Facilities Design - Introduction Facilities planning Objectives of facilities planning Applications EIN4891 – Senior Design Project II Facilities Planning Determines how an activity’s tangible fixed assets best support achieving the activity’s objective Determines the location of a facility and its design Manufacturing firm – how the manufacturing facility best supports production Airport – how the airport facility supports the passenger-airplane interface Hospital – how the hospital facility supports providing medical care to patients EIN4891 – Senior Design Project II Facilities Planning EIN4891 – Senior Design Project II Facilities Location vs. Facilities Design Facilities Location – How the location of a facility supports meeting the facility’s objective Placement with respect to customer, suppliers, and other facilities with which it interfaces Includes its placement and orientation on a specific plot of land Facilities Design – How the design components of a facility support achieving the facility’s objectives EIN4891 – Senior Design Project II Facilities Design Components Facility Systems Design: Structural systems, atmospheric systems, enclosure systems, lighting/electrical/communication systems, life safety systems, sanitation systems E.g., power, light, gas, heat, ventilation, a/c, water, sewage Layout Design: Equipment, machinery, furnishings within the building E.g., production areas, production-related or support areas, personnel areas within the building Handling System Design: Mechanisms needed to satisfy the required facility interactions E.g., materials, personnel, information, and equipment-handling systems required to support production Transportation, receiving, storage, retrieval, packaging, etc. EIN4891 – Senior Design Project II EIN4891 – Capstone Design Build your own house Assume you have 5,000 sqft lot You have the money to build a house on the lot How would you design it? What would be the layout? EIN4891 – Senior Design Project II Boeing Assembly Line, Charleston, SC Boeing South Carolina fabricates, assembles and installs systems for 787 Dreamliner aft fuselage sections New final assembly site built on June 2011 Location supports testing and delivery of airplanes Expands production capability to meet market demand About 55 airlines have ordered around 835 airplanes since 2003 ($162 billion) Features: Fuel efficiency – 20% less fuel More cargo capacity Interior improved environment Composite materials EIN4891 – Senior Design Project II http://www.boeing.com/commercial/787family/index.html Boeing Assembly Line, Charleston, SC 90% of Boeing direct-contracted dollars for the project have been with SC-based companies Across the street, Global Aeronautica is responsible for joining and integrating 787 fuselage sections from other structural partners 1.2 million square feet of usable space, building footprint about 12 football fields. $750 million cost for plant Key facilities: Final assembly, delivery center, support building, flight line Capacity: 3 airplanes per month Environmental: thin-film solar laminate panels on roof for electrical power Zero waste to landfill – recycle or reuse EIN4891 – Senior Design Project II Importance of Facilities Planning Considerable expenditure on new facilities Important component of operating expenses Economic considerations Employee health and safety Community consideration EIN4891 – Senior Design Project II Objectives of Facilities Planning Improve customer satisfaction Increase return on assets (ROA) Maximize inventory turns, minimize obsolete inventory, etc. Maximize speed for quick customer response Reduce costs and grow the supply chain profitability Integrate the supply chain through partnerships and communication Support the organization’s vision through improved material handling, material control, and good housekeeping Effectively utilize people, equipment, space, and energy Be adaptable and promote ease of maintenance Provide for employee safety and job satisfaction EIN4891 – Senior Design Project II Facility Planning Problem Multiobjective optimization problem with many non-quantifiable costs and benefits No optimal solution Facility design is a combination of art and engineering EIN4891 – Senior Design Project II Facilities Planning for IEs Focus on the requirements, resource allocation, and efficient use of resources Space requirements Personnel requirements Equipment requirements Layout design based on operations Movement within a facility Movement between facilities EIN4891 – Senior Design Project II Main Features of Facilities Flexibility Handles a variety of requirements without alterations Modularity Operates efficiently over a wide range Upgradeability Can easily incorporate advances in equipment and technology Adaptability Considers different cycles and peaks Selective operability Allows contingency plans EIN4891 – Senior Design Project II USF Campus Fitness Center Center gets about 550,000 visits annually from students, staff and faculty Area is increasing from 7,000 to 21,000 square feet $1.2 million worth of new fitness equipment First floor (strength and conditioning machines), second floor (cardio machines), third floor (running track) New