Lecture-1-LNkllllklklklklkllklllklkklkllk

• Implemented process improvements and streamlined operations, achieving a 20% increase in efficiency and significant klcost reductions.
• Coordinated logistics for events with up to 80,000 guests (football games) and 40,000 attendees (commencements), ensuring smooth operations and safety.
• Improved tracking systems, reducing discrepancies by 15% and ensuring timely, precise inventory management to meet business needs.
• Implemented process improvements and streamlined operations, achieving a 20% increase in efficiency and significant cost reductions.
• Coordinated logistics for events with up to 80,000 guests (football games) and 40,000 attendees (commencements), ensuring smooth operations and safety.
• Improved tracking systems, reducing discrepancies by 15% and ensuring timely, precise inventory management to meet business needs.

1. Facility Planning and
Material Handling
LECTURE 1: INTRODUCTION TO FACILITY PLANNING AND FACILITY
LAYOUT
1/16/2024

2. Dr. Laura Savage
Background
◦BS in Mechanical Engineering from Notre Dame
◦Masters in Integrated Manufacturing Systems
Engineering from NC State
◦Modeling and simulation for workforce development –
Huntington Ingalls Industries, Newport News Shipbuilding
◦PhD in Industrial and Systems Engineering from Virginia
Tech
◦Collegiate Faculty since fall 2019
Outside Activities
◦Knitter, reader, belly dancer, competitive pole dancer, all-
around nerd
◦Mother to Erin (3) and Connor (1)

4. Facilities Planning
Determines how an activity’s tangible fixed assets best support the
activity’s objective
Facilities Planning
Facility Location
Material
Handling
Systems &
Warehousing
Facility Layout
FixedAsset
Vehides
Buildings
Machines
-
MaterialHandling
whereeverythingsits
.

6. Facilities Planning
Example (from December 2015, ORMS Today, Volume 42, no. 6)
Problem: Roughly 1 in 6 people do not have adequate access to
water
◦Consider designing a network for water purification and delivery. A
purification and delivery subnetwork can cost >$1B to construct –
strategic planning is critical
Can be modeled as a facility location problem
◦Where to locate a purification system to serve customers and minimize
travel distance, cost, and provide adequate quantities of water?
◦Which customers should be allocated to which facility?

7. Facilities Planning
Determine:
◦Objective
◦Activities
◦Fixed assets for activities
◦Use of fixed assets

8. Objectives of Facilities Planning?
Minimize?
Maximize?
Other?

9. Facilities Planning
Affects an organization in two primary areas
Operational issues (flexibility, modularity, etc.)
◦Material handling –accounts for 20-50% of operational
costs
◦Effective facilities planning 10-30% reduction in MH
costs
Capital Expenses

10. Facilities Planning Process
Define the products
Specify the required
activities
Determine
interrelationships
between activities
Determine space
requirements
Generate
Alternatives
Evaluate Alternatives
Select preferred plan
Implement facilities
plan
Update products and
purpose of facility
Maintain and adapt
facilities plan
Gather
Data
Model
Analyze & Design
Implementation

11. Facilities Planning
Multidisciplinary –what does each group contribute?
◦Marketing
◦Product development
◦Manufacturing
◦Production and inventory control
◦Human resources and finance

12. Facility Layout
Facility Layout Problem
◦Find the most efficient non-overlapping arrangement of
departments with unequal area requirements, subject to
all location constraints, within a facility
What does “efficient” mean?
4b
1
2 3
4
5

13. Facility Layout
Result of many facility layout algorithms is a block layout
◦Shows the general placement, dimensions, and relative positions
of departments
4b
1
2 3
4
5

14. Facility Layout
What defines a good layout?
◦Right equipment
◦Right method
◦Right place
◦Effective processing
◦Shortest distance
◦Shortest time

15. Facility Layout Design Components
Generate or
Improve
Layout
Evaluate
Layout
Select
Layout
Collect
Flow and
Relationship
Data

16. Layout Evaluation
Layout
Evaluation
Flow pattern
analysis
Adjacency-
based
Distance-based
Qualitative
Quantitative

17. Effective Flow
Maximizing directed flow paths
◦Uninterrupted flow path progressing directly from origin to
destination
Uninterrupted flow paths
Interrupted flow paths

18. Flow Pattern Analysis
Graphically super-impose the flow data from the flow chart
onto the layout
Conclude if the resulting flow pattern is “efficient” or
“inefficient”
Characteristics
◦Easy to conduct
◦Provides a visual aid
◦May require significant trial and error to yield a “good” layout –
not necessarily an “optimal” layout

19. Flow Pattern Analysis
Efficient or inefficient?
1
8
3
7
9
6
2
4
5

20. Flow Pattern Analysis
1
9
8
7
3
6
5
4
2

21. Flow Pattern Analysis

22. Flow Pattern Analysis
Super-impose the flow chart data on this layout
1 4 7 10
2 5 8 11
3 6 9 12

23. Flow Pattern Analysis
1 4 7 10
2 5 8 11
3 6 9 12

24. Flow Pattern Analysis
One improved solution:
12 2 8 3
7 1 5 4
10 11 9 6