oil content of tahini, some manufacturers recommend refrigeration to
prevent spoilage. However, others argue that refrigeration can make the product more
viscous and more difficult to serve.

Jadallah Factory for Tahini and Halawa is a relatively new factory that was established in
2019 and is located in the Industrial Zone of Nablus. The factory is spread across two
floors, each with an area of 400 square meters, and contains various machines and
equipment for the production of tahini. These machines include a hulling machine, a
washing machine, a drying machine, several mills for grinding the sesame, and roasting
machines.

During our visit to the factory, we observed that the tahini production process begins with
the hulling machine, which separates the black husk from the white sesame. The sesame is
then washed in a large basin of water, followed by another basin to rinse it thoroughly. The
sesame is then transferred to the drying machine before it is roasted and ground in the mills.
The final product is cooled, sieved, and transported to the filling and packaging machines.

Despite the factory's best efforts, we identified several problems during our visit that
hindered the speed of production and limited the factory's profitability. The first issue we
identified was that most of the work was manual and required significant effort from the
workers. Additionally, the factory had a limited number of workers, with only 6 workers
performing all the tasks. Furthermore, the machine that dried the sesame was old and slow,
taking 6 to 7 minutes to dry the sesame. We suggested replacing it with a faster machine
that could dry the sesame seeds in 2 to 3 minutes.

We also noticed that the production speed in the mills was relatively low compared to
modern mills, with the first mill producing 130 kilos of tahini per hour and the second mill
producing 240 kilos of tahini per hour. Finally, the Halawa machine did not have a
complete production line, which affected its efficiency.
1.2 Problem Statement

The Jadallah factory in Nablus produces tahini with great effort to keep their business
running. However, our team noticed several issues during our visit that negatively impact
the production speed and profitability of the factory. Therefore, we aim to address these
problems to improve production efficiency and increase profits.

The problems that we discovered during our visit are as follows:

1- Manual Labor: Most of the work in the factory is done manually, which requires a
significant amount of effort from the workers. This can lead to a decrease in
productivity and worker fatigue.

2- Lack of Workers: The factory only has six workers who are responsible for all the
tasks, which is not enough to meet the demand. This leads to a slowdown in the
production process, causing delays and potential loss of business.

3- Old Drying Machine: The sesame drying machine used in the factory is very old
and slow. It takes 6 to 7 minutes to dry the sesame seeds, which can cause a
bottleneck in the production process. Replacing it with a faster machine that can dry
the sesame seeds in 2 to 3 minutes can significantly improve production speed.

4- Low Production Speed: The current production speed in the first mill is 130 kilos of
tahini per hour, while the second mill produces only 240 kilos of tahini per hour.
Modern mills have higher production speeds, and upgrading the machinery can
result in a significant increase in production.

5- Incomplete Halawas Production Line: The Halawas machine lacks a complete

production line, which can lead to delays and inconsistencies in the final product.
Implementing a complete production line can lead to a more streamlined production
process and improved product quality.

Addressing these problems will increase production speed and efficiency, which can help
the Jadallah factory increase profitability and secure its future in the competitive tahini
market.
1.3 Project Objectives

The goal of this project is to increase the production and profitability of the Jadallah factory
by addressing the various problems that were identified during our team's visit. By
implementing the necessary changes and improvements, we hope to achieve a more
efficient and effective manufacturing process for tahini production. The following are the
specific project goals:

1- Develop a plan to automate manual tasks to reduce the workload and effort required
from workers.
2- Increase the number of workers to improve the production process and reduce the
workload for each worker.
3- Replace the old and slow sesame drying machine with a faster and more efficient
machine to reduce the production time.
4- Upgrade the mills to modern and more efficient mills with higher production speeds
to increase the overall production rate.
5- Develop a complete production line for the Halawas machine to improve its
efficiency and output.
6- Ensure the new machines and equipment are maintained regularly to prevent
downtime and loss of production.
7- Train workers on the new equipment and processes to ensure they can operate them
effectively and efficiently.

By achieving these goals, we believe that the Jadallah factory will be able to increase its
production rate, reduce production time and effort, and ultimately achieve a higher level of
profitability.

Figure 1 Logo of Jadallah factory

Chapter 2
2.1 Operation analysis:

During our visit to the factory, we saw that the stages of tahini production start from placing the
sesame inside one of the mills for hulling, then it is placed in a large basin of water to separate the
black husk from the white sesame, after which the sesame is transferred to another basin to wash
it again, before it is entered into its oven. To prepare it for the final stages of production, then it is
taken out in one of the rooms to be cooled and sieved, to be transported to the final stage through
which it is placed inside its own machinery, to be squeezed and extracted into a paste that is usable.

Figure 3 Machine 1 Figure 2 Machine 2

Figure 4 Machine 3

After studying the first three operations we so there is a chance to combine them on one
operation by replace the first three machines by one machine that can perform all three
operations at one time, which will lead to reduce cycle time from 3.5 hr. to 1.5 hr., also this will
reduce number of personal needed from 3 to 1.
Below you can see the Flow Chart of the first three operations.

The Beginning

Sesame arrives at the factory.

