Facilities Planning

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Facilities Planning - Unit 07Layout Design
Systematic Layout Planning
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Hierarchy of Facility Planning
Source for Figure Tompkins and White, Facilities
Planning, 2nd edition, Wiley
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Facility DesignSequential Approach vs.
Integrated Approach
Material Handling System Design
Sequential Approach
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Facility DesignSequential Approach vs.
Integrated Approach
Integrated Approach Impressive results in cost,
quality, productivity, sales, customer
satisfaction, delivery time, inventory levels,
space handling requirements, building size, etc.
Concurrent Engineering Terms of product, process,
scheduling and facility design planners work with
marketing, purchasing, etc. Personnel address the
design process in an integrated way.
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Requirements of a Good Layout

• an understanding of capacity and space
  requirements
• selection of appropriate material handling
  equipment
• decisions regarding environment and aesthetics
• identification and understanding of the
  requirements for information flow
• identification of the cost of moving between the
  various work areas

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Engineering Design Process
Typically, design problems do not have
well-defined, unique, optimum solutions. We are
interested in obtaining a satisfactory solution.

• General Procedure for Solving Engineering Design
  Problems
• 1. Formulate the problem.
• 2. Analyze the problem.
• 3. Search for alternative solutions.
• 4. Evaluate the design alternatives.
• 5. Select the preferred design.
• 6. Implement the design.

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Application of the Engineering Design Process to
Facility Planning

• 1. Define (or redefine) the objective of the
  facility
• Specify quantitatively the products to be
  produced or service to be provided.
• Specify the primary and support activities to be
  performed in accomplishing the objective
• Requirements for primary activities include
  operations, equipment, personnel, and material
  flows.
• 3. Determine the interrelationships among all
  activities
• Both qualitative and quantitative relationships
  should be defined.
• 4. Determine the space requirements for all
  activities
• These are determined considering the equipment,
  materials, and personnel requirements.

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Application of the Engineering Design Process to
Facility Planning

• 5. Generate alternative facility plans
• Including alternative facility locations and
  alternative designs for the facility.
• 6. Evaluate alternative facility plans
• Determine the important factors (see list of
  factors). For each candidate plan, evaluate if
  and how those factors will affect the facility
  and its operations.
• 7. Select a facility plan
• Cost may not be the only major consideration.
• Use the information in step 6 to determine a plan
  (pair-wise comparison is a good ranking
  procedure).

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Application of the Engineering Design Process to
Facility Planning

• 8. Implement the facility plan
• Considerable amount of planning must precede the
  construction of a facility or the layout of an
  area.
• 9. Maintain and adapt the facility plan
• The facility plan must be modified as new
  requirements are placed, e.g., new energy saving
  measures, changes in product design may require
  different flow pattern or handling equipment,
  etc.
• 10. Redefine the objective of the facility
• Similar to step 1.
• Changes in product design and/or quantities may
  require changes into the layout plan.

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Layout Planning Important Factors

• In developing well-thought facilities design
  alternatives it is important to look into issues
  such as
• a) Layout characteristics
• - total distance traveled
• - manufacturing floor visibility
• - overall aesthetics of the layout
• - ease of adding future business
• b) Material handling requirements
• - use for the current material handling
  equipment
• - investment requirements on new equipment
• - space and people requirements

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Layout Planning Important Factors

• c) Unit load implied
• - impact on WIP levels
• - space requirements
• - impact on material handling equipment
• d) Storage strategies
• - space and people requirements
• - impact on material handling equipment
• - human factors risks
• e) Overall building impact
• - estimated cost of the alternatives
• - opportunities for new business

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Facility Layout Procedures

• Naddlers Ideal System Approach (1961)
• Immers Basic Steps (1950)
• Apples Plant Layout Procedure (1977)
• Reeds Plant Layout Procedure (1961)
• Muthers Systematic Layout Planning (1961)

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Naddlers Ideal System Approach

• The ideal system approach is based on the
  following hierarchical approach toward design
• 1. Aim for the theoretical ideal system.
• 2. Conceptualize the ultimate ideal
• system.
• 3. Design the technologically workable
• ideal system.
• 4. Install the recommended system.

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Immers Basic Steps

• Immer described the analysis of a layout problem
  as follows This analysis should be composed of
  three simple steps, which can be applied to any
  type of layout problem. These steps are
• 1. Put the problem on the paper.
• 2. Show lines of flow.
• 3. Convert flow lines to machine lines.