gymnasium for basketball and multiple sports tournaments such as volleyball, badminton and dodgeball http://news.usf.edu/article/templates/?z=0&a=3523 http://news.usf.edu/article/templates/?a=3645&z=158 EIN4891 – Senior Design Project II Facilities Planning as Continuous Activity Continuous re-evaluation and re-planning of facilities and continuous improvement Reasons: Economic considerations Employee health and safety Energy conservation Community considerations Disabilities considerations Fire protection EIN4891 – Senior Design Project II USF Engineering II Renovation Increase classroom spaces, laboratories and technological upgrades, and gathering areas 14,000 square feet for College’s 4,000 students Opened in 1987 Enhance and upgrade current space $2 million renovation http://www.eng.usf.edu/alumniAndFriends/renovation.htm EIN4891 – Capstone Design Cost of Design Changes EIN4891 – Senior Design Project II Location Selection What are the issues to consider for the following facilities? Hospital School Warehouse Car factory Ship construction company EIN4891 – Senior Design Project II Amazon 2nd Headquarter Plans to invest $5 billion in development and up to 50,000 jobs Location criteria: More than 1 million residents Proximity to airport Diverse demographics Connectivity, mass transit Local schools 238 bids to 20 options https://www.nytimes.com/2018/01/18/technology/cities-amazonheadquarters.html EIN4891 – Senior Design Project II Amazon $675 billion company More than 500,000 employees More than 300 warehouses Dozen satellite offices for R&D Robotics, machine translation, etc. https://www.nytimes.com/video/us/100000005684789/cities-bizarrebids-to-be-amazons-new-home.html EIN4891 – Senior Design Project II Light Industrial Facility For assembly, disassembly, fabrication, finishing, manufacturing, packaging, and repairing or processing of materials Must be designed to accommodate a structured working environment that is based on machinery and technology Circulation spaces are essential for safety of occupants and for increasing productivity Functional needs: Often designed with higher bays for vertical storage – utilization of space Designed to account for the loads of stored materials and associated material handling equipment Loading dock EIN4891 – Senior Design Project II Clinic/Health Unit Outpatient ambulatory health services, office spaces, toilets, storage areas Provide a sanitary environment where patients can be treated quickly and effectively by medical practitioners Accessible Layout should promote prompt and reliable medical attention Relationship and flow diagrams Office support spaces: workrooms, coat storage, lockers, etc. Flexibility EIN4891 – Senior Design Project II Strategic Planning for an Airport Location of airport Location of parking lots Location of ATC tower Location of baggage carousels Location of ticket counters Types of in/outbound planes Number of gates Type of air traffic control systems Number of hangars for servicing and maintenance of planes Number of employees and skill level to run operations Security control EIN4891 – Senior Design Project II Strategic Planning for Warehousing and Distribution Number of shipping/receiving docks How the product is shipped to customer Storage cube requirements Pallet rack, bulk storage conveyor requirements Inventory time Warehouse staffing Material handling procedures and equipment Building size Type and sizes of products to be stored EIN4891 – Senior Design Project II Replanning the University Campus Traffic patterns on campus Location of administration offices Handicapped accessibility to all buildings Pedestrian traffic Location of certain buildings, e.g., financial aid close to cashier’s office Maintenance facilities Adequate parking facilities Adequate eating establishments, restrooms, etc. Adequate computer, recreational facilities Room to expand in the future Room for student living EIN4891 – Senior Design Project II Facilities Layout There are no recipes for the layout Information needed: Departments or areas that are needed Building/facility footprint Entrances, exits, etc. Walls, columns, utilities, etc. Flow measurement or adjacency measurement Space requirements Departments Storage Administration Restrooms, etc. EIN4891 – Senior Design Project II Facilities Layout What is to be produced? How are the products to be produced? Product specifications Dimensions Materials Packaging, etc. When are the products to be produced? How much of each product will be produced? For how long will the products be produced? Where are the products to be produced? How the product will be produced EIN4891 – Senior Design Project II Production quantities Schedules for equipment Product Design Which products are to be produced Detailed design of individual products Aesthetics, function, materials, and manufacturing considerations Driven by users, market CAD designs 2D engineering drawings with dimensions Assembly designs Prototypes Minimize changes in design parameters once the design is finalized 70% of manufacturing cost is defined during the design phase EIN4891 – Senior Design Project II Product Design Inputs for facilities planning: Exploded assembly