1. Layout
Adapted from:
Facilities Planning, Tompkins, White, Bozer, Frazelle, Tanchoco, Trevino, Wiley, New York, 1996

2. Graph-Based Construction Method1 1
Directors Conference Room
President
Sales
Personnel
Plant manager 2 I 9 3 2 8 4 12 10 5 3 13 20 7 4 2 5
There are lots of decision processes described in available literature. We feel whatever process you select for your organization should accomplish the following:
You want to be able to explain the decisions to others. And the organization needs to feel comfortable that regardless who made the decision, it was reached in an acceptable manner.
Remove personalities and biases from the review/approval cycle. This is accomplished by establishing a weighted criteria. This criteria and the weighting serve as a focal point for debate. It forces biases to the surface, where they can be dealt with. Once the biases are resolved, alternatives can be generated.
Generates alternatives. We need to go beyond the old tried and true solutions. Forcing multiple approaches fosters creativity.
Include risk as a part of the decision, even if we cannot quantify it. Risk cannot be eliminated but if it is identified, we can manage it.
Select the best possible choice and communicate it throughout the organization.

3. Adjacency Graphs – Version A
Arc
Weight
1-2 9
1-5
2-3 12
2-4 13
2-5 7
3-4 20
4-5 2
Total 63 1 9 5 7 2 2 13 12 4
The process we describe here can be used for any situation you face. When you are using the process to select a strategy, the decision statement is the goal and the criteria comes from the cultural success factors and obstacles. The alternatives are the different approaches that are available to you.
This logic path assures objectivity and ensures that we cover all essential data.
Making good decisions depends on the quality of our:
Selection of a goal that describes the decision,
Definition of the specific factors that must be satisfied,
Evaluation of the available alternatives, and
Our understanding of the consequences of those alternatives. 20 3

4. Adjacency Graphs – Version B
Arc
Weight
1-5
2-5 7
1-2 9
1-4 10
2-4 13
2-3 12
3-4 20
Total 71 5 7 1 9 2 10 13 12 4
The process we describe here can be used for any situation you face. When you are using the process to select a strategy, the decision statement is the goal and the criteria comes from the cultural success factors and obstacles. The alternatives are the different approaches that are available to you.
This logic path assures objectivity and ensures that we cover all essential data.
Making good decisions depends on the quality of our:
Selection of a goal that describes the decision,
Definition of the specific factors that must be satisfied,
Evaluation of the available alternatives, and
Our understanding of the consequences of those alternatives. 20 3

5. Graph-Based – Step 2 3 4 Total 1 8 10 18 2 12 13 25 5 2 12 13 (Best) 42 12 13 3 4 20
The process we describe here can be used for any situation you face. When you are using the process to select a strategy, the decision statement is the goal and the criteria comes from the cultural success factors and obstacles. The alternatives are the different approaches that are available to you.
This logic path assures objectivity and ensures that we cover all essential data.
Making good decisions depends on the quality of our:
Selection of a goal that describes the decision,
Definition of the specific factors that must be satisfied,
Evaluation of the available alternatives, and
Our understanding of the consequences of those alternatives.

6. Graph-Based – Step 3 2 3 4 Total 1 9 8 10 27 5 7 2 (Best) 9 12 13 1 109 12 13 1 8 10 3 4 20
The process we describe here can be used for any situation you face. When you are using the process to select a strategy, the decision statement is the goal and the criteria comes from the cultural success factors and obstacles. The alternatives are the different approaches that are available to you.
This logic path assures objectivity and ensures that we cover all essential data.
Making good decisions depends on the quality of our:
Selection of a goal that describes the decision,
Definition of the specific factors that must be satisfied,
Evaluation of the available alternatives, and
Our understanding of the consequences of those alternatives.

