Systematic Facilities Planning

Transcript Systematic Facilities Planning

Systematic Facilities Planning

An Overview & Perspective 1

SYSTEMATIC FACILITIES PLANNING

 Systematic: Organized, disciplined rational approach to a problem  Facilities: Building, production & material handling equipment, land, access (supporting equipment)  Planning: Decide a course of action based on facts and analysis 2

THE OBVIOUS

“The obvious is that which is never seen until someone expresses it simply” 3

Obvious?

THE OBVIOUS

 Systematic Facilities Planning fits in this category:  Common Sense  Prior Experience  Simple Numerical Methods  Visual Representations Practical Perceptiveness 5

PRODUCTIVE SYSTEMS

CUSTOMERS INPUTS *Workers *Managers *Equipment *Facilities *Materials *Energy *Information *Environment Conversion Process *Operations *Transformations *Activities *Interrelationships OUTPUTS *Goods *Services Information feedback on performance 6

FACILITIES PLANNING AND DESIGN

I PROCESS Conceptualize Plan Analyze Design Implement Productive Systems Inter-Relationships People Materials Information FLOW Equipment Methods 7

SYSTEMATIC FACILITIES PLANNING

 Models  Physical Models  Analog Models  Mathematical Models  Modeling Tools  Mathematical Programming  Queuing Models  Simulation Modeling 8

WHY PLAN FACILITIES

The primary causes that trigger new or 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

THE NEED FOR GOOD FACILITIES PLANNING 1.

Plant facilities influence the costs of operating and therefore profits.

Planning allows facilities to comply with laws ad/or regulations.

Facilities involve high capital-cost expenditures.

Facilities are fixed investments, not readily convertible to money or resale.

Facilities are inflexible (i.e. physically fixed and have limited opportunities to be changed).

Facilities are long term commitments with protracted periods of financial return.

Facilities planning, design and construction require long lead times.

Sound plans for implementation can avoid disruptions in production, and discontinuities for shipping or delivery.

Operations often produce detrimental wastes that affect entire communities.

THE NEED FOR GOOD FACILITIES PLANNING 10.

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The safety, convenience, appearance, and comfort of industrial facilities influence the attitudes of and the ability to attract suitable employees.

Industrial facilities must be planned to meet anticipated future requirements yet compete profitably today.

Facilities need to be planned for an appropriate degree of flexibility, expandability, versatility… Good planning buys time for making commitments; it minimizes being taken by surprise.

If plans are made, managements can react faster and take advantage of business opportunities that arise.

Good planning, especially if presented well visually, is an aid to obtain financing monies.

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.” 11

SYSTEMATIC PLANNING OF INDUSTRIAL FACILITIES (SPIF) DEFINED SPIF is an organized, structured system of determining for an industrial plant what its current and future facilities should be. It is an integrated approach to planning the land, buildings, machinery, and equipment for an industrial enterprise, and in so doing, SPIF involves: 12

SYSTEMATIC PLANNING OF INDUSTRIAL FACILITIES (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.

FACILITIES PLANNING AND DESIGN

 Basic Elements of Layout Planning  Product  Quantity  Routing  Supporting Service  Time 14

THE KEY INPUT DATA: PQRST

PRODUCT-MATERIAL What

QUALITY-VOLUME How Much

ROUTING-PROCESS SEQUENCE When, How

SUPPORTING SERVICE Who

TIME Process Tm

PERT

H Y 15

MARKET RESEARCH AND SALES FORECASTING PRODUCT DESIGN Material & Process Requirements PROCESS DESIGN Tool & Equipment Specifications OPERATIONS DESIGN Work Meth. & Stds. Manpower Reqts. Equipment Reqts.

PROCURE FACILITIES INSTALL FACILITIES PROCURE MANPOWER PROCURE MATERIALS CUSTOMER PROCURE FUNDS COST DETERMINATION Financial Requirements FACILITIES DESIGN Facility Requirements --Production --Auxiliary --Service RE CEIVING STO RAGE MANUFACTURING PRODUCTION FABRICATE PRODUCT OR PERFORM SERVICE PKG ASSY WARE HOUSE Energy SALES AND MARKETING SHIP PING PHYSICAL DISTRIBUTION

Figure 1-1: The Enterprise Design Process—General Interrelationships among Major System Elements, Functions, and Activities

I EXTERNAL

FOUR PHASES

I II OVERALL PLAN II III DETAILED PLAN III IV IMPLEMENTATION IV Project Time 17

I EXTERNAL

FOUR PHASES

OK?

II OVERALL PLAN II

OK?