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Apples Plant Layout Procedure
Apple recommended that the following detailed sequence of steps be used in designing a plant layout Apple recommended that the following detailed sequence of steps be used in designing a plant layout
1. Procure the basic data. 11. Determine storage requirements
2. Analyze the basic data. 12. Plan service and auxiliary activities.
3. Design the productive process. 13. Determine space requirements
4. Plan the material flow pattern. 14. Allocate activities to total space
5. Consider the general material handling plan 15. Consider building type
6. Calculate equipment requirements. 16. Consider master layouts
7. Plan individual work stations. 17. Evaluate, adjust and check the layout
8. Select specific material handling equipment 18. Obtain approval
9. Coordinate groups of related operations. 19. Install the layout
10. Design activity relationships. 20. Follow up on implementation of the layout
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Reeds Plant Layout Procedure

• In planning for and preparing the layout, Reed
  recommended that the following steps be taken in
  his systematic plan of attach
• 1. Analyze the product to be produced.
• 2. Determine the process required to
  manufacture the product.
• 3. Prepare layout planning charts.
• 4. Determine work stations.
• 5. Analyze storage area requirements.
• 6. Establish minimum aisle widths.
• 7. Establish office requirements.
• 8. Consider personnel facilities and
  services.
• 9. Survey plant services.
• 10. Provide for future expansion.

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Muthers Systematic Layout Planning Procedure
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Systematic Layout Planning ProcedureInformation
Gathering

• PQRST items
• Product what is to be produced
• Quantity volume to be produced
• Routing how it is to be produced
• Support services with what will we produce
• Timing/Transport when to produce and how to move
  parts in out
• Quantity Variety often dictate the layout type
  (product/process, etc.)
• can be used to determine
• which products justify their own lines,
• which families justify their own cells.

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Systematic Layout Planning ProcedureInformation
Gathering

• Photographs about the product
• Exploded drawings
• Engineering drawings of individual parts
• Parts list
• Bill of materials (structure of product)
• Assembly chart
• Route sheet
• Operations process chart
• Etc.

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Systematic Layout Planning ProcedureInformation
Gathering
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Systematic Layout Planning ProcedureInformation
Gathering

• Schedule design decisions tell us how much to
  produce and when to produce.

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Systematic Layout Planning ProcedureFlow
Analysis and Activity Analysis
Flow analysis concentrates on some quantitative
measure of movement between departments or
activities Activity analysis is primarily
concerned with the non-quantitative factors that
influence the location of departments or
activities Charts and diagrams useful in flow
analysis - Flow process chart - Multi-product
process charts - Flow diagram - From-to-charts
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Systematic Layout Planning ProcedureFlow
Analysis and Activity Analysis
Basic Flow Patterns
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Systematic Layout Planning ProcedureFlow and
Activity Analysis
Layout Types
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Systematic Layout Planning ProcedureFlow and
Activity Analysis
Layout Types
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Systematic Layout Planning ProcedureFlow and
Activity Analysis
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Systematic Layout Planning ProcedureFlow and
Activity Analysis - A1
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Systematic Layout Planning ProcedureFlow and
Activity Analysis A-2
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Systematic Layout Planning ProcedureFlow and
Activity Analysis

• Desirability (or lack) of locating two
  work-centers together
• information that is difficult to quantify
• (example 1) shipping receiving - share common
  facilities (e.g., loading docks)
• (example 2) engineering purchasing - efficient
  communication, quality,
• (example 3) environmental factors - delicate
  testing vs. vibration
• Summarized in a relationship or REL chart

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Systematic Layout Planning ProcedureFlow and
Activity Analysis
Code Reason 1 Frequency of use high
2 Frequency of use medium 3
Frequency of use low 4 Information
flow high 5 Information flow medium
6 Information flow low
Activity Relationship Chart
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Systematic Layout Planning Procedure Activity
Relationship Chart
Activity Relationship Chart
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Systematic Layout Planning Procedure Activity
Relationship Chart
From
To
Area (sq. ft.)
2
3
4
5
1. Credit department
100
2. Toy department
U
I
A
400
--
1
6
3. Wine department
U
X
300
--
1
4. Camera department
X
100
1
5. Candy department
100
Closeness rating
Letter
Reason for rating
Number
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Systematic Layout Planning Procedure Relationship
Diagram
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Systematic Layout Planning Procedure Relationship
Diagram (or Activity Relationship Diagram)
The number of lines here represent paths required
to be taken in transactions between the
departments. The more lines, the more the
interaction between departments.
Note here again, Depts. (1) and (2) are linked
together, and Depts. (2) and (5) are linked
together by multiple lines or required
transactions.
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Systematic Layout Planning Procedure Activity
Relationship Chart
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Systematic Layout Planning Procedure Relationship
Diagram
The Relationship Diagram positions activities
spatially. Proximities are typically used to
reflect the relationship between pairs of
activities
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Muthers Systematic Layout Planning Procedure
Based on the input data and an understanding of
the roles and relationship between activities, a
material flow analysis (from-to-chart) and an
activity relationship analysis (activity
relationship chart) are performed. From the
analysis performed, a relationship diagram is
developed.
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Systematic Layout Planning Procedure
Space Determination
Production-center method Converting method the
present space requirements are converted to those
required for the proposed layout Roughed-out
layout method using templates or models on the
layout to obtain an estimate of configuration and
space requirements Ratio trend projection method
for general space requirements e.g. square feet
per direct labor hour, square feet per unit
produced, etc.
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Systematic Layout Planning Procedure
Space Determination