Transfer Sesame to the second

floor.

Put sesame in the first machine.

Water is run on it to soak it.

The water is stopped after a

certain period.

Not enough
Enough

Check the
amount of water

Leave it soaked with water

Transfer the sesame and for half an hour.
husks to the third machine.
Filter the sesame from the
water.
The third machine works to
separate the husk and dirt
from the sesame.
Transfer the sesame to the
second machine.
Transfer the sesame to the
fourth machine.
The second machine works
on peeling sesame.
After the completion of the third machine, the sesame is transferred to the fourth machine
manually. The fourth machine washes the sesame with water and salt, where the sesame is placed
in the machine, and water and salt are poured on it and left for 20 minutes.
After the washing is finished, the water is filtered and transferred automatically to the fifth
machine. The fifth machine dries the sesame well from the water and then sends it through a hole
of 50 cm in diameter in the ground to the basement.

Figure 5 Machine 4 Figure 6 Machine 5

The sesame is lowered directly to 4 roasters for roasting. One roaster can accommodate 180
kilograms of sesame, But it is used on a maximum of 125 kilos to reduce the time of roasting one
batch.
The roasting process continues for 55 minutes per ton, after which each roaster is manually
unloaded within 10 minutes and transferred automatically to the seventh machine for sifting
sesame, and then they are automatically transferred to the eighth machine, which works on
grinding Sesame to produce tahini. Then automatically transported to storage tanks, packaged and
sold to shops.

Figure 8 Machine 6 Figure 7 Machine 8

Below you can see Flow Chart of the completion of operations

Wash the sesame with water and

salt

Automatically transferred to the fifth

machine

Dry the sesame well

Transfer it automatically to the toaster

Remove it from the toaster manually

It is automatically conveyed to the

sieving process

It is automatically transferred to the

next process

Grinding sesame and then producing

tahini

Transported to the packing line and

packaged

The End
2.2 Material:

In this aspect, we took the material used for packing the final product, which is a plastic material
(HDPE) and is not optimal, and there is a better alternative (PET).
Our analysis was as follows:

After conducting research on HDPE and Polyethylene Terephthalate (PET), it is clear that each
material has its own set of advantages and disadvantages. HDPE, for example, has several
disadvantages that limit its potential use in certain applications. One of the most significant
drawbacks of HDPE is its poor weathering capabilities, as it is known to become brittle and lose
its strength over time when exposed to UV radiation. HDPE is also highly flammable and sensitive
to stress cracking, which can compromise its durability and reliability.
Another disadvantage of HDPE is that it is not biodegradable and cannot be composted, which can
have negative environmental impacts. HDPE is also not resistant to oxidizing acids or chlorinated
hydrocarbons, which limits its potential use in certain industries. Finally, HDPE has a high
coefficient of thermal expansion, which can cause dimensional instability in finished products.

Figure 9 plastic material (HDPE)

In contrast, PET has several advantages that make it an attractive alternative to HDPE. PET is
shatterproof, non-reactive when in contact with food or water, and provides a high strength-to-
weight ratio. Its lightweight nature also provides cost savings when transporting products using
PET packaging.
Overall, while HDPE has its benefits, its disadvantages may limit its potential use in certain
applications. In contrast, PET has several advantages that make it an attractive alternative to
HDPE. Its shatterproof nature, non-reactivity, and high strength-to-weight ratio make it ideal for
use in a variety of applications. However, it is important to consider the potential costs associated
with switching from HDPE to PET, such as retooling equipment and training staff on the new
material. Despite these costs, the long-term benefits of using PET may be worth the investment,
including improved product quality, efficiency, and potential cost savings in the transportation of
goods.

Figure 10 PET plastic material

The transition from the first material to the second achieves the following:
• less expensive and lighter material
• material that is easier to be processed
• Use salvage material: as some studies shows that PET can be recycled and empty cans
can be collected and used by selling them to a recycling plant
2.3 Material handling

In general, the plant is considered a young manufacturer, and the demand for its products is still
quite modest. Therefore, the factory is subject to traditional transportation methods, with workers
manually and without assistance transporting raw materials from the warehouse of raw materials
and finished products to the warehouse of finished products.

But we have made some proposals that will be valuable in the future to reduce material handling
operations when the demand becomes more than the current situation and thus becomes
economically justified.

1. Firstly: they can use Manually Operated Low-Lift Pallet Truck, which relieves workers and
saves time
2. Second: For the purpose of increasing accuracy in stock control in the future, it is preferable to
use a bar code (but for now the quantities can be followed mentally)

Thus, we have achieved the following:

1) First: Reducing the time spent on material handling
2) Second: the use of modern mechanical equipment
3) Reducing the effort on the workers
4) Finally: consider applying bar coding
2.4 Tolerance

One of the operations that takes place in the factory is weighing the packed cans, and this process
is done manually for each ready can, where a worker takes each can from the production line and
places it on an electronic scale to make sure that it matches the required weight, whether it is a 1
kg can or 0.5 kg, this consumes them a lot of time and effort and indirectly raises costs and thus
reduces factory productivity.

