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Facility Design-Week 3Traditional Approach for
Facility Layout: Systematics Layout
Planning
Anastasia L.M.
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Facility Layout
A Layout problem may be to determine the location for a new machine, develop a new layout for an existing production plant, develop a layout for a new production plant, etc.
A Layout problem may arises due to changes in the design of a product, addition or deletion of a product, change in the demand of a product, changes in the design of the process, addition or deletion of a process, replacement of equipment, etc.
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Objectives of Facility Layout
Minimize investment in equipment.
Minimize production time.
Minimize material handling cost.
Maximize utilization of space.
Maintain flexibility of arrangement and operation.
Provide safety and comfort to employees.
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Sequential Approach vs Integrated Approach
Sequential Approach :
Product Design
Production Planning
Process Design
Facility Layout
Material Handling System Design
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Sequential Approach vs Integrated Approach
Integrated Approach :
Impressive results in cost, quality, productivity, sales, customer satisfaction, delivery time, inventory levels, space + handling requirements, building size, etc.
Product Design
Process Design
Schedule Design
Layout Design
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Material Handling System Design
Concurrent Engineering
Terms of product, process, scheduling and facility design planners work with marketing, purchasing, etc. Personnel address the design process in an integrated way.
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Facility Layout Procedures
Naddler’s Ideal System Approach (1961)
Immer’s Basic Steps (1950)
Apple’s Plant Layout Procedure (1977)
Reed’s Plant Layout Procedure (1961)
Muther’s Systematic Layout Planning (1961)
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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
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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
SEARCH
SELECT
Source: John S. Usher class notes
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SLP
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Systematic Layout Planning
P Product: Types of products to be produced What
Q Quantity: Volume of each part type How Much
R Routing: Operation sequence for each part type How
S Services: Support services, locker rooms, inspection stations, and so on With What
T Timing: When are the part types to be produced ? What machines will be used during this time period? When
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Sample relationship diagram
1 2
4
3
5
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1. Relationships
1
.Collection of Input Data
2.Flow of Materials
3.Activity Relationships
4.Relationship Diagrams
2. Space 1
.Space Requirements
2.Space Available
3.Space Relationship Diagrams
3. Adjustments
1
.Modifying Considerations
2.Practical Limitations
3.Evaluation & Final Selection
Systematic Layout Planning Procedure
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Information Gathering
Information about product, process and schedule is required.
The major effect of product design decisions is felt by the process designer, i.e., the material used to make a part will influence processing decisions.
Design for automation programs have been developed that consider the impact of the design of the product on the assembly process.
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Information Gathering
Their primary thrusts are (1) dimensional reduction, (2) parts elimination, and (3) parts standardization.
For (1), the cost of assembly is reduced if it occurs in a single dimension. The complexity of programming a robot increases geometrically with the number of assembly dimensions.
For (2), if more complex parts can be produced, the number of parts can be reduced.
Schedule design decisions tell us how much to produce and when to produce. From the market forecast, the production demand is determined and decisions about the production
rate are made.
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Information Gathering
Information about product :
- Photographs about the product
- “Exploded” drawings
- Engineering drawings of individual parts
- Parts list
- Bill of materials (structure of product)
- Assembly chart
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Information Gathering
Information about process :
• Route sheet (equipment and operation times)
• Precedence Diagram (prerequisite assembly
steps before new assembly step)
• Operation process chart (processing
operations, assembly operations, and
inspections)
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Information Gathering
Information about schedule :
• Production rate
• Product mix
• Market forecast (it is better to work with tomorrow’s
data than today’s data)
• Gantt charts
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The information about Product Design and
Process Design as an input for SLP have
been discussed in week 2.
Information Gathering
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Flow Analysis and Activity Analysis
Flow of material analysis is related to quantitative analysis; to analyse the movement between departments/operational activities
Activity analysis is related to qualitative factors that affect the determination of a facility/depatment location should be placed.
