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Facility Design-Week 1 Introduction to Facility Planning. Anastasia L. Maukar. Definition of Factory. Factory/Plant:. MACHINES/ EQUIPMENTS. RESOURCES. MAN. PRODUCTION SYSTEM. MATERIAL. ENERGY. INFORMATION. MONEY. FINISHED GOODS. Factory/plant. Facilities Planning. - PowerPoint PPT Presentation
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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.