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Traditional Approaches to Facility Layout
Chapter 4
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Significance of Facilities Planning
20-50% of all manufacturing costs are related to material handling FP can reduce MH costs by 10-30% Therefore… 2-15% reductions in overall manufacturing costs could be achieved by effective facilities planning. Annual productivity would increase 3x more than it has in the past 15 years. Hard to make similar projections to other areas of our economy FP continues to be one of the most promising fields
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Objectives Minimize material handling costs Utilize space efficiently
Utilize labor efficiently Eliminate bottlenecks Facilitate communication and interaction between workers, between workers and their supervisors, or between workers and customers Reduce manufacturing cycle time or customer service time
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Objectives (continued)
Eliminate waste or redundant movement Facilitate the entry, exit, and placement of material, products, or people Incorporate safety and security measures Promote product and service quality Encourage proper maintenance activities Provide a visual control of operations or activities Provide flexibility to adapt to changing conditions Increase capacity
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The Nature of FP Objectives
As you can see, there are MANY! They are conflicting. How? There are constraints. Can you list some?
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The Facility Planning Problem
It is a constrained multi-objective optimization problem with many non-quantifiable costs and benefits. There is NO OPTIMAL SOLUTION! The best we can hope for is a “GOOD” solution. Effective designs must consider all stakeholders Owners Customers Suppliers Employees Neighbors
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Layout Problems Design or Optimization?
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Facility Design Process
Combination of art and engineering Many techniques available Muther’s SLP Approach (1973) Optimization based approaches We will focus on both
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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
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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
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Systematic Layout Planning
P Product: Types of products to be produced Q Quantity: Volume of each part type R Routing: Operation sequence for each part type S Services: Support services, locker rooms, inspection stations, and so on T Timing: When are the part types to be produced ? What machines will be used during this time period?
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Sample relationship diagram
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Special Considerations in Office Layout
Minimizing distance traveled by employees Permitting flexibility so that the current layout can be changed, expanded or downsized easily Providing a safe and pleasant atmosphere for people to work in Minimizing capital and operational costs of the facility
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Aesthetics
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Aesthetics
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Aesthetics
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Aesthetics
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Aesthetics
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Aesthetics
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SLP for MortAmerica, Inc.
Evaluation Planning Site selection Design and layout
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SLP for MortAmerica, Inc.
Review current space utilization Determine space projections Determine level of interaction between departments Identifying special consideration
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Current and Future Space Requirements
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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
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Relationship diagram for MortAmerica, Inc.
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Activity relationship diagram for MortAmerica, Inc.
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Space relationship diagram for MortAmerica, Inc.
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Engineering design approach
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OSHA, ADA and Local Codes
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OSHA, ADA and Local Codes
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