FACILITY PLANNING

FACILITY PLANNING

1. KIOT
Plant Layout and Facility Design
Course code: Greg 4181
Target group: 4
th
year GED
Chapter one
MANUFACTURING FACILITY PLANNING
By: Endashaw Yohannes
Kombolcha/Ethiopia
Nov, 2019
1/29/2020 1

2. Course Objectives
•Theobjectivesofthecourseare
•Tounderstandtheimportanceoffacilitydesigningeneraland
manufacturingunitinparticular.
•Toanalyzethebasicprinciplesofeffectiveplantlayoutanddesignas
theseapplytotheapparelindustry.
•Todevelopunderstandingofbuildingtypologyandindoorenvironment
•Todrawuponspecializedknowledgefromanumberofdisciplines
includingengineering,architecture,businessmanagement,and
economics,astheserelatetoplantengineering.
•Tolearntheplanningoflayoutusingsimulationexercisesinclassroom.
•Tounderstandprinciplesofmaterialsystemandequipments
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3. CHAPTER ONE: OUTLINE
oIntroductiontoFacilityPlanning
owhyfacilityplanningisimportant?
oObjectivesofFacilityPlanning
oClassificationofFacilityPlanning
oFacilityplanningprocesssteps
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4. 1. Introduction to facility planning
WhatisFacility?
•Afacilityisanentity(object)thatfacilitates
theperformanceofanyjob.
•Example Machine,tool,work center,
manufacturingcell,warehouse,land,buildings,
equipment,furnishingsandetc.
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5. WhatisFacilityPlanning?
FacilityPlanningdetermineshowanactivity’stangiblefixedassets
bestsupportinachievingtheactivity’sobjectives.
Examples:
a.Inmanufacturing,theobjectiveistosupportproduction.
(manufacturingfacilityPlanning)
b.Inanairport,theobjectiveistosupportthepassengerairplane
interface.
c.Inahospital,theobjectiveistoprovidemedicalcareto
patients.
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6. Facility plan
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7. Hierarchy of Facility Planning
Facility
Planning
Structural
Design
Facility
Location
Facility
Design
Layout
Design
Handling System
Design
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8. 1. Facility location : is the placement of a facility
with respect to customers, suppliers,
and other facilities with which it
interfaces.
2. Structure Design: consists of the building
and services (e.g., gas, water system,
lighting system, air conditioning system,,
sewage system, safety system, etc. )
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9. 3. Layout Design: consists of all equipment,
machinery, and furnishings within the
structure.
4. Handling System Design: consists of the
mechanism by which all interactions
required by the layout are satisfied
(e.g., materials, personnel, information,
and equipment handling systems).
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10. Plant lay out
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11. Why is Facility planning important?
1)Facility planning must be a continuing activity to be
competitive and keep developmentsin its field.
•Economic considerations of existing systems,
personnel and equipment
•New machines and processes
•Rapid changes in production techniques in the
present and future
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12. 2) Facility planning can increase plant productivity and
reduce costs by reducing or eliminating all activities
that are unnecessary and wasteful.
3) By incorporating vital health and safety measures
the employer may avoid unsafe conditions and losses
in both money and manpower resulting from industrial
accidents.
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Why is Facility planning important?
Cont..

13. 4) Energy conservation incorporating new methods of
energy to reduce the cost of energy
5) Other factors that requires investment in new facilities
Example
•Fire protection ,Security, Disability act
•Community rules and regulations regarding noise ,air
pollution, liquid and solid waste disposal.
6) Pilferage-stealing merchandise from manufacturing
companies etc…
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Why is Facility planning important?
Cont..

