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Production Plan Achieveit Assignment # 8

The document describes the production process and materials for geotubes. Geotubes are made from permeable geotextiles that are filled with dredged soil to create containment structures. Coco fiber is discussed as a potential geotextile material due to its high tensile strength, durability, and resistance to degradation. The production process involves securing facilities, equipment, and materials like coco fiber, mats, and sand. Non-woven geotextiles are manufactured through needle punching to entangle fibers. Initial capital needs are estimated at over $7 million which covers direct materials, manufacturing overhead, and facilities.

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Jubilyn Libor
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165 views

Production Plan Achieveit Assignment # 8

The document describes the production process and materials for geotubes. Geotubes are made from permeable geotextiles that are filled with dredged soil to create containment structures. Coco fiber is discussed as a potential geotextile material due to its high tensile strength, durability, and resistance to degradation. The production process involves securing facilities, equipment, and materials like coco fiber, mats, and sand. Non-woven geotextiles are manufactured through needle punching to entangle fibers. Initial capital needs are estimated at over $7 million which covers direct materials, manufacturing overhead, and facilities.

Uploaded by

Jubilyn Libor
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Production Plan

AchieveIT

Assignment # 8

PRODUCT DESIGN

Geotubes are made from permeable, soil-tight geotextiles that are filled with dredged soil. The
performance of pilot scale field tests using a geotube is presented. The geotube was made from a
woven geotextile. It was filled by hydraulically pumping dredged silty clay material into it. The
variations of the shape of the geotube and the dry unit weight, moisture content, and vane shear
strength of the soil at various locations in the geotube with time are summarized. Based on this
study, it appears that geotubes are feasible construction materials for use in coastal engineering
projects.

Coco fiber has the highest tensile strength among fibers and retains much of its tensile strength
when wet. Because of its high tensile and wet strength, cocomat can be used in very high flow
velocity conditions. Fibers also have high durability and slow biodegradation. These properties
are attributed to its high lignin content (Vishnudas et al, 2006). Cocomat can be woven or
nonwoven. Woven mats can be of different mesh sizes. In nonwoven mats, loose fibers are
arranged randomly and then mechanically entangled by needle punching. Physically, woven and
nonwoven mats differ in that more open area means more loose mesh and, therefore, lower
density. Nonwoven mats are normally denser than woven mats.

Among the natural materials used as a geotextile is coconut fiber. It is produced from coconut
husks (Cocus Nucifera) which are waste materials in the coconut industry. The process of
extracting fiber from coconut husk is called retting, wherein husks are submerged in water
storage tanks for a period of time. In the process, water interacts with the fiber matrix to remove
impurities (Vishnudas et al, 2006).

MATERIALS USED FOR GEOTUBE:

● Coco fiber/Coir - Coir: also known as a Coir mat is a type of natural fiber made from
the natural fiber that taken from the exterior husk of coconuts. Often this materials is
made into Turf Reinforcement Mats (TRM), doormats, mattresses, or even into
brushes. Many enjoy the natural aspect of using coconut fiber instead of synthetics and its
naturally durable properties along with its resistance to salt water damage also being
desirable.

● Mat

● Sand

PROCESS OF DEVELOPMENT

Non-woven Geotextile Manufacturing - are manufactured by entangling fibers, both long and
short, together through either needle punching or other suitable methods. In some instances,
thermal treatment is used to improve further the tensile of the geotextile. Because of this
manufacturing process, alongside their permeability, non-woven geotextiles are typically used in
drainage applications, separation, filtration as well as protection. Needle-punched non-woven
fabrics are usually made by taking a huge number of tiny textiles and using a barbed needle to
mesh the fabrics together. Non-woven geotextiles are usually measured by their weight, for
example, gsm/grams per square meter, or ounces per square yard. The non-woven geotextile
usually breaks down quicker than woven geotextiles. However, for construction projects where
water pooling is the main concern, non-woven fabrics are usually the best choice as they enable
better drainage.
TIMELINE AND COST OF EACH STEPS

Production Cost Time per day

1st 2nd 3rd 4th 5th 6th 7th

Securing the 180,000


storage and
production
facilities

Buying 6,000,000
necessary
equipment

Filament 0
Extrusion

Fiber Cutting 0

Bale Opening 0
& Blending

Carding and 0
Cross lapping

Needling 0

Inspection, 0
Slitting,
Winding
SUMMARY OF TOTAL COST OF PRODUCTION

INITIAL INVESTMENT REQUIREMENT REPORT

Direct Materials

Quantity Amount

Coco Fiber/Husk 100 sack 6,000

Machine 1 unit 6,000,000

Sand (1 cu.m.) 50 35,000

Total Direct Material Cost 6,041,000

Manufacturing Overhead Cost

Indirect Labor 15 225,000

Vehicles 3 672,000

Rent 1000 sqm 180,000

Utilities 50,000

Total Manufacturing Overhead 1,127,000


Cost

INITIAL CAPITAL NEEDED 7,168,000

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