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Facility Design-Week 3Traditional Approach for

Facility Layout: Systematics Layout

Planning

Anastasia L.M.

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Facility Layout

A Layout problem may be to determine the location for a new machine, develop a new layout for an existing production plant, develop a layout for a new production plant, etc.

A Layout problem may arises due to changes in the design of a product, addition or deletion of a product, change in the demand of a product, changes in the design of the process, addition or deletion of a process, replacement of equipment, etc.

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Objectives of Facility Layout

Minimize investment in equipment.

Minimize production time.

Minimize material handling cost.

Maximize utilization of space.

Maintain flexibility of arrangement and operation.

Provide safety and comfort to employees.

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Sequential Approach vs Integrated Approach

Sequential Approach :

Product Design

Production Planning

Process Design

Facility Layout

Material Handling System Design

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Sequential 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.

Product Design

Process Design

Schedule Design

Layout Design

+

Material Handling System Design

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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Facility Layout Procedures

Naddler’s Ideal System Approach (1961)

Immer’s Basic Steps (1950)

Apple’s Plant Layout Procedure (1977)

Reed’s Plant Layout Procedure (1961)

Muther’s Systematic Layout Planning (1961)

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Systematic Layout Planning

Phase I - Determination of the location of the area where departments are to be laid out

Phase II - Establishing the general overall layout

Phase III - Establishing detailed layout plans

Phase IV - Installing the selected layout

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Systematic Layout PlanningInput Data and Activities

1. Flow of materials 2. Activity Relationships

6. Space Relationship Diagram

5. Space Available4. Space Requirements

3. Relationship Chart

8. Practical Limitations7. Modifying Considerations

9. Develop Layout Alternatives

10. Evaluation

ANALYZE

SEARCH

SELECT

Source: John S. Usher class notes

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SLP

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Systematic Layout Planning

P Product: Types of products to be produced What

Q Quantity: Volume of each part type How Much

R Routing: Operation sequence for each part type How

S Services: Support services, locker rooms, inspection stations, and so on With What

T Timing: When are the part types to be produced ? What machines will be used during this time period? When

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Sample relationship diagram

1 2

4

3

5

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1. Relationships

 1

.Collection of Input Data

2.Flow of Materials

3.Activity Relationships

4.Relationship Diagrams

2. Space  1

.Space Requirements

2.Space Available

3.Space Relationship Diagrams

3. Adjustments

 1

.Modifying Considerations

2.Practical Limitations

3.Evaluation & Final Selection

Systematic Layout Planning Procedure

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Information Gathering

Information about product, process and schedule is required.

The major effect of product design decisions is felt by the process designer, i.e., the material used to make a part will influence processing decisions.

Design for automation programs have been developed that consider the impact of the design of the product on the assembly process.

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Information Gathering

Their primary thrusts are (1) dimensional reduction, (2) parts elimination, and (3) parts standardization.

For (1), the cost of assembly is reduced if it occurs in a single dimension. The complexity of programming a robot increases geometrically with the number of assembly dimensions.

For (2), if more complex parts can be produced, the number of parts can be reduced.

Schedule design decisions tell us how much to produce and when to produce. From the market forecast, the production demand is determined and decisions about the production

rate are made.

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Information Gathering

Information about product :

- Photographs about the product

- “Exploded” drawings

- Engineering drawings of individual parts

- Parts list

- Bill of materials (structure of product)

- Assembly chart

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Information Gathering

Information about process :

• Route sheet (equipment and operation times)

• Precedence Diagram (prerequisite assembly

steps before new assembly step)

• Operation process chart (processing

operations, assembly operations, and

inspections)

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Information Gathering

Information about schedule :

• Production rate

• Product mix

• Market forecast (it is better to work with tomorrow’s

data than today’s data)

• Gantt charts

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The information about Product Design and

Process Design as an input for SLP have

been discussed in week 2.

Information Gathering

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Flow Analysis and Activity Analysis

Flow of material analysis is related to quantitative analysis; to analyse the movement between departments/operational activities

Activity analysis is related to qualitative factors that affect the determination of a facility/depatment location should be placed.

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From – To Chart

A chart is used for Quantitative Measurement from material movements

2222

FromTo

A B C D E F G H I Total

A 0

B 20 5 45 70

C 45 20 5 70

D 30 65 5 100

E 5 45 20 70

F 5 20 25 25 75

G 5 20 50 75

H 5 25 30 60

I 25 45 30 100

Total 100

70 70 100

70 75 75 60 620

From-To Chart Example

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From – To Chart (cont’)

ForwardDistance from diagonal

BackwardDistance from diagonal

1 x 260 = 260 2 x 1 x 10 = 20

2 x 130 = 260 2 x 2 x 70 = 280

3 x 130 = 390 2 x 3 x 0 = 0

4 x 15 = 60 2 x 4 x5 = 40

5 x 0 = 0 2 x 5 x 0 = 0

6 x 0 = 0 2 x 6 x 0 = 0

Total = 970 Total = 340

Total moment = 1.310

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Activity Relationship Chart

Suatu metode utk merencanakan & menganalisis keterkaitan antara setiap kelompok kegiatan yg saling berkaitan

Jenis-jenis keterkaitan dapat terjadi:

Between 2 production processes Between production process and service

activity, or other activities. Between 2 service activities.

