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Systematic Facilities Planning. An Overview & Perspective. SYSTEMATIC FACILITIES PLANNING. Systematic : Organized, disciplined rational approach to a problem Facilities : Building, production & material handling equipment, land, access (supporting equipment) - PowerPoint PPT Presentation
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Systematic Facilities PlanningSystematic Facilities Planning
An Overview & PerspectiveAn Overview & Perspective
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SYSTEMATIC FACILITIES SYSTEMATIC FACILITIES PLANNINGPLANNING
SystematicSystematic::Organized, disciplined rational approach to a Organized, disciplined rational approach to a problemproblem
FacilitiesFacilities::Building, production & material handling Building, production & material handling equipment, land, access (supporting equipment, land, access (supporting equipment)equipment)
PlanningPlanning::Decide a course of action based on facts and Decide a course of action based on facts and analysisanalysis
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THE OBVIOUSTHE OBVIOUS““The obvious is that which is never seenThe obvious is that which is never seen
until someone expresses it simply”until someone expresses it simply”
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Obvious?Obvious?
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THE OBVIOUSTHE OBVIOUS
Systematic Facilities Planning fits in this Systematic Facilities Planning fits in this category:category: Common SenseCommon Sense Prior ExperiencePrior Experience Simple Numerical MethodsSimple Numerical Methods Visual RepresentationsVisual Representations
Practical PerceptivenessPractical Perceptiveness
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PRODUCTIVE SYSTEMSPRODUCTIVE SYSTEMSCUSTOMERS
Conversion Process
*Operations
*Transformations
*Activities
*Interrelationships
*Workers*Managers*Equipment*Facilities*Materials*Energy*Information*Environment
INPUTS
*Goods
*Services
OUTPUTS
Information feedback on performance
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FACILITIES PLANNING AND DESIGNFACILITIES PLANNING AND DESIGN
II PROCESSPROCESSConceptualizeConceptualizePlanPlanAnalyzeAnalyzeDesignDesignImplementImplement
Inter-RelationshipsInter-Relationships
ProductiveSystems
PeopleMaterialsInformation FLOWEquipmentMethods
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ModelsModels Physical ModelsPhysical Models Analog ModelsAnalog Models Mathematical ModelsMathematical Models
SYSTEMATIC FACILITIES SYSTEMATIC FACILITIES PLANNINGPLANNING
Modeling ToolsModeling Tools Mathematical ProgrammingMathematical Programming Queuing ModelsQueuing Models Simulation ModelingSimulation Modeling
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WHY PLAN FACILITIESWHY PLAN FACILITIES
The primary causes that trigger new or The primary causes that trigger new or altered facilities are:altered facilities are:1. Expanding production, based on increased demand.
2. Entering a new field of endeavor.
3. Replacing an obsolete or inadequate facility.
4. Reallocating or consolidating production facilities.
5. Improving service to market(s).
LONG TERM STRATEGIC DECISIONS
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THE NEED FOR GOOD FACILITIES PLANNINGTHE NEED FOR GOOD FACILITIES PLANNING
1.1. Plant facilities influence the costs of operating and therefore Plant facilities influence the costs of operating and therefore profits.profits.
2.2. Planning allows facilities to comply with laws ad/or regulations.Planning allows facilities to comply with laws ad/or regulations.3.3. Facilities involve high capital-cost expenditures.Facilities involve high capital-cost expenditures.4.4. Facilities are fixed investments, not readily convertible to money Facilities are fixed investments, not readily convertible to money
or resale.or resale.5.5. Facilities are inflexible (i.e. physically fixed and have limited Facilities are inflexible (i.e. physically fixed and have limited
opportunities to be changed).opportunities to be changed).6.6. Facilities are long term commitments with protracted periods of Facilities are long term commitments with protracted periods of
financial return.financial return.7.7. Facilities planning, design and construction require long lead Facilities planning, design and construction require long lead
times.times.8.8. Sound plans for implementation can avoid disruptions in Sound plans for implementation can avoid disruptions in
production, and discontinuities for shipping or delivery.production, and discontinuities for shipping or delivery.9.9. Operations often produce detrimental wastes that affect entire Operations often produce detrimental wastes that affect entire
communities.communities.
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THE NEED FOR GOOD FACILITIES PLANNINGTHE NEED FOR GOOD FACILITIES PLANNING
10. The safety, convenience, appearance, and comfort of industrial facilities influence the attitudes of and the ability to attract suitable employees.
