Facility Design-Week 3
Traditional Approach for Facility
Layout: Systematics Layout
Planning
Anastasia L.M.
1
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.
2
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.
3
Sequential Approach vs Integrated Approach
Sequential Approach :
Product
Design
Process
Design
Facility
Layout
Material
Handling
System
Design
Production
Planning
4
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.
Concurrent Engineering
Process
Design
Terms of product, process,
scheduling and facility design
planners work with marketing,
purchasing, etc. Personnel
address the design process in
an integrated way.
Layout Design
+
Material Handling
System Design
Product
Design
Schedule
Design
5
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)
6
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

7
Systematic Layout Planning
ANALYZE
Input Data and Activities
2. Activity Relationships
1. Flow of materials
3. Relationship Chart
SEARCH
4. Space Requirements
5. Space Available
6. Space Relationship
Diagram
7. Modifying Considerations
8. Practical Limitations
SELECT
9. Develop Layout
Alternatives
10. Evaluation
Source: John S. Usher class notes
8
9
SLP
10
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
11
Sample relationship diagram
1
2
3
4
5
12
Systematic Layout Planning Procedure
1. Relationships
1
2
3
4
3. Adjustments
Collection of Input Data
.
1
Flow of Materials
.
2
Activity Relationships
.
3
Modifying Considerations
.
Practical Limitations
.
Evaluation & Final Selection
.
Relationship Diagrams
.
2. Space
1
2
3
Space Requirements
.
Space Available
.
Space Relationship Diagrams
.
13
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.
14
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.
15
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
16
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)
17
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
18
Information Gathering
The information about Product Design and
Process Design as an input for SLP have
been discussed in week 2.
19
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.
20
From – To Chart

A chart is used for Quantitative
Measurement from material movements
21
From-To Chart Example
From
To
A
B
C
D
E
F
G
H
A
Total
0
B
20
C
45
D
30
E
5
5
20
45
70
5
70
65
5
45
20
5
20
25
G
5
20
H
5
25
F
100
70
70
100
100
70
I
Total
I
70
25
50
75
75
30
60
25
45
30
100
75
75
60
620
22
22
From – To Chart (cont’)
Forward
Distance from diagonal
1 x 260
=
260
Backward
Distance from diagonal
2 x 1 x 10
=
20
2 x 130
=
260
2 x 2 x 70
=
280
3 x 130
=
390
2x3x0
=
0
4 x 15
=
60
2 x 4 x5
=
40
5x0
=
0
2x5x0
=
0
6x0
=
0
2x6x0
=
0
Total
=
970
Total
=
340
Total moment = 1.310
23
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.
24
ARC (cont’)
Closeness codes are:
Code
Color
A
Merah
Definition/closeness
rating
Absolutely necessary
E
Jingga
Especially Important
I
Hijau
Important
O
Biru
Ordinary Important
U
Uncolored
Unimportant
X
Coklat
Undesirable
25
Relationship Diagramming: Example
A
E
I
O
U
X
Production
Absolutely necessary
Especially important
Important
Okay
Unimportant
Undesirable
O
A
Offices
U
E
O
Stockroom
Shipping and
receiving
I
A
A
X
U
U
U
O
O
Locker room
O
Toolroom
26
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
27
Relationship Diagram
28
Relationship Diagrams: Example (cont’)
Offices
Stockroom
Locker
room
Toolroom
Shipping
and
receiving
Production
Key: A
E
I
O
U
X
29
ARD (cont’)
A:
E:
X:
Department No
Departement Name
I:
O:
30
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
31
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.
32
Space Relationship Diagram

When the space requirements for the
departments are added to this relationship
diagram, then a space relationship
diagram has been constructed.
33
Space Relationships Diagram
34
Area Allocation Diagram
35
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?
36
SLP for MortAmerica, Inc.
Evaluation
 Planning
 Site selection
 Design and layout

37
SLP for MortAmerica, Inc.
Review current space utilization
 Determine space projections
 Determine level of interaction between
departments
 Identifying special consideration

