Embed Size (px)
Citation preview
Traditional Approaches to Facility Layout
Chapter 4
Significance of Facilities Planning
• 20-50% of all manufacturing costs are related to material handling
• FP can reduce MH costs by 10-30%• Therefore…
– 2-15% reductions in overall manufacturing costs could be achieved by effective facilities planning.
– Annual productivity would increase 3x more than it has in the past 15 years.
– Hard to make similar projections to other areas of our economy
– FP continues to be one of the most promising fields
Objectives• Minimize material handling costs• Utilize space efficiently• Utilize labor efficiently• Eliminate bottlenecks• Facilitate communication and interaction
between workers, between workers and their supervisors, or between workers and customers
• Reduce manufacturing cycle time or customer service time
Objectives (continued)• Eliminate waste or redundant movement• Facilitate the entry, exit, and placement of
material, products, or people• Incorporate safety and security measures• Promote product and service quality• Encourage proper maintenance activities• Provide a visual control of operations or
activities• Provide flexibility to adapt to changing
conditions• Increase capacity
The Nature of FP Objectives
• As you can see, there are MANY!
• They are conflicting. How?
• There are constraints. Can you list some?
The Facility Planning Problem
• It is a constrained multi-objective optimization problem with many non-quantifiable costs and benefits.
• There is NO OPTIMAL SOLUTION!• The best we can hope for is a “GOOD” solution.• Effective designs must consider all stakeholders
– Owners– Customers– Suppliers– Employees– Neighbors
Layout Problems
• Design or Optimization?
Facility Design Process
• Combination of art and engineering
• Many techniques available– Muther’s SLP Approach (1973)– Optimization based approaches
• We will focus on both
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
Systematic Layout PlanningInput Data and Activities
1. Flow of materials 2. Activity Relationships
6. Space Relationship Diagram
5. Space Available4. Space Requirements
3. Relationship Chart
8. Practical Limitations7. Modifying Considerations
9. Develop Layout Alternatives
10. Evaluation
ANALYZE
ANALYZE
SEARCH
SEARCH
SELECT
SELECT
Systematic Layout Planning
• P Product: Types of products to be produced• Q Quantity: Volume of each part type• R Routing: Operation sequence for each part
type• S Services: Support services, locker rooms,
inspection stations, and so on• T Timing: When are the part types to be
produced ? What machines will be used during this time period?
Sample relationship diagram
1 2
4
3
5
Special Considerations in Office Layout
• Minimizing distance traveled by employees
• Permitting flexibility so that the current layout can be changed, expanded or downsized easily
• Providing a safe and pleasant atmosphere for people to work in
• Minimizing capital and operational costs of the facility
Aesthetics
Aesthetics
Aesthetics
Aesthetics
Aesthetics
Aesthetics
SLP for MortAmerica, Inc.
• Evaluation
• Planning
• Site selection
• Design and layout
SLP for MortAmerica, Inc.
• Review current space utilization
• Determine space projections
• Determine level of interaction between departments
• Identifying special consideration
Current and Future Space Requirements
Categories of Employees and Number in Each Category Department Name Current/Future
Requirements Senior Executive
Senior Staff
Staff Clerical/Secretary Net Space
Required
Gross Space, 150% of Net Space
Current space/employee 150 100 75 Number of employees 1 4 1 Current total space/category
150 400 75 625 938
Future space/employee 120 75 Number of employees 6 1
Customer Service (CS)
Future space/category 720 75 795 1,193 Current space/employee 200 100 75 Number of employees 2 10 2 Current total space/category
400 1,000 150 1,550 2,325
Future space/employee 250 200 100 75 Number of employees 1 1 15 1
Mortgage processing/marketing (MP/M)
Future space/category 250 200 1,500 75 2,025 3,038 Current space/employee 100 75 Number of employees 10 1 Current total space/category
1,000 75 1,075 1,613
Future space/employee 80 Number of employees 5
Credit check (CC)
Future space/category 400 400 600 Current space/employee 200 100 90 75 Number of employees 2 4 15 5 Current total space/category
400 400 1,350 375 2,525 3,788
Future space/employee 250 100 100 75 Number of employees 3 4 20 2
Operations Audit (O/A)
Future space/category 750 400 2,000 150 3,300 4,950 Current space/employee 250 200 100 Number of employees 5 2 5
Top management (TM)
Current total space/category
1,250 400 500 2,150 3,225
Future space/employee 250 200 100
Current and Future Space Requirements
Support service areaCurrent net
spaceCurrent gross space150% of
net spaceFuture net space
Future gross space 150% of net space
Copying/Printing Area (C/P) 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
Relationship diagram for MortAmerica, Inc.
