Chapter 10. Facilities Layout and Location
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Transcript Chapter 10. Facilities Layout and Location
Facility Design-Week 1
Introduction to Facility
Planning
Anastasia L. Maukar
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Definition of Factory
Factory/Plant:
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Factory/plant
RESOURCES
MAN
MACHINES/
EQUIPMENTS
PRODUCTION SYSTEM
MATERIAL
ENERGY
MONEY
INFORMATION
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
Location
Structural
Design
Facility
Planning
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
Determining Flow of
Products (People)
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
Design of Components
(Service)
Layout of Machine
(Service) Cells
Inventory Control
Type, Number of
Equipment Required
Determination of Machine
(Service) Cells
Distribution of goods
Process Planning
Tooling, Fixture
Determination
Quality Control and
Customer Service
Overall System Design
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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 equipment
Maximize production throughput rate
Utilize space most efficiently
Provide for the safety and comfort of employees
Maintain a flexible arrangement
Minimize materials handling cost
Facilitate the manufacturing process
Facilitate 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 system
Layout of a manufacturing facility
Warehouse layout
Nontraditional layout
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Applications
Manufacturing
Healthcare
Service
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 image
Does customer physically participate in service delivery?
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Office structures
Closed structure
Semiclosed structure
Open structure
Semiopen 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 flow
Improve employee morale
Minimize or eliminate risk of injury and property
damage
Ease 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 layout
Warehouse is a facility for storing merchandise,
commodities or other items
4 main warehouse functions
1. Receiving
2. Storing
3. Order picking
4. Shipping
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Warehouse layout
• Where to locate
receiving and shipping
functions?
• Should the two
functions be combined
at one location or
separated?
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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 Problem
Factor: 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 layout
IC board layout
Computer disk storage layout
Airport gate layout
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Non Traditional Layout Problem
Ex: Control panel LP in the design of a
computer backboard.
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