FACILITIES MAN AG EM ENT Session 2. 1
CONTENTS (1 of 2) Objective facilities design function Major elements of facilities design Importance of facilities design Facilities design & productivity Objectives of facilities design (FD) Functions & activities in FD Need for FD Enterprise design process Sequence of steps in design process
CONTENTS (2 of 2) Types of layout and problems expected Placing a new facility Desirable characteristics of a good layout Organization for layout function Functions of Plant Engineering Department Inter Department help in layout design Facilities Design process Consideration of Facilities Design
The Facilities Design Function
OBJECTIVES to get the inputs (material, supplies, etc) into through and out of each facility in the shortest time practicable, at acceptable cost. Facilities Design deals with the design and arrangement of physical elements of an activity/s related to the manufacturing industry, whose drawing represents a plant layout. Facilities Design analyzes, conceptualizes, designs implements systems for the production of goods or services.
and
FD is represented as a floor plan, or an arrangement of physical facilities (equipment, land, buildings, utilities, etc.) 4
Major Elements of Facilities Design S.No
Typical Inputs
Production Activities
Outputs
1.
Plant
Materials and Supplies
Conversion of materials to parts assemblies, products
Production and Scrap!
2.
Warehouse
Large quantities of Merchandise
Safekeeping and availability
Orders of Merchandise
3.
Retail Store
Orders of Merchandise
Display, convenient access, Individual items for transfers of ownership customers
4.
Post Office
Letters and Parcels
Sorting and accumulating
Orderly arrangement of letters and parcels
5.
Restaurant
Food and supplies
Preparation of food
Meals
6.
Hospital
Sick Patients, Medicines, Supplies
Services required to “cure” patients
Cured Patients
7.
Home
Food, supplies, equipment, e.t.c
Meals and orderly activity
Happy people 5
Scope of Facilities Design Dealing only with the careful and detailed planning of production equipment arrangement. Should include a careful study of at least the following areas of interest : 1. Transportation 2. Receiving 3. Storage 4. Production 5. Assembly 6. Packaging and packing 7. Material handling 8. Personnel Services 9. Auxiliary production activities
10. Warehousing 11. Shipping 12. Offices 13. External Facilities 14. Buildings – Canteens 15. Grounds 16. Location 17. Safety 18. Scrap
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1. 2. 3.
4.
5. 6.
Importance of Facilities Design An efficient plan for the flow of material is a primary requisite for economical production. The material flow pattern becomes the basis for an effective arrangement of physical facilities. Material handling converts the static flow pattern into a dynamic reality, providing the means by which material is caused or permitted to flow. Effective arrangement of facilities around the material flow pattern should result in efficient operation of the various related processes. Efficient operation of the various related processes. Minimum production cost should result in maximum 7 profit.
Facilities Design & Productivity Increasing productivity is usually a desired result of facilities design or re-design. It is accomplished by the design efforts necessary to carry out the several objectives of the facilities design process
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Objectives of Facilities Design 1. 2. 3. 4. 5. 6. 7. 8.
Facilitate the manufacturing Process Minimize material handling Maintain flexibility of arrangement and of operation Maintain high turnover of work-in-process Hold down investment in equipment. Make economical use of building cube. Promote effective utilization of manpower. Provide for employee convenience, safety and comfort in doing the work. 9
Facilitating the Manufacturing Process 1. Arrange Machines, equipment and work areas so that material is caused to move smoothly along in as straight a line as is possible 2. Eliminate all delays possible. It has been said that during 80% of the time a part is in the plant it is either being moved or stored – only 20% of the time is productive. 3. Plan the flow so that the work passing through an area can be easily identified and counted, with little possibility of becoming mixed with other parts or batches in adjacent areas. 4. Maintain quality of work by planning for the maintenance of conditions that are conducive 10to quality.
Objectives of Facilities Design If a finished layout is to present an effective arrangement of related work areas, in which goods can be economically produced, it must be planned with the objectives of layout well fixed in mind. The major objectives are to : 1. Facilitate the manufacturing process 2. Minimize material handling 3. Maintain flexibility of arrangement and of operation 4. Hold down investment in equipment 5. Make economical use of building cube 6. Promote effective utilization of manpower 7. Provide for employee convenience, safety, and comfort 11 in doing the work
Functions and Activities in Facilities Design Facilities design & Plant layout group perform a wide variety of activities. The list contain a. Raw materials b. Theoretical potential activities c. Range of facilities design interests
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Functions and Activities in Facilities Design S.No
Actions
Areas of Interest
Nature of Interest
01.
Advise (on)
Assembly
Activities
02.
Allocate
Auxiliary Services
Analysis
03.
Analyze
Building
Appropriation
04.
Approve
Construction
Automation
05.
Classify
Containers
Availability
06.
Coordinate
Cost
Benefits
07.
Design
Distribution
Budgets
08.
Determine
Equipment
Capability
09.