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From – To Chart
A chart is used for Quantitative Measurement from material movements
2222
FromTo
A B C D E F G H I Total
A 0
B 20 5 45 70
C 45 20 5 70
D 30 65 5 100
E 5 45 20 70
F 5 20 25 25 75
G 5 20 50 75
H 5 25 30 60
I 25 45 30 100
Total 100
70 70 100
70 75 75 60 620
From-To Chart Example
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From – To Chart (cont’)
ForwardDistance from diagonal
BackwardDistance from diagonal
1 x 260 = 260 2 x 1 x 10 = 20
2 x 130 = 260 2 x 2 x 70 = 280
3 x 130 = 390 2 x 3 x 0 = 0
4 x 15 = 60 2 x 4 x5 = 40
5 x 0 = 0 2 x 5 x 0 = 0
6 x 0 = 0 2 x 6 x 0 = 0
Total = 970 Total = 340
Total moment = 1.310
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Activity Relationship Chart
Suatu metode utk merencanakan & menganalisis keterkaitan antara setiap kelompok kegiatan yg saling berkaitan
Jenis-jenis keterkaitan dapat terjadi:
Between 2 production processes Between production process and service
activity, or other activities. Between 2 service activities.
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ARC (cont’)Closeness codes are:
Code Color Definition/closeness rating
A Merah Absolutely necessary
E Jingga Especially Important
I Hijau Important
O Biru Ordinary Important
U Uncolored Unimportant
X Coklat Undesirable
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Relationship Diagramming: Example
Production
Offices
Stockroom
Shipping and receiving
Locker room
Toolroom
A A
A O
O
OO
O
U
U U
U
EX
I
A Absolutely necessaryE Especially importantI ImportantO OkayU UnimportantX Undesirable
A Absolutely necessaryE Especially importantI ImportantO OkayU UnimportantX Undesirable
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Activity Relationship Diagram
A relationship diagram is a spatial arrangement of the departments to represent the relationship data in a graphical way. This diagram is also called an adjacency graph.
There are 2 ways of making ARD:
By making an Activity Template Block Diagram (ATBD) By using the combination of standardized lines and color
codes
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Relationship Diagram
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Relationship Diagrams: Example (cont’)
Key: AEIOUX
Offices
Stockroom
Locker room
Toolroom
Shipping and
receiving
Production
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ARD (cont’)
A: E:
X:Department No
Departement Name
I: O:
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Space Requirements & Space Availability
Determination of the Production Rate Determination of Batch Production Quantities
Economic Order Quantity Models Reject Allowance Problem
Determination of Equipment Requirements Determination of Employee Requirements
Manual Assembly Operators Machine Operators
Determination of Space Requirements Tables for Aisle Allowance, Food Services and Restrooms Other Methods to Determine Space Requirements Parking Space
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Designing the Layout
After flow and activity analysis, determine the space requirement, the alternative layouts should be generated
Simply, overall layout is generated by combining the relationship diagram/ARD and space requirement.
This combination is called a space-relationship diagram. Then layout design could be modified based on practical limitation and other considerations.
Overall layout is performed as a block plan or area allocation diagram. Block plan uses scale and show the location using internal partitions or columns.
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Space Relationship Diagram
When the space requirements for the departments are added to this relationship diagram, then a space relationship diagram has been constructed.
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Space Relationships Diagram
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Area Allocation Diagram
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Operations Review for MortAmerica, Inc.
Is there a significant increase in mortgage lending operations of MortAmerica, Inc.?
Are the costs of leasing and refurbishing interior space too high?
Is there a problem with the current location? For example: There is not enough space for expansion Major attorneys’ offices, other related financial institutions and
restaurants, are not located within a reasonable distance of MortAmerica, Inc.
Adequate parking space is not available Traffic is too congested
Will a change in office location improve business?
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SLP for MortAmerica, Inc.
Evaluation Planning Site selection Design and layout
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SLP for MortAmerica, Inc.
Review current space utilization Determine space projections Determine level of interaction between
departments Identifying special consideration
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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
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Current and Future Space Requirements
Support service area Current net space Current gross space150% of net space Future 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
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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
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Activity relationship diagram for MortAmerica, Inc.
MP
CS
CR
RR
CC
C/U
TM
CW
O/A
FS
C/P EBR
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Space relationship diagram for MortAmerica, Inc.
MP
CS
CR
RR
CC
C/U
TM
CW
O/A
FS
C/P EBR
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Pre-architectural layout for MortAmerica, Inc.
TM
MP
CC
C/U
CW
RRM
RRW
CS
CR
C/P
FS
EBR
O/A
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