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ARC (cont’)Closeness codes are:

Code Color Definition/closeness rating

A Merah Absolutely necessary

E Jingga Especially Important

I Hijau Important

O Biru Ordinary Important

U Uncolored Unimportant

X Coklat Undesirable

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Relationship Diagramming: Example

Production

Offices

Stockroom

Shipping and receiving

Locker room

Toolroom

A A

A O

O

OO

O

U

U U

U

EX

I

A Absolutely necessaryE Especially importantI ImportantO OkayU UnimportantX Undesirable

A Absolutely necessaryE Especially importantI ImportantO OkayU UnimportantX Undesirable

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Activity Relationship Diagram

A relationship diagram is a spatial arrangement of the departments to represent the relationship data in a graphical way. This diagram is also called an adjacency graph.

There are 2 ways of making ARD:

By making an Activity Template Block Diagram (ATBD) By using the combination of standardized lines and color

codes

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Relationship Diagram

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Relationship Diagrams: Example (cont’)

Key: AEIOUX

Offices

Stockroom

Locker room

Toolroom

Shipping and

receiving

Production

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ARD (cont’)

A: E:

X:Department No

Departement Name

I: O:

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Space Requirements & Space Availability

Determination of the Production Rate Determination of Batch Production Quantities

Economic Order Quantity Models Reject Allowance Problem

Determination of Equipment Requirements Determination of Employee Requirements

Manual Assembly Operators Machine Operators

Determination of Space Requirements Tables for Aisle Allowance, Food Services and Restrooms Other Methods to Determine Space Requirements Parking Space

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Designing the Layout

After flow and activity analysis, determine the space requirement, the alternative layouts should be generated

Simply, overall layout is generated by combining the relationship diagram/ARD and space requirement.

This combination is called a space-relationship diagram. Then layout design could be modified based on practical limitation and other considerations.

Overall layout is performed as a block plan or area allocation diagram. Block plan uses scale and show the location using internal partitions or columns.

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Space Relationship Diagram

When the space requirements for the departments are added to this relationship diagram, then a space relationship diagram has been constructed.

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Space Relationships Diagram

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Area Allocation Diagram

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Operations Review for MortAmerica, Inc.

Is there a significant increase in mortgage lending operations of MortAmerica, Inc.?

Are the costs of leasing and refurbishing interior space too high?

Is there a problem with the current location? For example: There is not enough space for expansion Major attorneys’ offices, other related financial institutions and

restaurants, are not located within a reasonable distance of MortAmerica, Inc.

Adequate parking space is not available Traffic is too congested

Will a change in office location improve business?

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SLP for MortAmerica, Inc.

Evaluation Planning Site selection Design and layout

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SLP for MortAmerica, Inc.

Review current space utilization Determine space projections Determine level of interaction between

departments Identifying special consideration

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Current and Future Space Requirements

Categories of Employees and Number in Each Category Department Name Current/Future

Requirements Senior Executive

Senior Staff

Staff Clerical/Secretary Net Space

Required

Gross Space, 150% of Net Space

Current space/employee 150 100 75 Number of employees 1 4 1 Current total space/category

150 400 75 625 938

Future space/employee 120 75 Number of employees 6 1

Customer Service (CS)

Future space/category 720 75 795 1,193 Current space/employee 200 100 75 Number of employees 2 10 2 Current total space/category

400 1,000 150 1,550 2,325

Future space/employee 250 200 100 75 Number of employees 1 1 15 1

Mortgage processing/marketing (MP/M)

Future space/category 250 200 1,500 75 2,025 3,038 Current space/employee 100 75 Number of employees 10 1 Current total space/category

1,000 75 1,075 1,613

Future space/employee 80 Number of employees 5

Credit check (CC)

Future space/category 400 400 600 Current space/employee 200 100 90 75 Number of employees 2 4 15 5 Current total space/category

400 400 1,350 375 2,525 3,788

Future space/employee 250 100 100 75 Number of employees 3 4 20 2

Operations Audit (O/A)

Future space/category 750 400 2,000 150 3,300 4,950 Current space/employee 250 200 100 Number of employees 5 2 5

Top management (TM)

Current total space/category

1,250 400 500 2,150 3,225

Future space/employee 250 200 100

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Current and Future Space Requirements

Support service area Current net space Current gross space150% of net space Future net space Future gross space 150% of net

space

Copying/Printing Area (C/P) 300 450 465 700

File Storage Room (FS) 300 450 80 120

Customer Waiting Lounge (CW) 300 450 800 1200

Conference Rooms (CR) 500 750 1000 1500

Employee Break Room (EBR) 200 300 850 1275

Rest Rooms (RR) 200 300 500 750

Total 1800 2700 3695 5545

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Relationship diagram for MortAmerica, Inc.

Customer service (CS)

Mortgage processing (MP)

Credit check (CC)

Closing/underwriting (C/U)

Top Management (TM)

E

E

I

I

O

I

E

OI

Operations/audit (O/A)

Copying/printing (C/P)

Files storage (FS)

Customer waiting (CW)

Conference room (CR)

I

A

U

U

A

A

O

U

I

Employee break room (EBR)

Rest rooms (RR)

O

X

I

I

U

X

X

I

I

O

U

A

O

E

U

U

O

I

X

UU

U

U

O

I

I

U

I

I

X

X

U

U

I

I

U

U

U

A

U

U

I

A

U

O

O

OA

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Activity relationship diagram for MortAmerica, Inc.

MP

CS

CR

RR

CC

C/U

TM

CW

O/A

FS

C/P EBR

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Space relationship diagram for MortAmerica, Inc.

MP

CS

CR

RR

CC

C/U

TM

CW

O/A

FS

C/P EBR

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Pre-architectural layout for MortAmerica, Inc.

TM

MP

CC

C/U

CW

RRM

RRW

CS

CR

C/P

FS

EBR

O/A