14. 2. Objectives of Facility planning
oMinimize capital investment & increase productivity
oImprove customer satisfaction
oEffectively utilize people, equipment ,Space and energy
oImproved material handling, material control and good
house keeping.
oPromote flexibility & increase speed to customer
response (shorten lead time)
oProvide for employee safety and job satisfaction
oImprove productivity and reduce costs
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15. 3. Classification of Facility Planning
•It is important to organize and classify facility planning
into manageable sub-projects based on their Levels of
Detail.
•Each sub-projecthas a series of tasks that the design
team must complete.
•The tasks and their sequence differ for each level
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16. Facility planning levels of details
I. Global (Site Location)
Thisinvolvesfactorssuchasfreightcost,laborcost,skill
availabilityandsitefocus.
II. Supra (Site Planning)
This includes number, size, and location of buildings. It includes
infrastructure such as roads, water, gas and rail.
III. Macro (Building Layout)
Operating departments are defined and located at this level.
Frequently, this is the most important level of planning. A Macro-
Layout institutionalizes the fundamental organizational structure
in steel and apparel industry.
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17. Facility planning levels of details cont..
IV.Micro(Work cell/Department
Layout)
determinesthelocationofspecificequipmentand
furniture
V.Sub-Micro(WorkstationDesign)
focusesonindividualworkers.Herewedesign
workstationsforefficiency,effectivenessand
safety.Ergonomicsiskey.
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18. 18

19. 4. Facility planning process steps
1)Define or redefine the objective of the facility
2)Specify the primary and support activities to be performed in
accomplishing the objective
3)Determine the interrelationships among all activities
4)Determine the space requirement for all activities
5)Generate alternative facility plans
6)Evaluate alternative facility plans
7)Select a facilities plan
8)Implement the facilities plan
9)Maintain and adapt the facility plans
10)Redefine the objective of the facilities
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20. 1)Define or redefine the objective of the facility
•May be planning for new facility or improvement of
existing facility.
•Products to be produced or services to be provided
must be specified quantitatively
•Volumes or levels of activities are to be identified
when possible.
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21. 2)Specifytheprimaryandsupportactivitiestobe
performedinaccomplishingtheobjective
•Primaryandsupportactivitiestobeperformedand
shouldbespecifiedintermsofoperations,equipment
,personnelandmaterialflowinvolved.
•Supportactivitiesallowprimaryoperationsto
functionproperlywithoutinterruptions.
e.g Maintenancefunctionisasupportactivityfor
manufacturing.
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22. 3)Determinetheinterrelationshipsamongallactivities
•Definebothquantitativelyandqualitativelyhow
activitiesinteractandsupportoneanotherwithinthe
boundariesofthefacility.
4)Determinethespacerequirementforallactivities
•Allequipment,material,andpersonnelrequirements
mustbeconsideredwhileconsideringspace
requirementsforeachactivity.
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23. 5) Generate alternative facility plans
•Alternative facility plans will include both alternative
facility locations and alternative facility designs.
•Alternative facility designs will include alternative
layout design, structural designs and material handling
system designs.
•Depending on the situation the facility location decision
and facility designs may be decoupled
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24. 6) Evaluate alternative facility plans
•Determine the factors, set an accepted criteria and
rank the plans.
7) Select a facility plans
•Select the most acceptable in satisfying the goals and
objectives of the organizations.
•Most often cost is not the only major considerations
when evaluating a facility plans.
•Use the information generated in step 6.
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25. 8)Implementthefacilityplans
•Afterselection,considerableamountofplanningmust
precedebeforetheactualconstructionofthefacility.
•Supervisinginstallationoflayout,gettingreadyto
startup,actualstartingup,runningandcorrection
activitiesareallpartofimplantationphaseoffacility
planning.
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26. 9) Maintain and adapt facilities plans.
•When new requirements are placed on the facility, the
facility plan must be modified accordingly.
•Changes in product design, new machines ,material
handling equipments or flow patternsrequire an
updated facility plan.
10) Redefine the objective of the facility
•In case of potential modifications ,expansion and so on
for existing facilities, all recognized changes must be
considered and the objective of the facility should be
redefined in quantifiable terms
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27. Brainstorming
•Think about your role as a facility
planner and what kind of
improvements would you like to
suggest for garment industries.
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