7. Graph-Based – Step 4 1 2 3 4 5 7 Faces Total 1-2-3 7 1-2-4 9 (best)7 2
Faces
Total
1-2-3 7
1-2-4 9
(best)
1-3-4 2
2-3-4 9 7 13 12 5 2 1 10 8
The process we describe here can be used for any situation you face. When you are using the process to select a strategy, the decision statement is the goal and the criteria comes from the cultural success factors and obstacles. The alternatives are the different approaches that are available to you.
This logic path assures objectivity and ensures that we cover all essential data.
Making good decisions depends on the quality of our:
Selection of a goal that describes the decision,
Definition of the specific factors that must be satisfied,
Evaluation of the available alternatives, and
Our understanding of the consequences of those alternatives. 3 4 20

8. Block Layout From The Final Adjacency Graphs
Arc
Weight
1-2 9
1-3 8
1-4 10
1-5
2-3 12
2-4 13
2-5 7
3-4 20
4-5 2
Total 81 12 2 13 9 7 1 5 8 2 10
The process we describe here can be used for any situation you face. When you are using the process to select a strategy, the decision statement is the goal and the criteria comes from the cultural success factors and obstacles. The alternatives are the different approaches that are available to you.
This logic path assures objectivity and ensures that we cover all essential data.
Making good decisions depends on the quality of our:
Selection of a goal that describes the decision,
Definition of the specific factors that must be satisfied,
Evaluation of the available alternatives, and
Our understanding of the consequences of those alternatives. 3 4 20

9. Developing Alternative Layouts
Exert the necessary effort
Set a time limit – People need deadlines or milestones to mark progress on a long term project (celebrate small victories)
Seek many alternatives – decision makers will expect to see several options
Establish a goal – without a goal, success is difficult to measure
Make liberal use of the questioning attitude – 5 W’s, Devils advocate
Don’t get bogged down in details too soon – many times technical and operational people will tend to look at the details of a particular aspect of a project rather than continue to consider other alternatives.
The decision is stated in terms of a goal which directs the search for solutions in positive ways. A confused and unfocused group starts getting organized by concentrating on the goal of the solution, not on the solution itself.
In the planning process, the goal is a given, but that is not always the case. Too often we believe the decision statement is a given. In fact, the reason for our decision is essential to opening the search for a good solution. Goals direct the search for positive ways. Ostensibly expand our goal; then create a hierarchy of goals or decision statements.
Compose the decision statement using an action verb, an object and an adjective. The action verb should be prescriptive and concerned with the total set of conditions (for example, to select, choose, determine, have, establish, provide) as opposed to verbs that indicate a measurement of change or incremental goals (to increase, reduce, minimize). The adjectives modify or constrain. They reduce the range of possible solutions with a limitation.

10. Developing Alternative Layouts
Don’t “fail to see the forest for the tress” – fail to see the big picture because the focus is on the details
Think big, then think little – do not limit your thinking - consider the ideal situation even though it is not feasible
Don’t be conservative -
Avoid premature rejection – let seemly wild ideas remain in consideration until a large number of ideas have been developed and considered
The decision is stated in terms of a goal which directs the search for solutions in positive ways. A confused and unfocused group starts getting organized by concentrating on the goal of the solution, not on the solution itself.
In the planning process, the goal is a given, but that is not always the case. Too often we believe the decision statement is a given. In fact, the reason for our decision is essential to opening the search for a good solution. Goals direct the search for positive ways. Ostensibly expand our goal; then create a hierarchy of goals or decision statements.
Compose the decision statement using an action verb, an object and an adjective. The action verb should be prescriptive and concerned with the total set of conditions (for example, to select, choose, determine, have, establish, provide) as opposed to verbs that indicate a measurement of change or incremental goals (to increase, reduce, minimize). The adjectives modify or constrain. They reduce the range of possible solutions with a limitation.