drawings Facilitates better communication among all parties involved EIN4891 – Capstone Design Product Design Detailed component part drawings – engineering drawings Part specifications, dimensions, and materials EIN4891 – Capstone Design How to Design a Great Product Interview with Mike Krieger, Co-Founder of Instagram Four things to remember for any student of product design https://www.inc.com/daphne-koller/instagram-s-mike-krieger-isyour-tech-company-bringing-people-joy.html Simplicity “Focus on doing the right things instead of a bunch of things.” Get out of your head, and building, and country “If you try to assume what those people want, you’re likely to get it wrong.” Quantitative research “We knew we were onto something when users’ eyes lit up when they saw how intuitively our product worked. If you have data, put it to use – and always remember to test it out with real people.” EIN4891 – Senior Design Project II How to Design a Great Product Sketch before building “You can’t start a product simply by building it. You have to know why you’re building it, and you might go down the wrong rabbit hole, waste time, and confuse things. Spending long afternoons with a sketchbook or talking through your ideas with other people can save a year in software development later on.” “We were working on a product called Burbn, and it had all the elements designers look for – nice layout, good visual design – but it was far too complicated. When we had people sit down to test it, they just couldn’t grok why it would be useful to their lives.” EIN4891 – Senior Design Project II Process Design How the product is to be produced Who should do the processing? How will the part be produced? Which equipment will be used? How long will it take to perform the operation? Process identification Make or buy analysis Parts identification Process selection Identify required processes to make the product Process sequencing How the components will be assembled EIN4891 – Senior Design Project II Process Identification Make or Buy? Can the item be purchased? Can we make the item? Is it cheaper for us to make than to buy? Is the capital available so that we can make it? Should we buy the item? Supplier EIN4891 – Senior Design Project II Process Identification Scope of the facility Parts list - List of items to be made and items to be purchased Bill of materials - Structured parts list with hierarchy EIN4891 – Senior Design Project II Process Identification – Parts List EIN4891 – Capstone Design Process Identification – Bill of Materials EIN4891 – Capstone Design Process Identification – Bill of Materials EIN4891 – Capstone Design Product Design - App Planning phase What problem will the app solve? Who will use this app? What goals and objectives will it meet for users? Designing phase Specifications and designs Conceptual design Architectural design Deploying and refining phase Deploy app and evaluate Make modifications EIN4891 – Senior Design Project II Planning Phase - App Identify the problem, users and objectives Example: Expense reporting: create a process that is efficient for employees and accountants, allows faster budget tracking, and reduces exposure to audits EIN4891 – Senior Design Project II www.Microsoft.com Planning Phase - App Analyze the process Identify key contributors Understand what each user does in the process and how their actions are related Identify the tasks List all the tasks EIN4891 – Senior Design Project II www.Microsoft.com Planning Phase - App Identify the roles and when the tasks are performed Determine how often the task is done i.e., daily, weekly, occasionally, etc. Different design considerations EIN4891 – Senior Design Project II www.Microsoft.com Planning Phase - App Identify the activities performed on each step of the process Starting point Sequence of activities Determine the data or information requirements Data that needs to be presented to the person for the activities Source of data (i.e., previous step, internal or external database, etc.) Data that is created or edited Is there data that needs to be captured? What type of data, how does it need to be stored, who can access it, how does the user enters the data? …. EIN4891 – Senior Design Project II Planning Phase - App Determine how the outcomes are generated At the end of each activity in the process, what is the outcome? Decision made Decision communicated to other people Decision determines the next step of the process. How? What is the next task? How does this task pass to the next task? Who completes the next task? How is this person notified? EIN4891 – Senior Design Project II Planning Phase - App Process flowchart EIN4891 – Senior Design Project II www.Microsoft.com Planning Phase - App Prioritize features Communication with users is important! EIN4891 – Senior Design Project II www.Microsoft.com Product Design - App Planning phase What problem will the app solve? Who will use this app? What goals and objectives will it meet for users? Designing phase Specifications and designs Conceptual design Architectural design Deploying and refining phase Deploy app and evaluate Make modifications EIN4891 – Senior Design Project II Designing Phase - App Conceptual design Identify the tasks and sub-tasks to be done in the app based on process flowchart Determine the tasks that need to be accomplished on each screen and the user List the information required to complete each task – what needs to be displayed and stored? EIN4891 – Senior Design Project II Designing Phase - App EIN4891 – Senior Design Project II www.Microsoft.com Designing Phase - App Sketching the screens Sketch the screens needed for your app based on your process flowchart Try different versions, check other apps and templates Paper prototype EIN4891 – Senior Design Project II www.Microsoft.com Designing Phase - App Architectural design How is data retrieved and stored? New data Read/write on existing system Make copy of data Data modeling Define data to store and how to structure it based on the personas, tasks, process flowchart, goals Data security EIN4891 – Senior Design Project II www.Microsoft.com Process Design How the product is to be produced Who should do the processing? How will the part be produced? Which equipment will be used? How long will it take to perform the operation? Process identification Make or buy analysis Parts identification Process selection Identify required processes to make the product Process sequencing How the components will be assembled EIN4891 – Senior Design Project II Process Selection How the products will be made Define elemental operations Identify alternative process for each operation Standardize processes Evaluate alternative processes Select processes Outputs: processes, equipment and raw materials required – route sheet EIN4891 – Senior Design Project II Process Selection – Route Sheet Data Requirements EIN4891 – Senior Design Project II Process Selection – Route Sheet EIN4891 – Senior Design Project II Process Sequencing – Assembly Chart Method of assembling the product Can be constructed by starting with the product and tracing the disassembly back to its basic components Components: four-digit code starting with 1, 2, 3, and 4 Subassemblies (SA) and assemblies (A): letters and numbers EIN4891 – Senior Design Project II Process Sequencing – Operation Process Chart Route sheet provides production methods Assembly chart provides how components are combined Operation process chart provides overview of the flow within the facility EIN4891 – Capstone Design EIN4891 – Senior Design Project II Schedule Design How much to produce – Lot size decision When to produce – Production scheduling Interface with marketing, sales, and customers Impact machine selection, number of machines, number of shifts, number of employees, space requirements, storage equipment, material handling equipment EIN4891 – Senior Design Project II Schedule Design Need to know to start designing facilities: Number of products to be produced Number of machines required Number of employees required Sequence of operations Relationships between departments EIN4891 – Senior Design Project II Marketing Information From marketing: Production volumes Trends Future demands Minimum information needed by marketing: EIN4891 – Senior Design Project II Marketing Information Ideal information needed by marketing: Dynamic value of demands for the facility A facilities plan can be designed for each demand state with sufficient flexibility for yearly fluctuations EIN4891 – Senior Design Project II Marketing Information Qualitative information EIN4891 – Capstone Design Facilities Design Up to this point: Product design – What we are producing Process design – How we are producing it Schedule design – How many we are producing EIN4891 – Senior Design Project II Departmental Planning Planning departments – production, support, administrative, and service areas Combining workstations that perform similar functions Similar products or components Similar processes Classification of layouts based on product volume-variety Product layout Fixed product layout Group layout Process layout EIN4891 – Senior Design Project II Product layout Fixed product layout Group layout Process layout EIN4891 – Capstone Design Departmental Planning EIN4891 – Capstone Design Departmental Planning EIN4891 – Capstone Design Group Technology Aggregates medium volume-variety parts into families based on similar manufacturing operations or design attributes Machines are groups together to form a cell – cellular manufacturing Benefits: Reduced inventories, space, equipment, transportation, etc. Simplified communication, handling, scheduling, etc. Improved productivity, flexibility, quality, etc. EIN4891 – Senior Design Project II Group Technology Process layout Cellular layout EIN4891 – Senior Design Project II Manufacturing Cell Forming Classification and coding Grouping of parts based on design attributes and assigning numbers or symbols Production flow analysis Grouping parts based on the operation sequences and production routing through the plant EIN4891 – Senior Design Project II Classification and Coding Identification of similarities among parts and relating them using a numerical coding system EIN4891 – Capstone Design Production Flow Analysis Identifying part families and associated machine groupings based on production route sheets