• Raw material storage
• In-process inventory storage
• Finished-goods storage
• Aisles, cross isles, and main aisles
• Receiving and shipping
• Material handling equipment storage
• Tool rooms and tool cribs
• Maintenance
• Packaging

• Quality control and inspection
• Supervision
• Health and medical facilities
• Food service
• Lavatories, washrooms, etc.
• Offices
• Employee and visitor parking
• Receiving and shipping parking
• Other storage

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Muthers Systematic Layout Planning Procedure
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Systematic Layout Planning Procedure Relationship
Diagram
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Systematic Layout Planning Procedure Space
Relationship Diagram
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Systematic Layout Planning Procedure
Relationship diagram all departments are of
equal size. Space Relationship
diagram templates proportional in size to
departmental space requirement
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Systematic Layout Planning Procedure
Activity Relations and Relationship Diagram
Another example
Relationship diagram
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Systematic Layout Planning Procedure
Space relationship diagram
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Systematic Layout Planning Procedure
Alternative block layout
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Systematic Layout Planning Procedure

• Modifying considerations and limitations

• Site-specific and Operation-specific conditions
• possible adjustment to the layout
• Example
• Location of external transportation system (e.g.,
  rail, road, river access) ? may restrict the
  location of shipping and receiving
• limitations on access to utilities (HVAC,
  lighting, etc) in certain areas
• aisles should be straight and close to the point
  where move requests are generated without
  obstructing manufacturing activities

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Muthers Systematic Layout Planning Procedure
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Systematic Layout Planning Procedure

• Evaluation

• Factor-analysis method (evaluating the layout
  alternatives)
• List all of the factors to be considered
  important
• Weight the relative importance of each of these
  factors to each other
• Rate the alternative plans against one factor at
  a time
• Calculate the weighted rating values and sum up
  those values to obtain the total value for each
  of the alternatives
• Select the alternative with the highest total
  value
• Factors
• Cost, flexibility, maintainability, expandability
  (modularity), safety, operation ease

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Evaluation - Location Rating Factor
Systematic Layout Planning Procedure

• Identify important factors
• Weight factors (usually 0.00 - 1.00 or 0.00 -
  100)
• Subjectively score each factor
• Sum weighted scores

Also see Unit 06B
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Activity Relationship Charting
Systematic Layout Planning Procedure Example A
Page 1
A Absolutely necessary E Especially
important I Important O Okay U
Unimportant X Undesirable
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Systematic Layout Planning Procedure Example A
Page 2
Relationship diagram of original layout
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Systematic Layout Planning Procedure Example A
Page 3
Relationship diagram of revised layout
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Systematic Layout Planning Procedure Example B
Page 1
Branch Bank Example

• Area Space needs (ft2)
• Branch manager 200
• Head teller 150
• Teller counter/break room 600
• New accounts clerk 100
• Loan officers 200
• Customer waiting room/lounge 150
• Lobby 500

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Systematic Layout Planning Procedure Example B
Page 2
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Systematic Layout Planning Procedure Example B
Page 3
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Systematic Layout Planning Procedure Example B
Page 4
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Systematic Layout Planning Procedure Example B
Page 5
12-8
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Principles of a Good Layout - Manufacturing

• Straight-line Flow Pattern when possible
• Backtracking kept to a Minimum
• Predictable Production Time
• Little In-process materials storage
• Open Floor plans so everyone can see what is
  going on
• Bottlenecks under control
• Workstations close together
• Minimum of material handling
• Easy adjustment to changing conditions

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Layout Example - Manufacturing
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Principles of a Good Layout - Service

• Easily understood service flow pattern
• Adequate waiting facilities
• Easy communication with customers
• Customers in view of servers throughout the
  process
• Clear entry and exit points with adequate
  checkout facilities
• Customers see only what you want them to see
• Balance between waiting and service areas
• Minimum walking and material movement
• Lack of clutter

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Principles of a Good Layout - Service

• Office Layout Considerations
• Layouts need to account for physical environment
  and psychological needs of the organization
• One key layout trade-off is between proximity and
  privacy
• Open concept offices promote understanding
  trust
• Flexible layouts incorporating office
  landscaping help to solve the privacy issue in
  open office environments