FACILITY LAYOUT & LOCATION PROF. DR. ORHAN TORKUL M. RAŞİT CESUR

RESOURCES Manufacturing Facilities Design and Material Handling; Matthew P. Stephens, Fred E. Meyers. Facility Layout and Location: An Analytical Approach; Richard L. Francis, Leon F. McGinnis, Jr., John A. White

CONTENTS INTRODUCTION TO MANUFACTURING FACILITIES DESIGN AND MATERIAL HANDLING SOURCES OF INFORMATION FOR MANUFACTURING FACILITIES DESIGN TIME STUDY PROCESS DESIGN FLOW ANALYSIS TECHNIQUES

CONTENTS ACTIVITY RELATIONSHIP ANALYSIS ERGONOMICS AND WORKSTATION DESIGN SPACE REQUIREMENTS AUXILIARY SERVICES REQUIREMENT SPACE EMPLOYEE SERVICES—SPACE REQUIREMENTS MATERIAL HANDLING MATERIAL HANDLING EQUIPMENT

CONTENTS OFFICE LAYOUT TECHNIQUES AND SPACE REQUIREMENTS AREA ALLOCATION FACILITIES DESIGN – THE LAYOUT APPLICATION OF COMPUTER SIMILATION AND MODELING SELLING THE LAYOUT

INTRODUCTION TO MANUFACTURING FACILITIES DESIGN AND MATERIAL HANDLING OBJECTIVES; Understand the importance of a systematic approach to facilities planning Be able to define facilities planning and material handling Understand the relationship between facilities planning and lean thinking

INTRODUCTION TO MANUFACTURING FACILITIES DESIGN AND MATERIAL HANDLING Be able to identify various types of waste, “muda” Understand the goals of facilities planning and material handling Understand the systematic layout procedure

BASIC CONCEPTS Facilities planning is a multi-faceted process, influenced by numerous factors and variables which are not always necessarily in concert and at times may even have contradictory impact on the decision-making process. Manufacturing facilities design is the organization of the company’s physical assets to promote the efficient use of resources such as people, material, equipment, and energy.

BASIC CONCEPTS Facilities design includes plant location, building design, plant layout, and material handling systems. Layout is the physical arrangement of production machines and equipment, workstations, people, location of materials of all kinds and stages, and material handling equipment.

BASIC CONCEPTS Material handling is defined simply as moving material. Improvements in material handling have positively affected workers more than any other area of work design and ergonomics.

COST REDUCTION STRATEGY AskFor EverySo We Can WhyOperationEliminate WhoTransportationCombine WhatInspectionChange sequence WhereStorageSimplify WhenDelay How

LEAN THINKING AND LEAN MANUFACTURING Lean manufacturing is a concept whereby all production people work together to eliminate waste. Muda (waste) is defined as any expense that does not help produce value. There are eight kinds of muda: overproduction, waiting, transportation, processing, inventory, motion, rework, and poor people utilization.

LEAN THINKING AND LEAN MANUFACTURING The term autonomation (jidoka) has been coined to indicate the transmission of the human element into automation. In the culture of continuous improvement, kaizen is another effective tool that can be easily applied to different aspects of facilities planning and material handling.

LEAN THINKING AND LEAN MANUFACTURING The term autonomation (jidoka) has been coined to indicate the transmission of the human element into automation. In the culture of continuous improvement, kaizen is another effective tool that can be easily applied to different aspects of facilities planning and material handling.

LEAN THINKING AND LEAN MANUFACTURING Kanban is a signal board that communicates the need for material and visually tells the operator to produce another unit or quantity. Value stream mapping (VSM) can be defined as the process of assessment of each component or the step of production to determine the extent to which it contributes to operational efficiency or product quality.

THE GOALS OF MANUFACTURING FACILITIES DESIGN AND MATERIAL HANDLING Minimize unit and project costs. Optimize quality. Promote the effective use of (a) people, (b) equipment, (c) space, and (d) energy. Provide for (a) employee convenience, (b) employee safety, and (c) employee comfort. Control project costs.

THE GOALS OF MANUFACTURING FACILITIES DESIGN AND MATERIAL HANDLING Achieve the production start date. Build flexibility into the plan. Reduce or eliminate excessive inventory. Achieve miscellaneous goals.

THE GOALS OF MANUFACTURING FACILITIES DESIGN AND MATERIAL HANDLING 1.Determine what will be produced. 2.Determine how many will be made per unit of time. 3.Determine what parts will be made or purchased complete—some companies buy out all parts, and they are called assembly plants. 4.Determine how each part will be fabricated.

THE GOALS OF MANUFACTURING FACILITIES DESIGN AND MATERIAL HANDLING 5.Determine the sequence of assembly. 6.Set time standards for each operation. 7.Determine the plant rate (takt time). 8.Determine the number of machines needed. 9.Balance assembly lines or work cells.

THE GOALS OF MANUFACTURING FACILITIES DESIGN AND MATERIAL HANDLING 10.Study the material flow patterns to establish the best (shortest distance through the facility) flow possible. string diagram multiproduct process chart from-to chart process chart flow process chart flow diagram

THE GOALS OF MANUFACTURING FACILITIES DESIGN AND MATERIAL HANDLING 11.Determine activity relationships. 12.Lay out each workstation. 13.Identify needs for personal and plant services, and provide the space needed. 14.Identify office needs and layout as necessary. 15.Develop total space requirements from the above information.

THE GOALS OF MANUFACTURING FACILITIES DESIGN AND MATERIAL HANDLING 16.Select material handling equipment. 17.Allocate the area according to the space needed and the activity relationships established in item 11 above. 18.Develop a plot plan and the building shape. 19.Construct a master plan. 20.Seek input and adjust.

THE GOALS OF MANUFACTURING FACILITIES DESIGN AND MATERIAL HANDLING 21.Seek approvals, take advice, and change as needed. 22.Install the layout. 23.Start production. 24.Adjust as needed and finalize project report and budget performance.

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