Facility Design-Week 1
Introduction to Facility
Planning
Anastasia L. Maukar
1
Definition of Factory
Factory/Plant:
2
Factory/plant
RESOURCES
MAN
MACHINES/
EQUIPMENTS
PRODUCTION SYSTEM
MATERIAL
ENERGY
MONEY
INFORMATION
FINISHED GOODS
3
Facilities Planning
 Facilities planning determines how an
activity’s tangible fixed assets best support
achieving the activity's objectives
4
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.
5
Facility Planning-Hierarchy
Facility
Location
Structural
Design
Facility
Planning
Facility
Design
Layout
Design
Handling
System Design
6
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).
7
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
8
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.
9
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
10
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
11
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”
12
Types of layout problems
Layout of a service system
Layout of a manufacturing facility
Warehouse layout
Nontraditional layout
13
Applications
 Manufacturing
 Healthcare
 Service




Restaurants
Banks
Airports
Entertainment
 Logistics and
Distribution
 Ports/Terminals
 Distribution Centers
14
Service Layout Problem
 Minimize transportation among personnel
 Communication and privacy
 Conform building codes
 Safety & security for the personnel
15
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
16
Service system layout – Grocery store
17
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?
18
Office structures
Closed structure
Semiclosed structure
Open structure
Semiopen structure
19
Closed structure
20
Semiclosed structure
Teller
Teller
Teller
21
Open structure
22
Semiopen structure
23
Service Layout
24
Service Industry - Bank
25
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
26
Assembly facility layout
27
Driveway layout
28
Warehouse layout
29
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
30
Warehouse layout
• Where to locate
receiving and shipping
functions?
• Should the two
functions be combined
at one location or
separated?
31
Warehouse Layout Problem
Goal: utilize space effectively to minimize
storage and material handling cost(MHC).
32
Warehouse Layout Problem
Factor: shape and size of aisle,
warehouse height, location and orientation
of docking area, types of rack, storage &
retrieval automation
.
33
Warehouse Layout Problem
Shape and size of aisle factor
 MH equipment/ device
 Types of rack
34
Warehouse Layout
35
Nontraditional layout
Keyboard layout
IC board layout
Computer disk storage layout
Airport gate layout
36
Non Traditional Layout Problem
Ex: Control panel LP in the design of a
computer backboard.
37