11. Industrial facilities must be planned to meet anticipated future requirements yet compete profitably today.
12. Facilities need to be planned for an appropriate degree of flexibility, expandability, versatility…
13. Good planning buys time for making commitments; it minimizes being taken by surprise.
14. If plans are made, managements can react faster and take advantage of business opportunities that arise.
15. Good planning, especially if presented well visually, is an aid to obtain financing monies.
16. The single most important cause of high materials handling costs is “ad hoc” expansion of plant facilities “in the absence of a strategic site-development plan.”
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SYSTEMATIC PLANNING OF INDUSTRIAL SYSTEMATIC PLANNING OF INDUSTRIAL FACILITIES (SPIF) DEFINEDFACILITIES (SPIF) DEFINED
SPIF is an organized, structured system of SPIF is an organized, structured system of determining for an industrial plant what its determining for an industrial plant what its current and future facilities should be. It is an current and future facilities should be. It is an integrated approach to planning the land, integrated approach to planning the land, buildings, machinery, and equipment for an buildings, machinery, and equipment for an industrial enterprise, and in so doing, SPIF industrial enterprise, and in so doing, SPIF involves:involves:
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SYSTEMATIC PLANNING OF INDUSTRIAL SYSTEMATIC PLANNING OF INDUSTRIAL FACILITIES (SPIF) DEFINEDFACILITIES (SPIF) DEFINED
1. A framework of four planning phases through which each project proceeds.
2. Five physical components of an industrial facility, each with its distinct sequence of three planning fundamentals.
3. Certain short-range and long-range inputs.4. Appropriate non-physical influences.5. A sequential planning pattern that converts the
inputs and influences to a facilities plan.6. A set of conventions for rating, recording, and
visualizing the analyses, work sheets, and planning documents.
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FACILITIES PLANNING AND DESIGNFACILITIES PLANNING AND DESIGN
Basic Elements of Layout PlanningBasic Elements of Layout Planning Product Product Quantity Quantity RoutingRouting Supporting ServiceSupporting Service Time Time
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THE KEY INPUT DATA: PQRSTTHE KEY INPUT DATA: PQRST
PRODUCT-MATERIALP
QUALITY-VOLUMEQ
ROUTING-PROCESS SEQUENCE
R
TIMET
SUPPORTING SERVICES
W H Y
WhatWhat
When, HowWhen, How
How MuchHow Much
WhoWho
Process Tm Process Tm PERTPERT
Figure 1-1: The Enterprise Design Process—General Interrelationships among Major System Elements, Functions, and Activities
MARKET RESEARCH AND SALES
FORECASTING
PRODUCT DESIGN
Material & Process Requirements
PROCESS DESIGN
Tool & Equipment Specifications
OPERATIONS DESIGN
Work Meth. & Stds. Manpower Reqts. Equipment Reqts.
COST DETERMINATION
FinancialRequirements
FACILITIES DESIGN
Facility Requirements--Production--Auxiliary--Service
PROCUREFUNDS
INSTALLFACILITIES
PROCUREFACILITIES
PROCURE MANPOWER
PROCURE MATERIALS
CUSTOMER SALES AND MARKETINGPHYSICAL
DISTRIBUTION
MANUFACTURING
PRODUCTION
RE-CEIVING
STO-RAGE
WARE-HOUSE
SHIP-PING
PKG
ASSY
FABRICATE PRODUCT OR PERFORM SERVICE
Energy
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FOUR PHASESFOUR PHASESI EXTERNAL
II OVERALL PLAN
III DETAILED PLAN
IV IMPLEMENTATION
I
II
III
IV
Project Time
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FOUR PHASESFOUR PHASESI EXTERNAL
II OVERALL PLAN
III DETAILED PLAN
IV IMPLEMENTATION
I
II
III
IV
Project Time
OK?OK?
OK?OK?