11. Developing Alternative Layouts
Avoid premature acceptance – do not jump to a solution – continue to develop alternatives
Refer to analogous problems of others
Consult the literature
Consult peers in other organizations
Use the brainstorming technique
Divorce your thinking from the existing solution
Spread the effort out over time – creativity often requires time to develop
The decision is stated in terms of a goal which directs the search for solutions in positive ways. A confused and unfocused group starts getting organized by concentrating on the goal of the solution, not on the solution itself.
In the planning process, the goal is a given, but that is not always the case. Too often we believe the decision statement is a given. In fact, the reason for our decision is essential to opening the search for a good solution. Goals direct the search for positive ways. Ostensibly expand our goal; then create a hierarchy of goals or decision statements.
Compose the decision statement using an action verb, an object and an adjective. The action verb should be prescriptive and concerned with the total set of conditions (for example, to select, choose, determine, have, establish, provide) as opposed to verbs that indicate a measurement of change or incremental goals (to increase, reduce, minimize). The adjectives modify or constrain. They reduce the range of possible solutions with a limitation.

12. Developing Alternative Layouts
Involve operating people – people closest to the process often:
Understand the process better than anyone else since they operate it everyday
Know details about the process that are otherwise unknown to engineers and management
Management needs the buy-in of operators to make the new layout function to its full capability
Motivated people can make a bad plan work and a good plan fail
The decision is stated in terms of a goal which directs the search for solutions in positive ways. A confused and unfocused group starts getting organized by concentrating on the goal of the solution, not on the solution itself.
In the planning process, the goal is a given, but that is not always the case. Too often we believe the decision statement is a given. In fact, the reason for our decision is essential to opening the search for a good solution. Goals direct the search for positive ways. Ostensibly expand our goal; then create a hierarchy of goals or decision statements.
Compose the decision statement using an action verb, an object and an adjective. The action verb should be prescriptive and concerned with the total set of conditions (for example, to select, choose, determine, have, establish, provide) as opposed to verbs that indicate a measurement of change or incremental goals (to increase, reduce, minimize). The adjectives modify or constrain. They reduce the range of possible solutions with a limitation.

13. Developing Alternative Layouts
Involve management
Need management support for any large decision
May provide insight about:
Future business plans not documented in formal plans
Industry trends
Market trends
Experiences at other facilities – many managers have managed other facilities in the organization or other organizations, which may lead to lessons learned
May have contacts at other companies for benchmarking
The decision is stated in terms of a goal which directs the search for solutions in positive ways. A confused and unfocused group starts getting organized by concentrating on the goal of the solution, not on the solution itself.
In the planning process, the goal is a given, but that is not always the case. Too often we believe the decision statement is a given. In fact, the reason for our decision is essential to opening the search for a good solution. Goals direct the search for positive ways. Ostensibly expand our goal; then create a hierarchy of goals or decision statements.
Compose the decision statement using an action verb, an object and an adjective. The action verb should be prescriptive and concerned with the total set of conditions (for example, to select, choose, determine, have, establish, provide) as opposed to verbs that indicate a measurement of change or incremental goals (to increase, reduce, minimize). The adjectives modify or constrain. They reduce the range of possible solutions with a limitation.

14. Developing Alternative Layouts
Involve experienced people
Know a lot about the process
Know what has works and not worked in the past
Are often leaders (both formal and informal) that will be very influential to others in the facility – thus if the leaders are involved, then they will likely buy-in the decisions and support than during implementation
The decision is stated in terms of a goal which directs the search for solutions in positive ways. A confused and unfocused group starts getting organized by concentrating on the goal of the solution, not on the solution itself.
In the planning process, the goal is a given, but that is not always the case. Too often we believe the decision statement is a given. In fact, the reason for our decision is essential to opening the search for a good solution. Goals direct the search for positive ways. Ostensibly expand our goal; then create a hierarchy of goals or decision statements.
Compose the decision statement using an action verb, an object and an adjective. The action verb should be prescriptive and concerned with the total set of conditions (for example, to select, choose, determine, have, establish, provide) as opposed to verbs that indicate a measurement of change or incremental goals (to increase, reduce, minimize). The adjectives modify or constrain. They reduce the range of possible solutions with a limitation.

