Facilities Planning and Design PDF

INTRODUCTION FACILITIES PLANNING AND DESIGN  LEARNING OBJECTIVES 01 Define Facilities Planning and Design 02 Explain the importance of facilities planning and design in industrial engineering. 03 Identify key concepts and components involved in facilities planning...

INTRODUCTION FACILITIES PLANNING AND DESIGN  LEARNING OBJECTIVES 01 Define Facilities Planning and Design 02 Explain the importance of facilities planning and design in industrial engineering. 03 Identify key concepts and components involved in facilities planning and design. WHAT IS FACILITIES PLANNING AND DESIGN? Fo cusing on the optimal arrangement and utili zation of physi cal spaces to support organizational activi ties. It involves the strategic pl anning and detail ed design o f facil iti es, incl udi ng buil dings, equi pment, and infrastructure, to ensur e effi ci ent operations and meet t h e needs o f users. F acilities planning - encompasses the process of determini ng the best location, layout, and configuration of a facility. This involves analyzing factors such as workflow, material handling, space requirements, and environmental impact. The goal is to create a layout that mini mizes costs, ma xi mizes productivity, and enhances safety and comfort for occupants. WHAT IS FACILITIES PLANNING AND DESIGN? Facility design - It translates the planning p hase into tangible blueprints and specifications. This includes architectural design, engineering, and construction planning. The design phase ensures that the facilit y meets all regulatory requirements, adheres to industry standards, and aligns with the organization’s objectives Effective facilities planni ng and design can lead to si gnifica nt improvements in operational efficiency, cost savings, and employee satisfaction. It is a multi discipli nary effort involving industrial engineers, architects, civil engineers, and other professionals t o create environme OPERATIONAL EFFICIENCY AND COST EFFECTIVENESS Optimizes Space Utilization: Ensures efficient use of available space, reducing waste and maximizing productivity. Enhances Workflow: Streamlines processes and improves workflow, minimizing delays and bottlenecks. Reduces Costs: Lowers operational costs through efficient layout and resource allocation. Improves Safety: Designs facilities with safety in mind, reducing accidents and associated costs. OPERATIONAL EFFICIENCY AND COST EFFECTIVENESS Boosts Employee Morale: Creates a comfortable and ergonomic environment, enhancing employee satisfaction and productivity. Supports Scalability: Facilitates future expansion and adaptability to changing business needs. Increases Sustainability: Incorporates eco-friendly practices, reducing environmental impact and operational costs. KEY CONCEPT AND COMPONENTS 1.Facility Layout : means deciding where to put all the facilities, desks, machines, equipment and people in the operation. it is also concerned with the physical appear ance of an operation in a bro ader sense. it governs how safe, how attractive, how flexible and how efficient an operation is. objectives of the layout activity : Inherent safe ty – This is the prerequisite for any layout in any type of operation. All processes that might constitute any physical or other danger to either staff or customers should not be accessible to the unauthorized. Fire exits should be clearly marked with uninhi bited access. Pathways should b e clearly defined and not cluttered.  KEY CONCEPT AND COMPONENTS objectives of the layout activity : Security – Similar to safety in some ways, facilities and layouts shoul d ensure that anyone with mal icious intent cannot gain access to staff, customers or property Length of flow – The flow of materials, i nformation or customers sh ould be channeled by the layout so as to be appropriate for the objectives of the operation. In many operations thi s means minimizing the distance travelled b y transformed resources. Minimize delays – Delays can, of course, be caused by over-long routes through the layout, as described above, but inconvenient placing o f facilities, or in sufficient capacity allocated to parts of the layout (that is, a bottleneck, see previous chapter), may also cause them.  KEY CONCEPT AND COMPONENTS objectives of the layout activity : Reduce work-in- pro gress – E xcess ive work -in-progress can be caused by bottlenecks, but the layout of a process may be used deliberately to li mit t he abili ty of items to accumulate. Clarity of flow – All flow o f materials and customers s hould b e well signposted, clear and evident to staff and customers alike. Staff conditions – Layouts s hould be arranged so that staff are located away from noi sy or unpleasant parts of the operation. The layout shoul d provide for a well-ventilated, well - lit and, where possible, pleasant working environment.  