Customer service (CS)
Mortgage processing (MP)
Credit check (CC)
Closing/underwriting (C/U)
Top Management (TM)
E
E
I
I
O
I
E
OI
Operations/audit (O/A)
Copying/printing (C/P)
Files storage (FS)
Customer waiting (CW)
Conference room (CR)
I
A
U
U
A
A
O
U
I
Employee break room (EBR)
Rest rooms (RR)
O
X
I
I
U
X
X
I
I
O
U
A
O
E
U
U
O
I
X
UU
U
U
O
I
I
U
I
I
X
X
U
U
I
I
U
U
U
A
U
U
I
A
U
O
O
OA
Activity relationship diagram for MortAmerica, Inc.
MP
CS
CR
RR
CC
C/U
TM
CW
O/A
FS
C/P EBR
Space relationship diagram for MortAmerica, Inc.
MP
CS
CR
RR
CC
C/U
TM
CW
O/A
FS
C/P EBR
Engineering design approach
8. Continuously review after implementation
1. Identify the problem
2. Gather the required data
3. Formulate a model for the problem
4. Develop an algorithm for the model and solve it
5. Generate alternative solutions, evaluate, and select
7. Implement the solution
OSHA, ADA and Local Codes
OSHA, ADA and Local Codes
Service and Manufacturing Facilities
Organization Showers Lavatories Water Closets Water Fountain
Others
Restaurants - 1 per 200 1 per 75 1 per 500 1service sink
Arenas (capacity more than 3000)
- 1 per 200 (male); 1 per 150 (female)
1 per 120 (male); 1 per 60 (female)
1 per 1000 1 service sink
Schools - 1 per 50 1 per 50 1 per 100 1 service sink
Airports - 1 per 750 1 per 500 1 per 1000 1 service sink
Factories Section 411
1 per 100 1 per 100 1 per 1000 1 service sink
Hospitals 1 per 15 1 per room 1 per room 1 per 100 1 service sink
Prisons 1 per 15 1 per cell 1 per cell 1 per 100 1 service sink
Hotels 1 per room
1 per room 1 per room - 1 service sink
Dormitories 1 per 8 1 per 10 1 per 10 1 per 100 1 service sink
Service and Manufacturing Facilities
Organization Parking spaces
Restaurants (with drive- through facilities)
One space per 75 square feet of floor area or 1.5 persons (whichever is greater)
Theaters, Arenas, and Assembly areas
One space per 8 feet of bench length or 4 seats (whichever is greater)
Secondary schools and Colleges
One space per 8 students, one-and-a-half spaces per classroom, and number of spaces for gymnasium/assembly hall seating
Factories One space per 1000 square feet of area plus number of spaces for offices
Hospitals Two spaces per bed
Churches One space per three persons
Hotels One space per guest room plus number of spaces for accessory uses
Warehouses One space per 2000 square feet of floor area
Table 4.5 Minimum dimensions for parking stalls
Parking Angle Aisle-width (two-way)
Aisle-width (one-way)
Stall width Stall length
76-90o 25 feet 15 feet 9 feet 20 feet
30-75o 25 feet 12 feet 9 feet 22 feet
0-29o 18 feet 12 feet 9 feet 25 feet
Table 4.3 Accessible spaces for persons with disability
Total spaces in parking lot
1-25 26-50 51-75 76-100 101-150
151-200
201-300
301-400
401-500
501-1000
Minimum Accessible spaces
1 2 3 4 5 6 7 8 9 2%
