Lecture 1 2011

10/3/2010

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Dr. Ibrahim Rawabdeh (2010-2011)

What is Facilities Planning?

Facility:The company fixed assets.

Facility:The company fixed assets.

PlanningPlanning

Dr. Ibrahim Rawabdeh (2010-2011) ١

PlanningThe act of establishing an intended

method of accomplishingSomething

PlanningThe act of establishing an intended

method of accomplishingSomething

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Something that facilitates an action or a processaction or a processSomething created to serve a particular function

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Production/ManufacturingHealthcareHealthcareEducationTransportationMilitaryPublic assemblyRecreationalServiceServiceEmergencyCommercial/ResidentialFood

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Determines how an activity’s tangible fixed assets best support achieving the activity’s Objectivesupport achieving the activity s Objective.

Define the configuration and expected methods of operations for facilities.

The analysis conceptualization and design of arrangement of

Dr. Ibrahim Rawabdeh (2010-2011) 2

The analysis, conceptualization and design of arrangement ofphysical facilities and their interrelationships with the activities of personnel, materials and methods required to manufacture a product or provide a service to fulfill the objectives of the owners and managers efficiently economically and safely

Science face Art face

Collection of guideline, principles, techniques ,math

model,…etc.

Collection of guideline, principles, techniques ,math

model,…etc.

Experience, sense of engineering, common

sense.

Experience, sense of engineering, common

sense.


QT QL

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Facilities Location

Facilities Facilities planning

Facilities design

Facility systems design

Layout design


Handling systemsdesign

Placement with respect to customers, suppliers and other facilities that have a relationship with

it .

(Consists of structural systems, communication

systems, life safety systems…etc).

Facilities Location Facilities system design

Consists of equipment, machinery, and

Consists of (materials, personal, information, and machinery, and

furnishings within the building envelope.

Layout design

p , ,equipment handling systems required to support production).

Handling systemsdesign

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Manufacturingfacilitiesplanning

Plant location

Plant designPlant facility system

Plant layout

OfficeFacility

planning

g

Offi d i

Office location

Plant layout

Material handling

Offi l t

Office facility system

(a)


Facilities planning for specific types of facilities: (a) Manufacturing plant (b) Office

Office design

Information handling

Office layout

(b)


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Improve customer satisfaction by being easy to do business with,conforming to customer promises, and responding to customerneeds.Increase return on assets (ROA) by maximizing inventory turns,minimizing obsolete inventory, maximizing employee participation,and maximizing continuous improvement.Maximize speed for quick customer response.Reduced costs and grow the supply chain profitabilityIntegrate the supply chain through partnership and communication.Support the organization’s vision through improved material handling material control and good housekeeping


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.


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• The size of investment ( Fixed Cost )

• Continuous improvement capability

• Significant savings

• Increase productivity and reduce cost


• Flexibility .

Amount ($)

Planning Designing Building Installing Commissioning

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New facilityNew facilityExpansion due to volume or diversityNew machines and processesRelocating or consolidationLegal: New law or regulation Legal: New law or regulation (Occupational Safety & Health Act )

The facilities planning consists of the following six steps:

1 Define the problem1. Define the problem

2. Analyze the problem

3. Generate alternatives

4 Evaluate the alternatives 4. Evaluate the alternatives

5. Select the preferred design

6. Implement the design

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Problem New Symptoms Needs

1. Problem Definition

2. Analysis

3. Synthesis

4. Evaluation

Design 1 Design 2 Design n

5. Selection 6. Implementation

1. Problem definition:› Define objective (s)

Obj i i i i l / i i i di› Objective: to minimize total costs/minimize distance traveled

› Objectives: may be mathematical (analytical/quantitative) or qualitative

Productivity, Capital investment, Space utilizationFlexibility, Aesthetic, Material handling effectiveness

› Collect data: products / services to be delivered and quantities

› Important costs:› Important costs:Design, Construction, Installation, Material Handling (MH)Transportation/distribution, operation & maintenanceWIP

› Identify constraints

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1. P2. Analysis & synthesis:2. Analysis & synthesis:

a) Fact gathering; primary and secondary (support) activities and their interrelationship

b) Space requirements for all activities

3. Alternatives: generated by a search procedure

4. Evaluation: use models to assess performance with respect to criteria

5 Selection: approvals5. Selection: approvals6. Implementation: physical execution and monitoring

Ease of future expansionFlexibility of layoutFlexibility of layoutMaterial handling effectivenessSpace utilizationSafety and housekeepingWorking conditionsEase of supervision and controlEquipment utilizationq pAbility to meet capacity and requirementsInvestment or capital requiredAppearance and promotional value

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1. Define the problem (Planning facility)

a) Preplanning : i. Review the business plan ii. Define the methods and technologies employed to produce the product

iii. Define service activities required to support FP

b) Mission Statement : Facilities being planned must support the overall


company’s plans .

c) Organizing the planning project : Steering Committee with approved authority, define project manager and Committee members .

2. Analyze the problem

a) Location : identifying boundaries and characteristics of a facility external conditions :

i. Related to handling

ii. Related to communication ii. Related to communication

iii. Related to utilities and to building b) Facility Requirements

i. Capacity : desired product output per period of time

ii.Staffing : Estimation of the required number and

distribution


iii.Support system : information network, security ,

personnel service and maintenance .

iv. Space : amount (area) \ kind (physical features )\

shape of configuration

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c) Project schedule : Documenting the purpose, scope and timing of planned activities .

3. Determine the interrelationships between activities

Quantitative

Qualitative

4. Define space requirement for each activity

5. Generate alternative planes

Alternative Facilities Location


Alternative Facilities Design

6. Evaluate the alternatives (criteria, ranking, factors,.. Cost as an example)

7. Select a facility plan› The plan which will be most acceptable in satisfying

the objectives of the company

8. Implement the selected facility plan› Organizing, scheduling, budgeting,…

9. Maintain the facility plan

10. Redefine the objectives of the facility


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Winning FP Process (Table 1.3) 12 steps processg ( )

DEFINE

Analyze

N

ImplementFP Process is CI process

- Design and analysis of industrial facilities including g y gjust-in-time systems, queuing, material handling systems, material flow analysis, line balancing, systematic layout planning, design of warehouse facilities, and facilities location

- Facilities planning is a complex and broad subject that cuts across several specialized disciplines.that cuts across several specialized disciplines. (civil, electrical, industrial, mechanical, etc)

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All the facilities in the supply chain should have the following characteristics:have the following characteristics:

FlexibilityModularityUpgradabilityAdaptabilitySelective Operability

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Civil engineeringEl t i l/M h i l i iElectrical/Mechanical engineeringArchitecturalConstruction management/ContractorReal estateUrban planningUrban planningIndustrial engineering

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Industrial Engineers are focusing on requirements, resource allocation, and efficient use of resources

Facilities are the integration of many lower levelFacilities are the integration of many lower level systems• Space requirements with respect to flow and operations control• Personnel requirements• Equipment requirements• System design/layout with respect to flow and operations control• The use of information systems and technology to increase

effectiveness• Movement within a facility• Movement between facilities – Location• …

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Why are the components of this facility located as drawn?as drawn?Why are they arranged as drawn?Why are there so many duplicated items?Why is the facility so large or small?Why are there enclosed rooms and open areas?How many people will be working in the facility?Does this design meet requirements?etc.

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Industrial Engineers develop models to understand, design and validate systems, g yProcedures

e.g., Systematic Layout Planning (SLP)

Analytical modelse.g., machine fraction equations, queuing models

A l ti l l t d l / ftAnalytical layout models/softwareComputer simulations

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Documents

Lecture 1 2011