III DETAILED PLAN III IV IMPLEMENTATION IV Project Time 18

I Phase III IV II Time 19

The Phases of Systematic Layout Planning I LOCATION Time II OVERALL LAYOUT III DETAIL LAYOUTS IV INSTALLATION Phase III: Phase IV: Phase I: MFG BLDG NEW BLDG MAIN BLDG Phase II: B A C D D 20

THE FIVE COMPONENTS (Anatomy) of an Industrial Plant

II.

III.

IV.

LAYOUT

(Skeleton, Framework for Operations)

MATERIAL HANDLING

(Muscular System for Movement/Activity)

PROCEDURES/COMMUNICATIONS

(Nervous System for Control of Activity)

UTILITIES/AUXILIARIES

(Respiratory, Circulatory, & Digestive Systems)

BUILDING

(Skin, Hair, “protective covering”) 21

FUNDAMENTALS OF FIVE COMPONENTS I. LAYOUT A B C D 3 Fundamentals

Relationships Flow and Non-flow

A B C D A B C D 22

FUNDAMENTALS OF FIVE COMPONENTS I. LAYOUT A B C D 3 Fundamentals A B C D

Space

A B C D 23

FUNDAMENTALS OF FIVE COMPONENTS I. LAYOUT A B C D 3 Fundamentals A B C D A B C D

Adjustments

FUNDAMENTALS OF FIVE COMPONENTS II. MATERIAL HANDLING 3 Fundamentals

Materials

FUNDAMENTALS OF FIVE COMPONENTS II. MATERIAL HANDLING 3 Fundamentals

Moves

FUNDAMENTALS OF FIVE COMPONENTS II. MATERIAL HANDLING 3 Fundamentals

Methods

FUNDAMENTALS OF FIVE COMPONENTS III. PROCEDURES/ COMMUNICATIONS 3 Fundamentals

Information

FUNDAMENTALS OF FIVE COMPONENTS III. PROCEDURES/ COMMUNICATIONS 3 Fundamentals

Transmission Timelines

FUNDAMENTALS OF FIVE COMPONENTS III. PROCEDURES/ COMMUNICATIONS 3 Fundamentals

Means

FUNDAMENTALS OF FIVE COMPONENTS IV. UTILITIES/AUXILIARIES 3 Fundamentals

Substance

FUNDAMENTALS OF FIVE COMPONENTS IV. UTILITIES/AUXILIARIES 3 Fundamentals

Destination/Routing

FUNDAMENTALS OF FIVE COMPONENTS IV. UTILITIES/AUXILIARIES 3 Fundamentals

Conductors/Means

FUNDAMENTALS OF FIVE COMPONENTS V. BUILDING 3 Fundamentals

Form/Shape

FUNDAMENTALS OF FIVE COMPONENTS V. BUILDING 3 Fundamentals

Materials

FUNDAMENTALS OF FIVE COMPONENTS V. BUILDING 3 Fundamentals

Design

LAYOUT

FIVE COMPONENTS

HANDLING COMMUNICATION UTILITIES BUILDING

I P,Q,R P H A S E S II Block Diagram III Detailed Layout IV Train/ Install 37

I P H A S E S II III IV

LAYOUT

FIVE COMPONENTS

HANDLING COMMUNICATION UTILITIES BUILDING

P,Q,R,S Type and Size of Equipment Make of Equip.

Train/ Install 38

PROJECTING KEY INPUT DATA

Long-Range Facilities Planning should be based on Long-Range projection of Key Input Data N 0 W FUTURE TIME D A T A I N P U T P Q R S T 39

Key Elements P Q 1 R S T 1 1 1 1 S a S b S c S d T a T b T c T d P a P b P c P d Q a Q b Q c Q d R a R b R c R d $ or Units Cafeteria Parking Tool Rm 8 hrs/day 48 hrs $ or Units 8 48 PQRST PROJECTIONS Last Year TIME PROJECTION Current Year 412# 410# C.I.

Steel “Other Physical Characteristics” Plus 2 Years 380# Alum.

Plus 4 Years 350# Stainless $ or Units (Man. Ovens) Manual Semi Auto Elect. Ovens N/C(1/10) (1/2)N/C 7 36 6 24 Plus 6 Years 275# Plastic Coat Fully Auto N/C (Heat Treating) (Machining) 6 (Labor) 12 (Delivery Time)

SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING SYSTEM

P Q R S T

I II III IV Layout Handling Communication Utilities Building 5 6 1 2 3 4 41

SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING SYSTEM

Key Input Data P Q R S T

I II III IV Layout Handling Communication Utilities Building 5 6 1 2 3 4 42