1. Facilities Planning and Design Course code: 1704031511
Spring
Required Text: Tompkins et al., (2003). Facilities Planning, 3rd or later Edition, John Wiley and Sons Inc.
Students are encouraged to refer to the text book, and to take notes during the lectures.

2. Chapter 3- Flow Systems, Activity Relationships and Space Requirements
Facility Layout is the process that plans for the location of all machines, utilities, employee work stations, customer service area, material storage areas, aisles, restrooms, lunchrooms, drinking fountains, offices and computer rooms, and for the flow patterns of materials and people around, into and within buildings.
Objectives of facility layout is to minimize the total cost of processing, transporting, and storing material throughout the production system.
The materials used in manufacturing are many: raw materials, purchased components, materials-in-process, finished goods, packaging materials, maintenance and repair supplies, and scrap and waste.
A material-handling system is the entire network of transportation that receives material, store material in inventories, moves them about between processing points within and between buildings and finally deposits the finished products into vehicles that will deliver them to customer.

3. To determine the requirements of a facility, the following considerations should be emphasized:
Flow
Flow into, within and from manufacturing facility
Flow of materials, people, equipment, information, money, etc.
Flow depends on lot sizes, unit load size, material handling system, equipment arrangement and building configuration
Space
The amount of space required in the facility
Workstation specification, department specification and other space requirements
Enough space should be given to production equipment, material storage, material handling, offices, restrooms and cafeteria.
Activity relationships
Activity relationship is the key input in facilities design
Defined by flow relationships, organizational relationships, environmental relationships, process requirements and control relationships

4. Manufacturing Layouts:
Depending on product
volume-variety, facility
layout can be classified as:
Product Layout (Flow Shop)
Product Family (group technology) Layout
Process Layout (Job Shop)
Fixed Location (Static) Layout
Specialized Layouts:
Warehouses
Offices
Large shopping centers

5. Product layout (Flow shop)
Mass production, standard product, layout according to processing sequence
Examples include manufacturers of vehicles, assembly of electronic devices, food industry
Major problem: idle time (layout problem) or possibility of bottleneck (scheduling problem), solved by line balancing

6. Process layout (Job shop)
Used for Batch production, non-standard product
Examples include hospitals, colleges, banks, auto repair shops, and public libraries
Major problem is that different routings are possible (different products are to be made), which increases the cost of material handling between departments, to minimize this cost process layout should be developed such that departments having high flow between them are made close to each other.

7. Fixed product layout
Fixed product layout (Static Layout) is used in aircraft assembly, shipbuilding, and most construction projects

8. and product variety is not high to justify process layout
Group layout
Hybrid Layout
Hybrid (Mixed) Layout is used in cases where production volume is not high to justify Product Layout,
and product variety is not high to justify process layout
Examples:
One worker Many Machines
Group technology-Manufacturing Cells
Flexible Automation
Assembly cell for disk-drive HP company

9. Combining workstations
Comparison between layout types
Product
Layout
Combining workstations
Standardized
Product layout (Flow Shop)
Combine all workstations required to produce the product
Large stable Demand
Physically large
Fixed product layout
Combine all workstations required to produce the product with the area required for staging the product
Awkward to move
Low Demand
Capable of being grouped into families of similar parts
Group layout (product family layout)
Combine all workstations required to produce the family of products
None of the above
Process layout (Job Shop)
Combine identical workstations into departments
Combine similar departments

10. Advantages and disadvantages of different layout types

12. Group Technology – Cellular Manufacturing
Manufacturing cells group machines, employees, materials, tooling and Material handling and storage equipment to produce families of parts.
Manufacturing cell operation needs minimum external support
Often designed, controlled and operated using
JIT : Just in Time
TQM: Total Quality Management
TEI: Total Employee Involvement
Benefits of cell manufacturing:
Reduction: inventories, space, paperwork, equipment, transportation, etc.
Simplification: communication, handling, scheduling, etc.
Improvement: productivity, flexibility, quality, customer satisfaction, etc.

13. Group Technology – Cellular Manufacturing
Group layout
Hybrid Layout
Group Technology – Cellular Manufacturing
Group technology (product family) departments aggregate medium volume-variety parts into families based on similar manufacturing operations and design attributes.

14. Before GT
After GT

15. Before GT
After GT

16. Manufacturing cell forming Algorithms and Heuristics
Classification: grouping and coding according to design attributes to obtain part families (classes)
Production flow analysis: analysis of operation sequences and production routing through the plant
Clustering Methodologies: Direct Clustering Algorithm
Heuristic procedures: work load factors and percent of processing in a cell.
Mathematical models (Operations Research Algorithms)

17. Clustering methodologies
Link parts and machines in machine-part matrix (incidence matrix)
Group parts together so that they can be processed as a family
Direct Clustering Algorithm (Chan and Milner, 1982)
Machine-Part Matrix
Formation of two cells

18. Direct Clustering Algorithm (Steps and Example)
Form machine-part matrix (Incidence Matrix)
Sum the 1s in each column & row
Order the rows in descending order
Order the columns in ascending order
Sort the columns (1 in the first row moves left, then in the second row, etc.)
Sort the rows (1 in the first column moves upward, then in the second column, etc.)
Form sells
Example 1 1

19. Direct Clustering Algorithm
Form machine-part matrix
Sum the 1s in each column & row
Order the rows in descending order
Order the columns in ascending order
Sort the columns (1 in the first row moves left, then in the second row, etc.)
Sort the rows (1 in the first column moves upward, then in the second column, etc.)
Form sells 1 2

20. Direct Clustering Algorithm
Form machine-part matrix
Sum the 1s in each column & row
Order the rows in descending order
Order the columns in ascending order
Sort the columns (1 in the first row moves left, then in the second row, etc.)
Sort the rows (1 in the first column moves upward, then in the second column, etc.)
Form sells 2 3

21. Direct Clustering Algorithm
Form machine-part matrix
Sum the 1s in each column & row
Order the rows in descending order
Order the columns in ascending order
Sort the columns (1 in the first row moves left, then in the second row, etc.)
Sort the rows (1 in the first column moves upward, then in the second column, etc.)
Form sells 3 4

22. Direct Clustering Algorithm
Form machine-part matrix
Sum the 1s in each column & row
Order the rows in descending order
Order the columns in ascending order
Sort the columns (1 in the first row moves left, then in the second row, etc.)
Sort the rows (1 in the first column moves upward, then in the second column, etc.)
Form sells- Final Solution 4 5

23. Direct clustering algorithm “bottleneck machines”
Example 2
Possible solutions:
Locate the bottleneck machines close to each
other :
in different cells
at the boundary between cells
Redesign the parts
Outsource the parts
Duplicate machines and place them in each cell

24. Direct clustering algorithm “bottleneck machines”
Duplicate machines and place them in each cell 2a 2b
Duplicate machines and place them in each cell 3a 3b

25. Example 3