Develop
Fabrication
Capacity
10.
Establish
Facilities
Changes
11.
Estimate
Flow
Contracts
12.
Evaluate
Grounds
Controls
13.
Forecast
Handling
Costs
14.
Improve
Location
Criteria
15.
Investigate
Maintenance
Data
16.
Measure
Manpower
Efficiency
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Functions and Activities in Facilities Design… S.No
Actions
Areas of Interest
Nature of Interest
17.
Minimize
Manufacturing
Equipment
18.
Model
Material
Expansion
19.
Modify
Office
Facilities
20.
Monitor
Packaging
Feasibility
21.
Organize
Packing
Flexibility
22.
Plan
Plant layout
Flow
23.
Predict
Pollution
Functions
24.
Promote
Process
Hazards
25.
Provide
Production
Incentives
26.
Qualify
Productivity
Installation
27.
Reduce
Repair
Interrelationships
28.
Review
Safety
Layout
29.
Select
Salvage
Liason
30.
Specify
Scrap
Location
31.
Study
Security
Long range Planning
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Functions and Activities in Facilities Design… S.No
Actions
Areas of Interest
Nature of Interest
32.
Supervise
Space
Measurements
33.
Test
Storage
Mechanization
34.
Up-date
Traffic
Methods
35.
Transportation
Modifications
36.
Utilities
Needs
37.
Warehousing
Objectives
38.
Waste
Operations
39.
Organization
40.
Performance
41.
Plans
42.
Policies
43.
Problems
44.
Procedures
45.
Processes
46.
Programs
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Functions and Activities in Facilities Design… S.No
Actions
Areas of Interest
Nature of Interest
47.
Progress
48.
Records
49.
Regulations
50.
Replacements
51.
Reports
52.
Requirements
53.
Resources
54.
Schedules
55.
Services
56.
Sources
57.
Specifications
58.
Standards
59.
Systems
60.
Tests
61.
Trends
62.
Utilization
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Need for Facilities Design 1. Design a new plant. 2. Make changes and improvement to present design. 3. Integrate & locate new equipment. 4. Develop future plans.
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Functions and Activities in Facilities Design… Long and Short Term Plans: 10 years ahead 5 years ahead 2 years ahead 1 year ahead 6-12 months ahead
Estimate total space by function. Area allocation diagram by department. Rough layout of area under consideration. Detailed Layout. Appropriation approved.
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Enterprise Design Process
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The Enterprise Design Process Market Research: Determining what the customer wants Sales Forecasting: Determining how many, or how much. Product Design: Delineating product or service details Process Design: Determining how to make the product, or provide the service. Operation Design: Working out methods for effecting the processes, and from that, the number of machines and amount of manpower required.
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The Enterprise Design Process…
Facilities Design: Determining the material flow paths, and designing the arrangement of activities to provide an orderly and efficient movement of material through the overall process. Equipment Design: (as necessary) Building Design: By the architect and his associates. 5. Financing the facility 6. Procurement a. Building b. Equipment c. Manpower 7. Installation of facilities 21
The Enterprise Design Process… The actual manufacturing or productive process :
• •
• • • •
Manufacturing - the conversion of materials and supplies into products, such a typewriters, lamps, foods, automobiles, etc • The productive process – the organization and use of human effort to accomplish a desired result, in the form of a product or a service, ( dry cleaning, retailing, banking food services, etc). Warehousing of the finished goods. Distribution of goods. Marketing and sales. Customer: who use, evaluation, complaints, suggestions, etc., come back to the enterprise by way22of Market Research, beginning the whole cycle over again
Sequence of Steps in Design Process 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Procure basic data Analyze basic data Design productive process Plan material flow pattern Consider general material handling plan Calculate equipment requirements Plan individual work stations Select specific material handling equipment Coordinate groups of related operations Design activity interrelationships
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Sequence of Steps in Design Process…
1. 2. 3. 4. 5. 6. 7.
Determine storage requirements Plan service and auxiliary activities Determine space requirements Allocate activities to total space Consider building tyres Construct master layout Evaluate, adjust, and check layout with appropriate persons 8. Obtain approvals 9. Install layout’ 24 10. Follow-up on implementation of the layout
Types Layout Problems Expected 1. 2. 3. 4. 5. 6. 7. 8. 9.