KEY CONCEPT AND COMPONENTS objectives of the layout activity : Communication – Communication between staff can be particularly important for some types of operation, such as those in creative industries. The layouts of some operations are deliberately designed to promote the kind of chance meetings between staff that can lead to the formulation of creative ideas. Management co-ordinatio n – Supervision and communi cation should be assisted by the relative location of staff, the use of communication devices and information points.  KEY CONCEPT AND COMPONENTS objectives of the layout activity : Accessibility – All machines, plant or equipment should be accessible to a degree that is sufficient for proper inspection, cleaning and maintenance. Use of space – Al l layouts should achieve an appropriate use of the total space available in the operation (including height as well as floor space). Use of capital – Capital investment should be mini mized (consistent with other objectives) when finalizing layout.  KEY CONCEPT AND COMPONENTS objectives of the layout activity : Long-term flexibility – Layouts need to be changed periodically as the needs of the operation change. A good layout will have been devised with the possi ble future needs of the operation in mind. Image – The l ayout of an operation can help to shape the ima ge of an organization, both in i ts customer markets and in the labor market from which i t recruits. The appearance of a layout can be used as a deliberate attempt to establish a company’s brand. KEY CONCEPT AND COMPONENTS Different types of Layout : Fixed - position layo ut - is in some ways a contradiction in terms, s ince the transformed resources do not move between the transforming resources. Instead of materials, in formation or customers flowing through an op eration, the recipient of the processing is stationary an d the equip ment, machinery, plant and people who do the processing move as necessary. Thi s could be because the product or the recipient of the service is too l arge to be moved conveniently, or it might be too delicate to move, or perhaps it could object t o being moved. KEY CONCEPT AND COMPONENTS Different types of Layout : Fixed-position layout, For example : Motorway construction – the product is too large to move. Operating room (hospital) – patients are too delicate to move. High -class service restaurant – customers would object to being moved to where food is prepared. Shipbuilding – the product is too large to move. Mainframe computer maintenance – the product is too big and probably also too delicate to move, and the customer might object to bringing it in for repair.  KEY CONCEPT AND COMPONENTS Different types of Layout : Functi onal layout - si mil ar resources or processes are located together. This may be because it i s convenient to group them together, or that the utilization of transforming resources i s i mproved. It means that when products, information or customers flow through the operati on, they will take a route from activity to activity according to their needs. Different products or customers will have different needs and therefore take different routes. Usually this makes the flow pattern in the operation very complex.  KEY CONCEPT AND COMPONENTS Different types of Layout :  KEY CONCEPT AND COMPONENTS Different types of Layout : Cell layout - is one where the transformed resources entering the operation are pre -selected (or pre-select themselves) to move to one part of the operation (or cell) in which all the transforming resources, to meet their immediate processing needs, are located. The cell itself may be arranged in either a functional or line layout. After being processed in t he cell, the transformed resources may go on to another cell.  KEY CONCEPT AND COMPONENTS Different types of Layout : Cell layout, For example : Some computer component manufacture – the processing and assembly of some types of computer parts may n eed a special area dedicated to the manufacturing of parts for one particular customer who has special requirements, such as particularly high - quality levels. ‘Lunch’ products area in a supermarket – some customers use the supermarket just to purchase sandwiches, s avory snacks, cool drinks, yoghurt, etc., for their lunch. These products are often located close together so th at customers who are just buying l unch d o not have to search around the store.  KEY CONCEPT AND COMPONENTS Different types of Layout : Line layout - involves locating the transforming resources entirely for the convenience of the transformed resources. Each product, piece of information or customer follows a prearranged route in which the sequence of activities that are required matches the s equence in which the processes have been located. The transformed resources ‘flow’ along a ‘line’ of pro cesses according t o their ‘product’ needs. This is why this type of layout i s sometimes called flow or product layout. Flow is clear, predictable and therefore relatively easy to control.  KEY CONCEPT AND COMPONENTS Different types of Layout : Line layout, For example : Auto mobile assembly – almost all variants of the same model require the same sequence of processes. Mass -i mmunization programme – all cus tomers require the same se quence of cle rical, medical and counselli ng activities. Self-s ervice cafeteria – generally the sequence of customer requirements (starter, main course, dessert and drink) is common to all cus tomers, but layout also helps control customer flow.  