__________________________________________________________________________________
Faculty
: Engineering
Program
: Industrial Engineering
Unit
: Facility Design
Code
: IEN10243
Credits
: 3 credits
Semester
: 1
Prerequisite
: -
Lecturer
: Anastasia Lidya Maukar
Period
: 12th September - 10th December 2013
Content
This course is a study of principles and methods for analyzing and designing plant facilities and location. Selected
topics include traditional facility layout planning methods, systematic and computerized layout planning, warehouse
design, materials handling and facility location.
Objectives
Upon completion of this course, the student will:
1.
Understand the facility layout design process.
2.
Be able to prepare a facilities layout for the efficient flow of materials through a facility.
3.
Be able to calculate the number of machines required to meet a desired production capacity.
4.
Be able to prepare a from-to chart to measure and analyze quantitative flow requirements.
5.
Be able to prepare a Relationship chart to analyze qualitative relationships between departments.
6.
Be able to determine space requirements for equipment, materials, and people.
7.
Know the basic algorithms and computerized techniques for facilities layout
8.
Be able to determine the facility location using facility location models.
9.
Be able to prepare a written technical report and deliver a template.
Learning Activities/Classroom Policy
Students are required to be in class and to actively participate in class instructions. Students will complete a
project, quizzes, and a final evaluation.
1
Assessments*
Assignments
Week due
Percentage
Projects
Week #3, 5, 11
35%
Quiz
Week # 3, 5, 10, 12
15%
Mid-term Examination
Week # 7
25%
Final-Term Examination
Week # 13
25%
Total
100%
Grading Policy
A
-
85-100
B
-
70-84
C
-
60-69
D
-
55-59
E
-
<55
References**
Tompkins, J.A., et al., Facilities Planning, 3rd ed, John Wiley & Sons, 2003.
Heragu, Sunderesh, S., Facilities Design, CRC Press, 2008.
Meyers, Fred, E., Stephens, M.P.”Manufacturing Facilities Design and Material Handling, 3rd ed, Prentice Hall Inc.,
2000.
Meyers, Fred, E., Plant Layout and Material Handling, Prentice Hall, 1999
Sule, D.R., Manufacturing Facilities: Location, Planning, and Design, 3rd ed, CRC Press, 2009.
Apple, James M.., Plant Layout and Material Handling, 3rd ed, John Wiley & Sons, 1983. (Reprint 1999)
Project
A term project will be assigned that will require students to use the material being taught in the course. The
project should be performed in a group of 4 students. The project will be given and should be submitted as a
weekly assignment. The team will make periodic written report. At the end of the class, the team will make an oral
presentation of their result. A written final report will also be submitted at the time of the presentation.
Project Schedules
Week Assignment
1
Product and Process Analysis
3
Machine Requirement
5
Space Requirement
Description
Photograph, Bill of Material, Parts and Material
Specification, Operation Process Chart and
Assembly Chart, Machine Specification and
Dimension.
Routing Sheet,
MPPC, Determination of number of machine
and operators, organization structure and
determination of the number of personnel
Space requirement for: office, production floor,
Submitted in
Week 3
Week 3
Week 6
2
6
8
10
storage, warehouse, and other supporting
facilities (parking, toilet, canteen, etc)
Quantitative Data Analysis and From-to Chart
Week 10
Qualitative Data Analysis
ARC
ARD (activity relationship diagram for office
and the plant)
Layout Design and Material Handling
Layout Design using the algorithm.
Week 12
Material Handling Cost
Template and Written Final Report
Week 13
MATRIX
Week
1
Topics/
Brief Content
Introduction to the Course
Introduction to
Facility Planning
Objectives
Assignments and
Assessments
Source**
In this unit, the students will :
- Understand the
significance of facility
planning
- Understand different type
of facility layout
problems.
Heragu (2008)
chap. 1.,
Meyers(2000)
chap1,
Tompkins(2003)
chap 1
Heragu(2008)
chap. 2,
Meyers(2000)
chap 2 & 4,
Tompkins(2003)
chap 2
2
Product, Process, and
Equipment Design and
Analysis
In this unit, the students will
- define
and
analyze
product, process and
schedule
design
interactions by studying
the functions involved in
the product development
cycle.
3
Traditional Approaches to
Facility Layout:
Systematics Layout
Planning (SLP)
In this unit, the students will:
- Understand the step how
to design facilities layout
using traditional method ,
especially SLP
4
Flow, Space, and Activity
Relationships
In this unit, the students will:
- Understand the material
flow
- Be able to define the
activity relationship by
material flow or personnel
flow, environmental
considerations,
organizational structure,
and other considerations.
Meyers(2000)
chap 6-8,
Tompkins(2003)
chap 3-4
5
Flow, Space, and Activity
Relationships (continued)
Personnel Requirements
In this unit, the students will:
- Be able to calculate labor
and machine
requirements for a
manufacturing facility, by
Meyers(2000)
chap 6-8,
Tompkins(2003)
chap 3-4
Quiz #1
Heragu(2008)
chap. 3-4,
Meyers(2000)
chap 5,
Tompkins(2003)
chap 3
3
discussing the make-buy
issues, man-machine
charts and capacity
requirement methods.
- Be able to calculate and
plan personnel
requirements include
planning for employee
parking, locker rooms,
rest room and other
supporting facilities.
6
Group Technology
7
In this unit, the students will:
- Be able to design the
group technology layout
using clustering approach
Heragu(2008)
chap. 6
MID TERM TEST
8
Basic Algorithm for Facility
Layout
In this unit, the students will:
- solve facility design
problems through
analyzing layout models
and design basic
algorithms theoretically
using MST and GTA
Heragu(2008)
chap. 5,
Tompkins
(2003) chap.6
9
Computerized Layout
Planning: CORELAP,
ALDEP
In this unit, the students will:
- Understand the step how
to design facilities layout
using computerized
layout planning for
qualitative approach
Heragu(2008)
chap. 5,
Tompkins
(2003) chap.6
10
Computerized Layout
Planning: CRAFT
In this unit, the students will:
- Understand the step how
to design facilities layout
using computerized
layout planning for
quantitative approach
Heragu(2008)
chap. 5,
Tompkins
(2003) chap.6
11
Material Handling
In this unit, the students will:
- Understand, design and
analyze material handling
systems through different
material handling
equipment and material
handling principles used
in the warehousing,
manufacturing
12
Warehouse Operation
In this unit, the students will:
- Understand the
Quiz# 2
Tompkins
(2003) chap.5
Tompkins
(2003) chap.7
4
warehouse function and
storage operation
- Be able to design a
warehouse
13
14
Facility Location
In this unit, the students will:
- understand the basic
model of facility location
- be able to determine the
best location based on
quantitative and
qualitative factors
- solve facility location
problems by applying
analytical facilities
location method
Heragu(2008)
chap. 11-12,
Tompkins(2003)
chap. 10, Sule
(2009) chap.
17-19
FINAL TERM EXAMINATON
5