Design change Reduces department Enlarged department Adding a new product Moving a department Adding a new department Replacing obsolete equipment Change in production methods Cost reduction 25
Planning A New Facility 1. Building not suited to requirements. 2. Failure to apply line production techniques when applicable. 3. Product design or process changes made without making necessary changes in the layout. 4. Installation of additional equipment without considering. 5. Unexplainable delays and idle time. 6. Stock control difficulties. 7. Decreased production in an area. 8. Crowded conditions. 9. Many men moving material. 26
Planning A New Facility… 1. Bottlenecks in production 2. Backtracking 3. Excessive temporary storage. 4. Obstacles in material flow 5. Scheduling difficulties 6. Wasted “cube” 7. Idle people and equipment 8. Excessive time in process 9. Poor housekeeping 27
A Good Layout Desirable Characteristics 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Planned activity interrelationships Planned material flow pattern Straight-line flow Minimum back-tracking Auxiliary flow lines Straight aisles Minimum handling between operations Planned material handling methods Minimum handling distances Processing combined with material handling 28
A Good Layout Desirable Characteristics… 1. Movement progresses from receiving towards shipping 2. First operations near receiving 3. Last operations near shipping 4. Point-of-use storage where appropriate 5. Layout adaptable to changing conditions 6. Planned for orderly expansion 7. Minimum goods in process 8. Minimum material in process 9. Maximum use of all plant levels 10. Adequate storage space
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A Good Layout Desirable Characteristics… 1. Adequate spacing between facilities 2. Building constructed around planned layout 3. Material delivered to employees and removed from work areas 4. Minimum walking by production operators 5. Proper location of production and employee service facilities 6. Mechanical handling installed where practicable 7. Adequate employee service functions 8. Planned control of noise, dirt, fumes, dust, humidity, etc. 9. Maximum processing time to overall production 30 time
A Good Layout Desirable Characteristics… 1. 2. 3. 4. 5. 6.
Minimum manual handling Minimum re-handling Partitions don’t impede material flow Minimum handling by direct labor Planned scrap removal Receiving and shipping in logical locations.
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Organization for Layout Function Large Organizations : Plant Layout Department Small Organizations : Fireman / Manager / GM
Small Organizations : In many organization the designations of layout mangers differ widely 32
Organization for Layout Function General Manager
Finance
Purchasing
Manufacturing
Sales
Product Engineering
Industrial Relations
Quality Control
Production Control
Production
Plant Engineering
Industrial Engineering
Production Engineering
Plant Layout
OR
Plant Layout 33
Functions of Plant Engineering Department 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Construction Housekeeping and custodial service Maintenance Material handling Facilities design Pollution control Safety Transportation Utilities Shops
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Organization Of Layout Function
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Interdepartmental help in Layout Design A. Sales Department 1. Determining quantities for production runs 2. Determining quantities to manufacture for replacement parts B. Purchasing Department 1. Finding necessary factory equipment 2. Procuring equipment at lowest practicable cost C. Product engineering department 1. Providing blueprints and parts lists 2. Offering information on manufacture, as gained 36 in research and development work
Interdepartmental help in Layout Design… A. Industrial Relations Department 1. Helping to design safety into the layout 2. Looking after employee comfort and services in layout 3. Training personnel for new jobs necessitated by new layouts B. Finance Department 1. Aiding in determining cost of layout 2. Aiding in keeping equipment records 37
Interdepartmental help in Layout Design… A. Production Engineering Division 1. Design of processing and production methods 2. Design of special tools and equipment 3. Planning operation sequence 4. Specifying machines and equipment to be used 5. Trying out tools, etc 6. Mechanization and automation 7. Production capability analysis 8. New process and equipment development 38
Interdepartmental help in Layout Design…
A. Industrial Engineering Division 1. Determining work methods for each work area 1. Determine production standards for all operation 2. Determining machine capacities and number of machines needed 3. Aid in comparing effectiveness of methods between alternate layouts 4. Suggestions on methods B. Production Control Division 1. Supply routings or operation lists 2. Determine production schedules 3. Aid in planning materials flow 39
Interdepartmental help in Layout Design… • •
Offer suggestions on materials handling methods Plan storage methods and space requirements A. Production Division 1. Suggestions on machine arrangement 2. Suggestions on human relations problems involved in layout 3. Ideas on materials handling • Plant Engineering division ( other than plant layout group) 1. Aid in planning for utilities 2. Plan for building changes or construction 3. Move machinery and equipment 40
Interdepartmental help in Layout Design… 1. Install machinery and equipment A. Quality Control Divisions 1. Help plant layout to maintain quality in processes 2. Assure proper handling to protect product from damage. 3. Plan scrap disposal
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Facilities Design Procedure Plan and design the arrangement of • • • • • •
Production equipment Handling equipment Auxiliary equipment Space Land Buildings
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Considerations in Facilities Design 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Collect basic data Analyze basic data Design production process Plan material flow pattern Consider general material handling plan Calculate Equipment requirements Plan individual work areas Select specific material handling equipments Coordinate groups of related operations Design activity relationships
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Considerations in Facilities Design… 1. 2. 3. 4. 5. 6. 7.
8. 9. 10.
Determine storage requirements Plan service and auxiliary activities Determine space requirements Allocate activity areas to total space Consider building types Construct master layout Evaluate, adjust and check layout with appropriate personnel Obtain approvals Install layout Follow up implementation of Layout.
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REFERENCES • “Plant Layout and Material Handling”, Chapter: 1, Pages 3-24, James M Apple, John Wiley & Sons
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