1. Facility planning and Design Lecture 1 A– introduction
Dr. Husam Arman

2. Outline Syllabus Introduction to the course Course contents ILOs
Text book
Grading
Subjects detail
Introduction to the course

3. Syllabus
This course covers various areas related to facility planning and design. The materials covered include mainly three parts; facility location, plant layout and material handling. The first two parts will be discussed extensively, while little emphasis on the materials handling part (see detail subjects).

4. ILOs Understand the importance of facility planning as an IE.
Be able to formulate quantitative and qualitative models to address facilities planning problems
Be able to analyze practical problems considering the fundamental principles of material handling
Be able to design a factory layout incorporating product, process, and schedule.
Be able to work in a team and confident in presenting and defending his work

5. Text book
Text book:
Facilities Planning, J.A. Tompkins et al., John Wiley & Sons, Inc., New York, 2010
Additional references;
Facility layout and location, Francis, McGinnis & White, Prentice Hall NJ, 1992.
Facilities Planning and Design, Alberto Garcia-Diaz and J. MacGregor Smith, Prentice Hall, 2007

6. Assessment criteria
Midterm Exams
40 %
Project
20 %
Final Exam

7. Subjects detail Week Subject 1 Introduction to Facilities Planning 2
Strategic Facilities Planning 3
Rectilinear-Distance Facility Location Problems
(Single and Multi-facility) 4 5
Euclidean-Distance Facility Location Problems 6 7
Product, Process and schedule design 8
Flow systems, activity relationships and space requirements 9
Layout planning models 10 11
Locations and Layout using computer 12
Product layout 13
Material Handling 14
Personnel requirements 15
Selecting the facility plan 16
Manufacturing systems

8. Group Project
Study a real location or layout problem and try to improve upon the current situation using analytical tools developed in the course.
You are free to suggest a project that interests you
More information will be provided duly!

9. Project Planning Group Project will incorporate: Course content
Teamwork
Data collection and analysis (will use software)
Project Presentation
Project Report

10. Our ground rules Please switch off/silent our phones when in class.
Arrive on time
Keep our presentations to agreed upon lengths
In general be courteous to others ….
Do you want to add anything!

11. Ok, shall we start now!

12. Facility location and plant layout
The location of facilities and also determination of the configuration at certain types of facilities
Also called Facilities planning!
Facilities planning is complex and broad subject cuts across several disciplines (engineering, civil, electrical, architecture, etc)
However, here we’ll focus on industrial engineer’s role in developing effective and efficient facilities plans.

13. Facilities Planning Viewpoints
Civil engineering
Electrical
Mechanical engineering
Architectural
Real estate
Urban planning
Industrial engineering
What is the role of each in facility planning?

14. IE Viewpoint of Facilities Planning
IEs are focusing on requirements, resource allocation, and efficient use of resources.
Facilities are the integration of many lower level systems
Space requirements with respect to flow and operations control
Personnel requirements
Equipment requirements
System design/layout with respect to flow and operations control
The use of information systems and technology to increase effectiveness
Movement within a facility
Movement between facilities – Location …

15. Definitions
Facility location refers to the choice of region and the selection of a particular site for setting up a business or factory
Plant layout Plant layout refers to the arrangement of physical facilities such as machinery, equipment, furniture etc. within the factory building in such a manner so as to have quickest flow of material at the lowest cost and with the least amount of handling in processing the product from the receipt of material to the shipment of the finished product

16. Definitions
Facilities Planning determines how an activity’s tangible, fixed assets should contribute to meeting the activity’s objectives .
This course will focus on facilities planning.
Emphasis on location and layout.
Some coverage of materials handling.

17. Facilities planning Facilities location Facilities planning
Facilities design

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20. Why matters?
To stimulate your thought, think of the following questions:
What impact does facilities planning have on handling and maintenance costs?
What impact does facilities planning have on employee moral?
What impact does facilities planning have on management of a facility?
What impact does facilities planning have on a facility’s capability to adapt to change and satisfy future requirements?

21. Why matters?

22. Why matters?
Corporate strategy
Business strategy

23. Facility Location in Location Strategy
PLANNING
ORGANIZING
CONTROLLING
Transport Strategy •
Transport fundamentals
Transport decisions
Customer
service goals
The product
Logistics service
Ord
. proc. & info. sys.
Inventory Strategy
Forecasting
Inventory decisions
Purchasing and supply
scheduling decisions
Storage fundamentals
Storage decisions
Location Strategy
Location decisions
The network planning process .

24. Why matters?
All the facilities in the supply chain should have the following characteristics:
Flexibility
Modularity …

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Why matters?
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26. Strategic Planning Def.: High level of planning:
Identify a process to obtain an objective
Identify and utilize resources (physical aspects)
Identify and execute processes (time aspects)
Identify and coordinate methods (control aspects)
Longer term (Strategic) vs. shorter term (Tactical)
Plan a trip from Nablus to London – (map?)
Resources
Timing
Control
Strategic and Tactical relationship
Objective of strategic plan doesn’t change!

27. Strategic Planning Applied to Facilities Planning:
Requires an understanding of feasibilities:
Marketing
Product development
Manufacturing / Processing
Production / Inventory control
Human resources
Finance
Impacts the performance of each, too
Concurrent design process seems best
Facilities planning occurs simultaneously
Evolving requirements
Multiple alternatives
Design iterations probable

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29. Steps in Engineering Design
IENG 471 Facilities Planning
4/21/2017
Steps in Engineering Design
Ideal Sequence:
Defining the Problem
Gathering Pertinent Information
Generating Multiple Solutions
Analyzing and Selecting a Solution
Testing and Implementing the Solution
Actual process is iterative…
Frequently back-track to a previous stage
(c) D.H. Jensen

30. Facilities Planning Process Steps
Defining the Problem
Define
Gathering Pertinent Information
Specify
Determine .

31. Facilities Planning Process Steps
Generating Multiple Solutions
Generate …
Analyzing and Selecting a Solution
Evaluate …
Select …
Testing and Implementing the Solution
Implement the facilities plan
Maintain and update the facilities plan

32. Facilities Planning Process Steps
Frequently back-track to a previous stage
Update the products and redefine the objective of the facility

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34. Data for Strategic Facility Design
What is to be produced?
How are the products to be produced?
When are the products to be produced?
How much of the product is to be produced?
How long will the product be produced?
Where are the products to be produced?

35. Example Data for Strategic Facility Design
What is to be produced?
1/16 scale models of new and old tractors
How are the products to be produced?
Die & sand casting, trimming/drilling, painting, assembling, direct shipping
When are the products to be produced?
Within 1/2 month prior to introduction, and 2 months after order
How much of the product is to be produced?
Batch production runs of 100 to 1000, ~ 8 new & 20 total models/yr
How long will the product be produced?
2 – 3 yrs/model, product lifecycle of 15 – 30 yrs, facility life >50 yrs
Where are the products to be produced?
Small, rural Iowa town (~ 3000 pop.; supplied from Chicago, WI; adjacent to rail, near major U.S. highway; OEMs in IL, WI, IA

36. Issues Impacting a Strategic Facilities Plan:
Number, location, sizes of warehouse/distribution centers
Centralized vs. decentralized storage / manufacturing
Acquire existing (brownfield) vs. build new (greenfield)
Flexibility required for marketing & technology
Interfacing storage and manufacturing
Level of vertical integration
Control of materials and equipment
Inbound and outbound material movement
Technology changes for suppliers, firm, customers
Financial goals for the design of the facility

37. HW – next time