Figure 11 Tahini filling machine

One of the proposed solutions is to convert the inspection process into an automated process by
placing a sensor on the packing pipe that controls the opening and closing of the opening of the
pipe. Thus, we have controlled the weight of the output cans with high accuracy, and we have
saved the examination time for each can and reduced the costs related to examination.
Also, with regard to the roasting temperature, the factory restricts the process to a temperature of
210 degrees with an upper and lower tolerance of 10 degrees, this is to make the sesame take the
golden color that affects the color of the final product, but it was through some similar studies that
it was proven that the temperature is 180 degrees with a tolerance of 20 degrees higher. And down
enough to deliver the sesame to the desired color, and with this modification, the special costs of
this process are reduced.

Figure 12 Sesame roasting machine

2.5 Flow diagram of Jadallah factory

Figure 11The current layout of Jadallah factory (second floor)

Figure 12 The current layout of Jadallah factory (First floor)
 Operator Machine 1 Machine 3 Machine 5 Machine 6 Machine 8

8:00 AM L-M1 Unloaded & Idle Idle Idle Idle

loaded
30 min
Machining Loading
& unloaded
30 min
Machining Loaded
& unloaded
30 min Machining Loaded
& unloaded Machining Loaded
& unloaded Machining
30 min & unloaded

30 min

30 min
 Machine Machine Function Area (m^2)
Number Name
1) M1 Put sesame in it and soak it with water 4.5
2) M2 Put sesame in it and soak it with water 2.5
3) M3 Sesame peeling 1.76
4) M4 Separate the husk from the sesame 4.52
5) M5 Separate the husk from the sesame 4.52
6) M’ Combined machine 4
7) M6 Sesame wash 3
8) M7 Sesame wash 3
9) M8 Sesame drying 4.52
M9 Sesame roasting 18
10)
M10 Sesame roasting 18
11)
M11 Sesame roasting 18
12)

13) M12 Sesame roasting 18

14) M13 Sesame Sieve 1.4

15) M14 Sesame grinding 2.7

16) M15 Tahini filling 3

Store Number Store Name Function Area (m^2)

1) S1 Store for raw materials 7.5

2) S2 Store for raw materials 50

3) S3 Store for raw materials 24

4) S4 Store for Finished products

Four factors were taken into consideration with different weights in
the selection process of the new layout:

Factor Weight
Plant service requirements and areas 35%
Less distance travelled 20%
Extra inventory space 30%
Maintenance requirements and areas 15%

Factor Weight Current layout

Score Weight
Score
Plant service requirements 35% 7.5 2.625

and areas

Less distance travelled 20% 5.2 1.04

Extra inventory space 30% 6.7 2.01

Maintenance requirements 15% 5 .75

and areas
Total 6.425
Find the cycle length of the machine assignment problem :

Am1= 40 min , bm1= 180 min , tm1=15 min

Am3= 30 min , bm3= 0 , tm3= 60 min
Am5=20 min , bm5 = 0, tm5 = 30 min

Am6= 10 min , bm6= 0 , tm6= 40 min

Am8= 10 min , bm8= 0 , tm8=90 min

Machine cycle time ( Tm ) : (a + t)

Machine 1 = 40 + 15 = 55 min

Machine 3 = 90 min
Machine 5 = 50 min
Machine 6 = 50 min
Machine 8 = 100 min

Cycle length = 100 min

Total time operator needs to work during the full cycle (To) : Σ(ai + bi)
(40+180) + (30) + (20) + (10) + (10) = 290 min

→ Since To < Tm cycle, then Cycle time is 290 minutes = Tc

From-to-chart :
The following diagram shows the distances between the machines on each floor .

Floor Routing
Floor 2 M1-M3-M5-M6-M8
Floor 1 M9-M10-M13-M14

Floor 2 :

M1 M3 M5 M6 M8

M1 - 2.71 4.69 3.58 2.42

M3 2.71 - 3.95 4.05 4.3

M5 4.69 3.95 - 2.4 4.2

M6 3.58 4.05 2.4 - 2.75

M8 2.42 4.3 4.2 2.75 -

Triangular mileage chart for floor 2 :

From-to-chart for floor 1 :

M9 M10 M13 M14 M15

M9 - 2.4 9.7 11.7 11.4

M10 2.4 - 7.3 9.4 6.9

M13 9.7 7.3 - 6.5 3.7

M14 11.7 9.4 6.5 - 3.2

M15 11.4 6.9 3.7 3.2 -

Triangular mileage chart for floor 1 :

Find the cycle length of the machine assignment problem :
for the new path ( with new machine )

Machine cycle time ( Tm ) :

Machine M’ = 130

Machine 6 = 50 min

Machine 8 = 100 min

Cycle length = 130 min

Total time operator needs to work during the full cycle (To) :
(55)+ (10) + (10) = 75 min

→ Since To > Tm cycle, then Cycle time is 75 minutes = Tc

From-to-chart :
The following diagram shows the distances between the machines for the new path .

Floor Routing
Floor 2 M’-M6-M8

M' M6 M8

M' - 4 5.9

M6 4 - 2.75

M8 5.9 2.75 -

Triangular mileage chart for new path :