15. Developing Alternative Layouts
Involve inexperienced people
Do not know a lot about the process and thus are not biased toward a given solution
Often provide new ideas from their previous experience
Bring enthusiasm to the project since they were chosen to be a part of the layout process
The decision is stated in terms of a goal which directs the search for solutions in positive ways. A confused and unfocused group starts getting organized by concentrating on the goal of the solution, not on the solution itself.
In the planning process, the goal is a given, but that is not always the case. Too often we believe the decision statement is a given. In fact, the reason for our decision is essential to opening the search for a good solution. Goals direct the search for positive ways. Ostensibly expand our goal; then create a hierarchy of goals or decision statements.
Compose the decision statement using an action verb, an object and an adjective. The action verb should be prescriptive and concerned with the total set of conditions (for example, to select, choose, determine, have, establish, provide) as opposed to verbs that indicate a measurement of change or incremental goals (to increase, reduce, minimize). The adjectives modify or constrain. They reduce the range of possible solutions with a limitation.

16. Developing Alternative Layouts
Involve those who oppose change
If you can convince that person that the new layout is a positive change, then others will be influenced by that person’s conversion
These people, once converted, will often be your best advocate for the new layout
Involve those who promote change
Often open to new ideas
Willing to sell those ideas to others
Good at offering new ideas
The decision is stated in terms of a goal which directs the search for solutions in positive ways. A confused and unfocused group starts getting organized by concentrating on the goal of the solution, not on the solution itself.
In the planning process, the goal is a given, but that is not always the case. Too often we believe the decision statement is a given. In fact, the reason for our decision is essential to opening the search for a good solution. Goals direct the search for positive ways. Ostensibly expand our goal; then create a hierarchy of goals or decision statements.
Compose the decision statement using an action verb, an object and an adjective. The action verb should be prescriptive and concerned with the total set of conditions (for example, to select, choose, determine, have, establish, provide) as opposed to verbs that indicate a measurement of change or incremental goals (to increase, reduce, minimize). The adjectives modify or constrain. They reduce the range of possible solutions with a limitation.

17. Developing Alternative Layouts
Be aware of what the competition is doing
Do not get caught by surprise by what the competition/industry is doing
Recognize your own limitations
Look for trends
Do your homework first
Understand the requirements
Don’t overlook an improved present method
Think long range
The decision is stated in terms of a goal which directs the search for solutions in positive ways. A confused and unfocused group starts getting organized by concentrating on the goal of the solution, not on the solution itself.
In the planning process, the goal is a given, but that is not always the case. Too often we believe the decision statement is a given. In fact, the reason for our decision is essential to opening the search for a good solution. Goals direct the search for positive ways. Ostensibly expand our goal; then create a hierarchy of goals or decision statements.
Compose the decision statement using an action verb, an object and an adjective. The action verb should be prescriptive and concerned with the total set of conditions (for example, to select, choose, determine, have, establish, provide) as opposed to verbs that indicate a measurement of change or incremental goals (to increase, reduce, minimize). The adjectives modify or constrain. They reduce the range of possible solutions with a limitation.

18. Need For Change Changes in design of product
Eliminating products from the product line
Introduction of new products
Changes in process sequence for existing products
Replacement of equipment
Changes in production quantities and schedule
Changes in organizational structure

19. Planning for Facility Reorganization
The facility should have a long term plan that supports the long term plan of the organization
The facility “Master Plan” should:
Attempt to anticipate future requirements
Make provisions for adapting to changes in facility requirements – otherwise a decision could be made that will significantly limit future changes
Placement of shipping and receiving docks
Location of heavy machinery and other equipment that are difficult to move
Clear building heights
Load bearing walls

20. Pallet Security Options
Glue – concrete
Stretch wrap – bonds to pallet and around 3 times – when an interlocked pattern cannot be found, irregular shaped objects,
Shrink wrap – plastic bag to cover the load and apply heat – boxes, bags, - anything to cover to keep moisture from entering