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Time
Lev
el o
f D
etai
l
Phase
I
II
III
IV
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The Phases of Systematic Layout PlanningThe Phases of Systematic Layout Planning
I LOCATION
II OVERALL LAYOUT
III DETAIL LAYOUTS
IV INSTALLATIONTime
NEW BLDG
MFGBLDG
MAINBLDG
HIW
AY
BD
CA
D
Phase I: Phase II: Phase III: Phase IV:
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THE FIVE COMPONENTSTHE FIVE COMPONENTS(Anatomy)(Anatomy)
of an Industrial Plantof an Industrial PlantI.I. LAYOUTLAYOUT
(Skeleton, Framework for Operations)(Skeleton, Framework for Operations)II.II. MATERIAL HANDLINGMATERIAL HANDLING
(Muscular System for Movement/Activity)(Muscular System for Movement/Activity)III.III. PROCEDURES/COMMUNICATIONSPROCEDURES/COMMUNICATIONS
(Nervous System for Control of Activity)(Nervous System for Control of Activity)IV.IV. UTILITIES/AUXILIARIESUTILITIES/AUXILIARIES
(Respiratory, Circulatory, & Digestive Systems)(Respiratory, Circulatory, & Digestive Systems)V.V. BUILDINGBUILDING
(Skin, Hair, “protective covering”)(Skin, Hair, “protective covering”)
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FUNDAMENTALS OF FIVE COMPONENTSFUNDAMENTALS OF FIVE COMPONENTS
I. LAYOUT 3 Fundamentals
A B
C
D
C
A
A B
CD
D
B
RelationshipsRelationships
Flow and Non-flowFlow and Non-flow
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FUNDAMENTALS OF FIVE COMPONENTSFUNDAMENTALS OF FIVE COMPONENTS
I. LAYOUT 3 Fundamentals
A B
C
D
C
A
A B
CD
D
B
Space Space
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FUNDAMENTALS OF FIVE COMPONENTSFUNDAMENTALS OF FIVE COMPONENTS
I. LAYOUT 3 Fundamentals
A B
C
D
C
A
A B
CD
D
B
AdjustmentsAdjustments
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FUNDAMENTALS OF FIVE COMPONENTSFUNDAMENTALS OF FIVE COMPONENTS
II. MATERIAL HANDLING 3 Fundamentals
MaterialsMaterials
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FUNDAMENTALS OF FIVE COMPONENTSFUNDAMENTALS OF FIVE COMPONENTS
II. MATERIAL HANDLING 3 Fundamentals
MovesMoves
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FUNDAMENTALS OF FIVE COMPONENTSFUNDAMENTALS OF FIVE COMPONENTS
II. MATERIAL HANDLING 3 Fundamentals
MethodsMethods
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FUNDAMENTALS OF FIVE COMPONENTS
III. PROCEDURES/COMMUNICATIONS
3 Fundamentals
InformationInformation
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FUNDAMENTALS OF FIVE COMPONENTS
III. PROCEDURES/COMMUNICATIONS
3 Fundamentals
Transmission Transmission
TimelinesTimelines
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FUNDAMENTALS OF FIVE COMPONENTS
III. PROCEDURES/COMMUNICATIONS
3 Fundamentals
MeansMeans
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FUNDAMENTALS OF FIVE COMPONENTS
IV. UTILITIES/AUXILIARIES 3 Fundamentals
SubstanceSubstance
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FUNDAMENTALS OF FIVE COMPONENTS
IV. UTILITIES/AUXILIARIES 3 Fundamentals
Destination/RoutingDestination/Routing
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FUNDAMENTALS OF FIVE COMPONENTS
IV. UTILITIES/AUXILIARIES 3 Fundamentals
Conductors/MeansConductors/Means
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FUNDAMENTALS OF FIVE COMPONENTS
V. BUILDING 3 Fundamentals
Form/ShapeForm/Shape
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FUNDAMENTALS OF FIVE COMPONENTS
V. BUILDING 3 Fundamentals
MaterialsMaterials
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FUNDAMENTALS OF FIVE COMPONENTS
V. BUILDING 3 Fundamentals
DesignDesign
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FIVE COMPONENTSFIVE COMPONENTSLAYOUT HANDLING COMMUNICATION UTILITIES BUILDING
I
II
III
IV
PHASES
P,Q,RP,Q,R
Block Block DiagramDiagram
Detailed Detailed LayoutLayout
Train/ Train/ InstallInstall
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FIVE COMPONENTSFIVE COMPONENTSLAYOUT HANDLING COMMUNICATION UTILITIES BUILDING
I
II
III
IV
PHASES
Train/ Train/ InstallInstall
P,Q,R,SP,Q,R,S
Type and Type and Size of Size of EquipmentEquipment
Make of Make of Equip.Equip.
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PROJECTING KEY INPUT DATAPROJECTING KEY INPUT DATA
Long-Range Facilities Planning should be based on Long-Range projection of Key Input Data
P
Q
R
S
T
FUTURE TIMEN0W
INPUT
DATA
PQRST PROJECTIONSPQRST PROJECTIONS
Key Elements
Last Year
CurrentYear
Plus 2Years
Plus 4Years
Plus 6Years
P1
Pa
Pb
Pc
Pd
Q1
Qa
Qb
Qc
Qd
S1
Sa
Sb
Sc
Sd
T1
Tb
Tc
Td
Ta
412#C.I.“Other Physical Characteristics”
410#Steel
380#Alum.