rather than part design data EIN4891 – Capstone Design Layout Decisions - Data Requirements Frequency of trips or flow of materials A measure of interaction between departments Shape and size of departments Floor space available Location restrictions for departments Adjacency requirements between pairs of departments EIN4891 – Senior Design Project II A Manufacturing Cell EIN4891 – Senior Design Project II Activity Relationships One of the most important elements in the layout of departments within a facility Quantitative: Amount of materials, information, and number of people moving between departments Qualitative: Communication and organizational interrelation between departments EIN4891 – Senior Design Project II Quantitative Flow Measurement From-to chart Measures the flows between departments Looks like mileage charts Seldom symmetric EIN4891 – Capstone Design From-To Chart EIN4891 – Capstone Design From-To Chart Procedure List all departments down the row and across the column following the overall flow pattern Establish a measure of flow for the facility that accurately indicates equivalent flow volumes Measure flow and record the flow volumes in the chart EIN4891 – Senior Design Project II From-To Chart Example EIN4891 – Capstone Design Qualitative Flow Measurement Flows can be measured qualitatively using closeness relationship values EIN4891 – Senior Design Project II Relationship Chart Constructed as follows: List all departments on the relationship chart Conduct interviews or surveys with persons from each department listed on the chart Define the criteria for assigning closeness relationships Establish the relationship value and the reason Evaluate and modify if needed EIN4891 – Capstone Design Relationship Chart Constructs separate relationship charts for each major relationship being measured Material flow Personnel flow Information flow Organizational, control, environmental, and process relationships, etc. EIN4891 – Senior Design Project II Visualizing Relationships Owens, R., IE Magazine, November 2011 http://www.proplanner.com/documents/filelibrary/documents/papers_case_studies/Advancing_Facility_Planning__IE_Mag_B585236C34A67.pdf EIN4891 – Senior Design Project II Material Flow in an Automotive Assembly Plant Owens, R., IE Magazine, November 2011 http://www.proplanner.com/documents/filelibrary/documents/papers_case_studies/Advancing_Facility_Planning__IE_Mag_B585236C34A67.pdf EIN4891 – Senior Design Project II Congestion Diagram at an Automotive Parts Factory Owens, R., IE Magazine, November 2011 http://www.proplanner.com/documents/filelibrary/documents/papers_case_studies/Advancing_Facility_Planning__IE_Mag_B585236C34A67.pdf EIN4891 – Senior Design Project II Space Requirements One of the most difficult issues to determine Uncertainty in terms of technology, products, demand, organization, etc. Parkinson’s Law: Things will expand to fill all available capacity sooner than you plan Space requirements should be determined for: Individual workstations Department requirements EIN4891 – Senior Design Project II Workstation Requirements Equipment space Equipment Machine travel Machine maintenance Plant services Materials space Receiving and storing materials Holding in-process materials Storing and shipping materials Storing and shipping waste and scrap Tools, fixtures, dies, etc. EIN4891 – Senior Design Project II Workstation Requirements Personnel area Operator motion Material handling Operator entrance and exit Equipment space requirements – Machinery data sheets Materials space requirements – Dimensions of unit loads and flow of material through the machine Personnel area – Task motion and ergonomic studies EIN4891 – Senior Design Project II Department Specification Sum of area of machines Equipment maintenance Tooling, dies, plant services Storage area Spare parts, etc. Material handling within department Aisle space EIN4891 – Capstone Design Departmental Specification Total area specified based on departmental service and area requirement sheet Dimensions of materials, machines, for personnel space, material storage, and aisle Process layout. Not included: maintenance, quality, meeting space, etc. EIN4891 – Capstone Design Tesla Gigafactory Located in Sparks, NV One of the most technologically advanced factories in the world 1.9 million square feet footprint with 5.3 million square feet of operational space across floors – largest in the world Expected to be fully powered by renewable energy sources Other gigafactories in Buffalo, NY, Austin, TX, Shanghai, and Berlin https://www.cnbc.com/2019/05/03/we-went-inside-teslasgigafactory-heres-what-it-looked-like.html https://cleantechnica.com/2020/07/18/the-science-channelpresents-inside-the-tesla-gigafactory/ EIN4891 – Senior Design Project II Tesla Factory – Freemont, CA 400 cars manufactured a day 160 robots – 10 of the world’s largest robots EIN4891 – Senior Design Project II https://medium.com/tradr/teslas-approach-to-recycling-is-the-way-of-the-future-for-sustainable-production-5af99b62aa0e https://www.manufacturingtomorrow.com/article/2016/07/what-super-efficient-manufacturing-looks-like/8262
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