Degree Name

BS in Industrial Engineering


Industrial and Manufacturing Engineering Department


Kurt Colvin


This report details a facilities design for Ernie Ball’s guitar and bass guitar manufacturing facility in San Luis Obispo, CA. Specifically, this project will redesign the layout for the Woodshop, the largest of the 5 manufacturing cells in the facility. This project was completed using the Systematic Layout Planning procedure and focused mostly on phase II and III in which the specifics for a layout are determined, however, space requirements were not evaluated as it was not within scope.

The first step was to develop departments in the facilities; two master departments were identified for the neck manufacturing process and the body manufacturing process. Within each of these, smaller departments were identified, five in the body department and nine in the neck department. These departments were then organized within the walls of the facility using an Activity Relationship Diagram.

Three alternative layouts were generated. The first is called Alternative A: Least Change, then Alternative B: Least Forklift Travel and finally Alternative C: Separated. These layouts were evaluated according to metrics developed with input from the client. Analysis determined that Alternative A: Least Change was the best choice. There is a cost of $2400 associated with implementing this change, and with a savings of 460 feet, it will be paid back in 9 months.