350#Stainless
275#Plastic Coat
$ orUnits
$ orUnits
$ orUnits
CafeteriaParkingTool Rm
8 hrs/day
48 hrs
8
48
7
36
6
24
6 (Labor)
12 (Delivery Time)
R1
Ra
Rb
Rc
Rd
(Man. Ovens)Manual
Semi Auto Elect. OvensN/C(1/10) (1/2)N/C Fully Auto N/C
(Heat Treating)(Machining)
TIME PROJECTION
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SYSTEMATIC FACILTIES SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING AS AN INTEGRATED
PLANNING SYSTEMPLANNING SYSTEM
1
2
3
4
5
6
I
II
III
IV
LayoutHandling
CommunicationUtilities
Building
P Q R S TP Q R S T
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SYSTEMATIC FACILTIES SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING AS AN INTEGRATED
PLANNING SYSTEMPLANNING SYSTEM
1
2
3
4
5
6
I
II
III
IV
LayoutHandling
CommunicationUtilities
Building
P Q R S TP Q R S T Key Input DataKey Input Data
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SYSTEMATIC FACILTIES SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING AS AN INTEGRATED
PLANNING SYSTEMPLANNING SYSTEM
1
2
3
4
5
6
I
II
III
IV
LayoutHandling
CommunicationUtilities
Building
P Q R S TP Q R S T Key Input DataKey Input Data
Projection in TimeProjection in Time
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SYSTEMATIC FACILTIES SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING AS AN INTEGRATED
PLANNING SYSTEMPLANNING SYSTEM
1
2
3
4
5
6
I
II
III
IV
LayoutHandling
CommunicationUtilities
Building
P Q R S TP Q R S T Key Input DataKey Input Data
Projection in TimeProjection in Time
FundamentalsFundamentals
45
SYSTEMATIC FACILTIES SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING AS AN INTEGRATED
PLANNING SYSTEMPLANNING SYSTEM
1
2
3
4
5
6
I
II
III
IV
LayoutHandling
CommunicationUtilities
Building
P Q R S TP Q R S T Key Input DataKey Input Data
Projection in TimeProjection in Time
FundamentalsFundamentals
PhasesPhases
46
SYSTEMATIC FACILTIES SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING AS AN INTEGRATED
PLANNING SYSTEMPLANNING SYSTEM
1
2
3
4
5
6
I
II
III
IV
LayoutHandling
CommunicationUtilities
Building
P Q R S TP Q R S T Key Input DataKey Input Data
Projection in TimeProjection in Time
FundamentalsFundamentals
PhasesPhases
ComponentsComponents
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SYSTEMATIC FACILTIES SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING AS AN INTEGRATED
PLANNING SYSTEMPLANNING SYSTEM
1
2
3
4
5
6
I
II
III
IV
LayoutHandling
CommunicationUtilities
Building
P Q R S TP Q R S T Key Input DataKey Input Data
Projection in TimeProjection in Time
FundamentalsFundamentals
PhasesPhases
ComponentsComponents
Time ScheduleTime Schedule
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APPLE: FACILITIES DESIGN PROCEDUREAPPLE: FACILITIES DESIGN PROCEDURE-20 STEPS--20 STEPS-
1.1. Procure DataProcure Data
2.2. Analyze DataAnalyze Data
3.3. Design Production ProcessDesign Production Process
4.4. Design Material Flow PatternDesign Material Flow Pattern
5.5. Design/Select Material Handling PlanDesign/Select Material Handling Plan
6.6. Calculate Equipment RequirementsCalculate Equipment Requirements
7.7. Plan Work AreasPlan Work Areas
8.8. Select Material Handling EquipmentSelect Material Handling Equipment
9.9. Plan Groups of Related OperationsPlan Groups of Related Operations
10.10. Design Activity RelationshipsDesign Activity Relationships
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APPLE: FACILITIES DESIGN PROCEDURE-20 STEPS- (Continued)
11. Calculate Storage Requirements
12. Plan Service (Auxiliary) Activities
13. Calculate (Total) Space Requirements
14. Allocate Activities to Space
15. Consider Building Types
16. Construct Layout (Model)
17. Evaluate, Adjust, Check Layout
18. Justify, (Approval ?)
19. Install Layout
20. Nurture Layout