KEY CONCEPT AND COMPONENTS Different types of Layout : KEY CONCEPT AND COMPONENTS Different types of Layout: Mixed Layout - Many operations either design themselves hybrid layouts which combine elements of some or all of the basic layout types, or use the ‘pure’ basic layout types in different parts of the operation. Advantages and Disadvantages KEY CONCEPT AND COMPONENTS 2. Facility Location : Factors influencing location decisions (e.g., proximity to suppliers/customers, transportation costs, labor availability). Methods for evaluating location options (e.g., factor rating method, center of gravity method). KEY CONCEPT AND COMPONENTS Key Components of Facility Location : 1.Proximity to Customers and Suppliers Custo mers : Being close to customers reduces delivery times and transportation costs, enha ncing customer satisfaction. Suppliers : Proxim ity to suppliers ensures a steady supply of raw materials and reduces transportation costs. KEY CONCEPT AND COMPONENTS Key Components of Facility Location : 2. Availability of Skilled Labor Access to a skilled workf orce is essential f or maintaining high productivity and quality standards. 3. Infrastructure and Utilities Adequate infrastructure, including transportation netw orks, power supply, water, and waste management, is crucial for smooth operations. KEY CONCEPT AND COMPONENTS Key Components of Facility Location : 4. Environmental Regulations Compliance with local environmental laws and regulations is necessary to avo id lega l issues and promote sustainability. 5. Financial Incentives Governments often provide f inancial incentives, s uch as tax breaks and grants, to attract businesses to specific locations. KEY CONCEPT AND COMPONENTS Key Components of Facility Location : 6. Quality of Life The quality of life in the area can aff ect employee satisfa ction and retention. Factors include housing, education, healthcare, and recreational facilities. 7. Potential for Future Expansion The chosen location should have enough space and resources to accommodate future growth and expansion plans. LOCATION OF COMPANY (EXAMPLE) DAIHO ( PHILIPPINES), INC. DYNAPAC AND MALINTA ( PHILIPPINES) INC BANDAI NAMCO PHILIPPINES INC. EPSON PR ECISION ( PHILIPPINES), INC. HITACHI CABLE PHILIPPINES, INC. MITSUBA PHILIPPINES COR P. LIMA TECHNOLOGICAL PARK YAMAHA MOTOR (MALVAR BATANGAS) PHILIPPINES, INC. TOYOTA TSUSHO PHILIPPINES COR POR ATION LOCATION OF COMPANY (EXAMPLE) B/E AER OSPACE HONDA PHILIPPINES EATON INDUSTR IES ( PHILIPPINES) TE CONNECTIVITY IBIDEN EMD TECHNOLOGIES PHILIPPINES INC. NIPPON EXPR ESS MUR ATA INNOVATORS FIRST PHILIPPINE INDUSTRIAL IN ELECTR ONICS PARK (FPIP) ETC. KEY CONCEPT AND COMPONENTS Key Components of Facility Location : 3. Facility Design : is a crucial aspect of industrial engineering that involves planning and designing the physical layo ut of a facility to optimize the f low of m aterials, people, and inform ation. Effective fac ility d esign can significantly enhance productivity, reduce costs, and improve overall operational efficiency. KEY CONCEPT AND COMPONENTS Key Components of Facility Design : Material Flow The movement of raw material s, work-in- progress, and finished goods within a facility. Equipment Placement Strate gic positioni ng of machinery and equipment within the facility. KEY CONCEPT AND COMPONENTS Key Components of Facility Design : Space Utilization Optimal use of available space to accommodate all necessary activities. Workstation Placement Arranging works tations to facilitate efficient workflow and communication.  SUMMARY Key Components of Facility Planning & Design: 1.FACILITY LAYOUT Objectives of layout activity. Different types of layout. 2.FACILITY LOCATION Proximity to Customers and Suppliers. Availability of skilled labor. Infrastructure and Utilities. Environmental Regulations. 3.FACILITY DESIGN Material Flow Equipment placement Space Utilization Workstation placement  ANY QUESTIONS? FACILITY LAYOUT ASSESSMENT. Facili ties layout involves the arrangement of physical spaces, equipment, and resources within a faci li ty to optimize workflow, efficiency, and productivity. It is crucial in various industries, including manufacturing, healthcare, and retail, to ensure smooth operations and minimize costs. FACILITY LAYOUT ASSESSMENT. Practical Applications Questions : Manufacturing Plant Layout : How can the layout of a manufacturing plant be optimized to reduce material handling costs and improve production efficiency? Healthcare Facility Layout : How can t he layout of a hospital be designed to minimize patient transfer times and improve the efficiency of medical staff? FACILITY LAYOUT ASSESSMENT. Practical Applications Questions : Retail Store Layout : What strategies can be employed in the layout design to enhance the customer shopping experience and encourage longer store visits?