1. Facility Design-Week 3 Traditional Approach for Facility Layout: Systematics Layout Planning
Anastasia L.M.

2. Facility Layout A Layout problem may be to
determine the location for a new machine,
develop a new layout for an existing production plant,
develop a layout for a new production plant,
etc.
A Layout problem may arises due to
changes in the design of a product,
addition or deletion of a product,
change in the demand of a product,
changes in the design of the process,
addition or deletion of a process,
replacement of equipment,

3. Objectives of Facility Layout
Minimize investment in equipment.
Minimize production time.
Minimize material handling cost.
Maximize utilization of space.
Maintain flexibility of arrangement and operation.
Provide safety and comfort to employees.

4. Sequential Approach vs Integrated Approach
Product Design
Production Planning
Process Design
Facility Layout
Material Handling System Design

5. Sequential Approach vs Integrated Approach
Impressive results in cost, quality, productivity, sales, customer satisfaction, delivery time, inventory levels, space + handling requirements, building size, etc.
Concurrent Engineering
Terms of product, process, scheduling and facility design planners work with marketing, purchasing, etc. Personnel address the design process in an integrated way.
Product Design
Process Design
Schedule Design
Layout Design +
Material Handling System Design

6. Facility Layout Procedures
Naddler’s Ideal System Approach (1961)
Immer’s Basic Steps (1950)
Apple’s Plant Layout Procedure (1977)
Reed’s Plant Layout Procedure (1961)
Muther’s Systematic Layout Planning (1961)

7. Systematic Layout Planning
Phase I - Determination of the location of the area where departments are to be laid out
Phase II - Establishing the general overall layout
Phase III - Establishing detailed layout plans
Phase IV - Installing the selected layout

8. Systematic Layout Planning
Input Data and Activities
2. Activity Relationships
ANALYZE
1. Flow of materials
3. Relationship Chart
4. Space Requirements
5. Space Available
6. Space Relationship Diagram
SEARCH
7. Modifying Considerations
8. Practical Limitations
9. Develop Layout Alternatives
SELECT
10. Evaluation
Source: John S. Usher class notes

10. SLP

11. Systematic Layout Planning
P Product: Types of products to be produced What
Q Quantity: Volume of each part type How Much
R Routing: Operation sequence for each part type  How
S Services: Support services, locker rooms, inspection stations, and so on  With What
T Timing: When are the part types to be produced ? What machines will be used during this time period?  When

12. Sample relationship diagram

13. Systematic Layout Planning Procedure
3. Adjustments
1. Relationships 1.
Collection of Input Data 2.
Flow of Materials 3.
Activity Relationships 4.
Relationship Diagrams 1.
Modifying Considerations 2.
Practical Limitations 3.
Evaluation & Final Selection
2. Space 1.
Space Requirements 2.
Space Available 3.
Space Relationship Diagrams

14. Information Gathering
Information about product, process and schedule is required.
The major effect of product design decisions is felt by the process designer, i.e., the material used to make a part will influence processing decisions.
Design for automation programs have been developed that consider the impact of the design of the product on the assembly process.

15. Information Gathering
Their primary thrusts are (1) dimensional reduction, (2) parts elimination, and (3) parts standardization.
For (1), the cost of assembly is reduced if it occurs in a single dimension. The complexity of programming a robot increases geometrically with the number of assembly dimensions.
For (2), if more complex parts can be produced, the number of parts can be reduced.
Schedule design decisions tell us how much to produce and when to produce. From the market forecast, the production demand is determined and decisions about the production rate are made.

16. Information Gathering
Information about product :
- Photographs about the product
- “Exploded” drawings
- Engineering drawings of individual parts
- Parts list
- Bill of materials (structure of product)
- Assembly chart

17. Information Gathering
Information about process :
Route sheet (equipment and operation times)
Precedence Diagram (prerequisite assembly steps before new assembly step)
Operation process chart (processing operations, assembly operations, and inspections)

18. Information Gathering
Information about schedule :
Production rate
Product mix
Market forecast (it is better to work with tomorrow’s data than today’s data)
Gantt charts

19. Information Gathering
The information about Product Design and Process Design as an input for SLP have been discussed in week 2.

20. Flow Analysis and Activity Analysis
Flow of material analysis is related to quantitative analysis; to analyse the movement between departments/operational activities
Activity analysis is related to qualitative factors that affect the determination of a facility/depatment location should be placed.

