IND501 Facility
Dr. Sayed Ali Zayan
Planning
2022/2023
Topics:
Introduction to Facilities Planning
Facilities Location
Facilities Design Procedure
Layout Design
Assembly Line balancing and Flow Analysis
Using Relationship chart
CRAFT Algorithm
Material Handling Systems
Structural Design
Student Assessment
Final Exam.
40
Mid-Term Exam.
30
2nd Exam. (+Report)
20
Semester Work (Assigm., quiz, attend.,..)
10
Total
100 Pts.
Text Books:
Tompkins J. A. and et. al.
“Facilities Planning” 4th ed.
2010, by John Wiley & Sons, Inc.
Stephens M. P. and Meyers F. E.
“Manufacturing Facilities Design
& Material Handling” 4th ed.
2010, by Pearson edu. Inc. USA.
Lecture 01: Introduction to Facilities Planning
Definition of Facilities Planning :
 Is concerned with the design, layout, location, and
accommodation of people, machines, and activities of
a system or enterprise (manufacturing or service) within
a physical spatial environment.
 People, machines, vehicles, and processes are
accommodated within the physical environment so that
the objectives of the system or enterprise (e.g., hospital,
bank, manufacturing, telecommunications call center)
housed within the facility can be satisfactorily achieved.
Facility
Planning
Facilities: Examples
Production systems
Health care
Education
Food
Commercial / Residential
Government/Public services
Military
Transportation
Public assembly
Religious
Objectives of Facilities Planning
Improve customer satisfaction
Increase return on assets
Maximize speed for quick customer response
Reduce costs and grow the supply chain
profitability
Reduce costs and grow the supply chain
profitability
Integrate the supply chain.
Objectives of Facilities Planning (cont.)
Support the organization’s vision through improved
material handling, material control, and good
housekeeping.
Effectively utilize people, equipment, space, and
energy.
Maximize return on investment (ROI) on all capital
expenditures.
Provide for employee safety, job satisfaction,
energy
efficiency,
and
environmental
responsibility
Reasons for facilities planning/design
 New field of endeavor
 Expansion due to volume or diversity
 Replacing an obsolete facility
 Relocating or consolidation
 Legal: Occupational Safety & Health Act (1970)
Facilities Planning Hierarchy
Facilities
Planning
Facilities Location
Facilities Design
Structural Design
Layout Design
(building and support
services - gas, water,
light, air,…)
(space requirements
and
location
of
resources in available
space.)
Handling System
Design
(movement of material,
people, information and
equipment.)
Major functions of facilities design
 Location of the facility placement of the facility w.r.t
customers/suppliers
 Choice of resources
 Layout of resources/components
 Performance evaluation
The design process ends when the implementation phase of the
physical design begins
 Structure design: building and support services - gas, water, light,
air,…
 Layout design: space requirements and location of resources in
available space.
 Handling system design: movement of material, people, information
and equipment.
Layout Design
Layout Design
Objective of Layout Design:
 Facilitate attainment of product or service quality
 Use workers and space efficiently
 Avoid bottlenecks
 Minimize unnecessary material handling costs
 Eliminate unnecessary movement of workers or
materials
 Minimize production time or customer service time
 Design for safety
Facilities Planning Process
Facilities Planning Process
1) Problem Definition:
 Criteria, wishes, constraints -- data: products / services to
delivered and quantities
 Objective: to maximize overall efficiency & minimize total
costs.
 Important costs:
– Design - Construction - Installation - MH
– Transportation/distribution - Operating & maintenance
– WIP - Change
 Criteria: may be mathematical function or wishes
– Productivity - Capital investment - Space utilization
– Flexibility - MH effectiveness - Aesthetics
Facilities Planning Process
2) Analyze the problem
a) Location : identifying boundaries and characteristics of a
facility external conditions :
 Related to handling
 Related to communication
 Related to utilities and to building
b) Facility Requirements
 Capacity: desired product output per period of time
 Staffing: Estimation of the required number and distribution
 Support system: information network, security , personnel
service and maintenance .
 Space : amount (area)\kind (physical features )\shape of
configuration
Facilities Planning Process
3) Synthesis the problem
Alternatives: generated by a search procedure
 Exert the necessary effort‫بذل الجهد الالزم‬
 Do not get bogged‫ عجز‬down in details too soon
 Make liberal‫ تحرر‬use of the questioning attitude
 Seek many alternatives
 Avoid conservatism‫التحفظ‬
 Avoid premature satisfaction or rejection‫تجنب الرضا او الرفض المبكر‬
 Refer to analogous problems for ideas‫الرجوع الي االفكار المماثلة‬
 Attempt to divorce your thinking from the existing solution ‫افصل‬
‫تفكيرك عن الحل الحالي‬
 Consult others
 Try the group approach
Facilities Planning Process
4) Evaluation:
Use models to assess performance w.r.t. criteria
Evaluation criteria:
 Ease of future expansion
 Flexibility of layout
 Material handling effectiveness
 Space utilization
 Safety and housekeeping
 Working conditions
 Ease of supervision and control
 Equipment utilization
 Ability to meet capacity and requirements
 Investment or capital required
 Appearance and promotional value
Facilities Planning Process
5) Selection:
Approvals
6) Implementation:
Physical execution and monitoring
“Single most important cause of high material
handling costs is lack of strategic facilities
planning”