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Facility Design-Week 1Introduction to Facility Planning

Anastasia L. Maukar

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Definition of Factory

Factory/Plant:

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Factory/plant

PRODUCTION SYSTEM

RESOURCESMACHINES/EQUIPMENTS

MATERIAL

INFORMATIONMONEY

ENERGY

MAN

FINISHED GOODS

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Facilities Planning

Facilities planning determines how an activity’s tangible fixed assets best support achieving the activity's objectives

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Facilities Planning

Examples:a. In manufacturing, the objective is to support

production.

b. In an airport, the objective is to support the passenger airplane interface.

c. In a hospital, the objective is to provide medical care to patients.

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Facility Planning-Hierarchy

Facility Planning

Structural Design

Facility Location

Facility Design

Layout Design

Handling System Design

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Facility Planning

Location : is the placement of a facility with respect to customers, suppliers, and other facilities with which it interfaces.

Structure : consists of the building and services (e.g., gas, water, power, heat, light, air, sewage).

Layout :consists of all equipment, machinery, and furnishings within the structure.

Handling System :consists of the mechanism by which all interactions required by the layout are satisfied (e.g., materials, personnel, information, and equipment handling systems).

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Typical Design and Planning Problems

Facility Location Type, Number of Material Handling Devices

Distribution of goods Determination of Machine (Service) Cells

Type, Number of Equipment Required

Inventory Control Layout of Machine (Service) Cells

Design of Components (Service)

Overall System Design

Determining Flow of Products (People)

Quality Control and Customer Service

Tooling, Fixture Determination

Process Planning

Type, Volume of Products to be Manufactured or Service to be Provided

Determining Material Handling Methods

Scheduling and planning of Jobs (Service steps)

Manufacturing (Service) Processes Required

Layout of Equipment Within Each Cell

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Facility Planning Objectives

1. Support the organization's mission through improved material handling, materials control, and good housekeeping.

2. Effectively utilize people, equipment, space, and energy.

3. Minimize capital investment.

4. Be flexible and promote ease of maintenance.

5. Provide for employee safety and job satisfaction.

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Issues in Facilities Design

Minimize investment in new equipmentMaximize production throughput rateUtilize space most efficientlyProvide for the safety and comfort of employeesMaintain a flexible arrangementMinimize materials handling costFacilitate the manufacturing processFacilitate the organizational structure

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Facility Plant Layout

Facility layout: Arrangement of machines, storage areas, and/or work areas usually within the confines of a physical structure, such as a retail store, an office, a warehouse, or a manufacturing facility. for the location of all machines, utilities, employee

workstations, customer service areas, material storage areas, aisles, restrooms, lunchrooms, internal walls, offices, and computer rooms

for the flow patterns of materials and people around, into, and within buildings

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Why is facilities layout important?

20-75% of product cost attributed to materials handling (Sule, 1991 and Tompkins et al. 2003)

Layout of facilities affects materials handling costs

Facilities includes machines, departments, workstations, locker rooms, service areas, etc.

“You can make as many mistakes as you want in layout planning, and they’ll all any for themselves if they avoid mistakes in the physical installation”

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Types of layout problems

Layout of a service systemLayout of a manufacturing facilityWarehouse layoutNontraditional layout

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Applications

Manufacturing HealthcareService

Restaurants Banks Airports Entertainment

Logistics and Distribution Ports/Terminals Distribution Centers

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Service Layout Problem

Minimize transportation among personnel Communication and privacy Conform building codes Safety & security for the personnel

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Retail/Service Layout

Design maximizes product exposure to customers

Decision variables Store flow pattern Allocation of (shelf) space to products

Types Grid design Free-flow design

Video

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Service system layout – Grocery store

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Operations review for office layouts (Suskind, 1989) Is the company outgrowing its space? Is available space too expensive? Is building in the proper location?How will a new layout affect the organization and

service?Are office operations too centralized or decentralized?Does the office structure support the strategic plan? Is the new layout in tune with the company’s imageDoes customer physically participate in service delivery?

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Office structures

Closed structureSemiclosed structureOpen structureSemiopen structure

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Closed structure

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Semiclosed structure

Teller Teller Teller

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Open structure

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Semiopen structure

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Service Layout

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Service Industry - Bank

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Manufacturing layout

Minimize transportation cost of raw materials, sub-assemblies, work-in-process inventory, tools, parts, finished products, etc.

Facilitate traffic flowImprove employee moraleMinimize or eliminate risk of injury and property

damageEase of supervision and face-to-face

communication

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Assembly facility layout

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Driveway layout

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Warehouse layout

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Warehouse is a facility for storing merchandise, commodities or other items

4 main warehouse functions1. Receiving2. Storing3. Order picking4. Shipping

Warehouse layout

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• Where to locate receiving and shipping functions?

• Should the two functions be combined at one location or separated?

Warehouse layout

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Warehouse Layout Problem

Goal: utilize space effectively to minimize storage and material handling cost(MHC).

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Warehouse Layout ProblemFactor: shape and size of aisle,

warehouse height, location and orientation of docking area, types of rack, storage & retrieval automation

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Warehouse Layout Problem

Shape and size of aisle factor MH equipment/ device

Types of rack

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Warehouse Layout

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Nontraditional layout

Keyboard layoutIC board layoutComputer disk storage layoutAirport gate layout

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Non Traditional Layout Problem

Ex: Control panel LP in the design of a computer backboard.