21. From – To Chart
A chart is used for Quantitative Measurement from material movements

22. From-To Chart Example From To A B C D E F G H I Total 20 5 45 70 30 6520 5 45 70 30 65
100 25 75 50 60
620

23. From – To Chart (cont’) Forward Distance from diagonal Backward
1 x =
2 x 1 x =
2 x =
2 x 2 x =
3 x =
2 x 3 x =
4 x =
2 x 4 x =
5 x =
2 x 5 x =
6 x =
2 x 6 x =
Total =
Total =
Total moment = 1.310

24. Activity Relationship Chart
Suatu metode utk merencanakan & menganalisis keterkaitan antara setiap kelompok kegiatan yg saling berkaitan
Jenis-jenis keterkaitan dapat terjadi:
Between 2 production processes
Between production process and service activity, or other activities.
Between 2 service activities.

25. ARC (cont’) Closeness codes are: Code Color
Definition/closeness rating A
Merah
Absolutely necessary E
Jingga
Especially Important I
Hijau
Important O
Biru
Ordinary Important U
Uncolored
Unimportant X
Coklat
Undesirable

26. Relationship Diagramming: Example
Production
Offices
Stockroom
Shipping and receiving
Locker room
Toolroom A O U E X I
A Absolutely necessary
E Especially important
I Important
O Okay
U Unimportant
X Undesirable

27. Activity Relationship Diagram
A relationship diagram is a spatial arrangement of the departments to represent the relationship data in a graphical way. This diagram is also called an adjacency graph.
There are 2 ways of making ARD:
By making an Activity Template Block Diagram (ATBD)
By using the combination of standardized lines and color codes

28. Relationship Diagram

29. Relationship Diagrams: Example (cont’)
Key: A E I O U X
Offices
Stockroom
Locker room
Toolroom
Shipping and receiving
Production

30. ARD (cont’)
A: E: X:
Department No
Departement Name
I: O:

31. Space Requirements & Space Availability
Determination of the Production Rate
Determination of Batch Production Quantities
Economic Order Quantity Models
Reject Allowance Problem
Determination of Equipment Requirements
Determination of Employee Requirements
Manual Assembly Operators
Machine Operators
Determination of Space Requirements
Tables for Aisle Allowance, Food Services and Restrooms
Other Methods to Determine Space Requirements
Parking Space

32. Designing the Layout
After flow and activity analysis, determine the space requirement, the alternative layouts should be generated
Simply, overall layout is generated by combining the relationship diagram/ARD and space requirement.
This combination is called a space-relationship diagram. Then layout design could be modified based on practical limitation and other considerations.
Overall layout is performed as a block plan or area allocation diagram. Block plan uses scale and show the location using internal partitions or columns.

33. Space Relationship Diagram
When the space requirements for the departments are added to this relationship diagram, then a space relationship diagram has been constructed.

34. Space Relationships Diagram

35. Area Allocation Diagram

36. Operations Review for MortAmerica, Inc.
Is there a significant increase in mortgage lending operations of MortAmerica, Inc.?
Are the costs of leasing and refurbishing interior space too high?
Is there a problem with the current location? For example:
There is not enough space for expansion
Major attorneys’ offices, other related financial institutions and restaurants, are not located within a reasonable distance of MortAmerica, Inc.
Adequate parking space is not available
Traffic is too congested
Will a change in office location improve business?

37. SLP for MortAmerica, Inc.
Evaluation
Planning
Site selection
Design and layout

38. SLP for MortAmerica, Inc.
Review current space utilization
Determine space projections
Determine level of interaction between departments
Identifying special consideration

39. Current and Future Space Requirements

40. Current and Future Space Requirements
Support service area
Current net space
Current gross space150% of net space
Future net space
Future gross space 150% of net space
Copying/Printing Area (C/P)
300
450
465
700
File Storage Room (FS) 80
120
Customer Waiting Lounge (CW)
800
1200
Conference Rooms (CR)
500
750
1000
1500
Employee Break Room (EBR)
200
850
1275
Rest Rooms (RR)
Total
1800
2700
3695
5545

41. Relationship diagram for MortAmerica, Inc.

42. Activity relationship diagram for MortAmerica, Inc.

43. Space relationship diagram for MortAmerica, Inc.

44. Pre-architectural layout for MortAmerica, Inc.