38
Current and Future Space Requirements
D ep a rtm e n t N a m e
C u sto m er S ervice (C S )
M o rtgage p ro cessing/m arketin g
(M P /M )
C red it check (C C )
O p eratio ns A ud it (O /A )
T op m a nage m e nt (T M )
C u rren t/F u tu re
R eq u ire m e n ts
C urren t sp ace/e m p lo yee
N u m b er o f e m p lo yee s
C urren t to tal
sp ace/catego ry
F uture sp ace/e m p lo yee
N u m b er o f e m p lo yee s
F uture sp ace/catego ry
C urren t sp ace/e m p lo yee
N u m b er o f e m p lo yee s
C urren t to tal
sp ace/catego ry
F uture sp ace/e m p lo yee
N u m b er o f e m p lo yee s
F uture sp ace/catego ry
C urren t sp ace/e m p lo yee
N u m b er o f e m p lo yee s
C urren t to tal
sp ace/catego ry
F uture sp ace/e m p lo yee
N u m b er o f e m p lo yee s
F uture sp ace/catego ry
C urren t sp ace/e m p lo yee
N u m b er o f e m p lo yee s
C urren t to tal
sp ace/catego ry
F uture sp ace/e m p lo yee
N u m b er o f e m p lo yee s
F uture sp ace/catego ry
C urren t sp ace/e m p lo yee
N u m b er o f e m p lo yee s
C urren t to tal
sputure
ace/catego
rym p lo yee
F
sp ace/e
C a teg o ries o f E m p lo y ees a n d N u m b er in E a ch C a teg o r y
S en io r
S en io r
S ta ff
C lerica l/S ecreta ry
N et
G ro ss
E xec u tiv e
S ta ff
S p a ce
S p a ce,
R eq u ired
150%
o f N et
S p a ce
250
1
250
150
1
150
100
4
400
75
1
75
200
2
400
120
6
720
100
10
1 ,0 0 0
75
1
75
75
2
150
100
15
1 ,5 0 0
100
10
1 ,0 0 0
75
1
75
75
1
75
80
5
400
90
15
1 ,3 5 0
75
5
375
200
1
200
200
2
400
100
4
400
250
3
750
250
5
1 ,2 5 0
100
4
400
200
2
400
250
200
100
20
2 ,0 0 0
75
2
150
100
5
500
100
625
938
795
1 ,1 9 3
1 ,5 5 0
2 ,3 2 5
2 ,0 2 5
3 ,0 3 8
1 ,0 7 5
1 ,6 1 3
400
600
2 ,5 2 5
3 ,7 8 8
3 ,3 0 0
4 ,9 5 0
2 ,1 5 0
3 ,2 2 5
39
Current and Future Space Requirements
Current net space
Current gross space150% of net
space
Future net space
Future gross space 150% of net
space
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
Support service area
Copying/Printing Area (C/P)
40
Relationship diagram for MortAmerica, Inc.
C ustom er service (C S)
E
M ortgage processing (M P)
I
E
C redit check (C C )
I
O
E
I
C losing/underw riting (C /U )
O
I
O
I
C opying/printing (C /P)
A
C ustom er w aiting (C W )
U
O
X
U
U
X
A
X
E m ployee break room (E B R )
A
O
I
U
U
A
C onference room (C R )
U
I
U
U
O
U
U
U
I
U
U
U
U
U
O
A
U
U
U
A
X
X
A
Files storage (FS)
I
I
U
I
I
O
I
O perations/audit (O /A )
I
I
O
I
E
O
T op M anagem ent (T M )
O
I
X
I
R est room s (R R )
41
Activity relationship diagram for
MortAmerica, Inc.
TM
CC
MP
O /A
RR
C /U
CS
CW
FS
CR
C /P
EBR
42
Space relationship diagram for MortAmerica,
Inc.
TM
CC
MP
O /A
RR
C /U
CS
CW
FS
CR
C /P
EBR
43
Pre-architectural layout for MortAmerica, Inc.
TM
CC
MP
RR
M
RR
W
O /A
C /U
CS
CW
FS
CR
C /P
EBR
44