IE17: FACILITIES PLANNING AND DESIGN PDF

IE17: FACILITIES PLANNING AND DESIGN Plant Layout In a business operation, plant layout is fundamental. It is as to whether the business enterprise is engaged in manufacturing or production that involves conversion or transformation of input materials, marketing that includes warehouse and...

IE17: FACILITIES PLANNING AND DESIGN Plant Layout In a business operation, plant layout is fundamental. It is as to whether the business enterprise is engaged in manufacturing or production that involves conversion or transformation of input materials, marketing that includes warehouse and distribution, and in office work processes. The plant layout will contribute to the economic success of an enterprise because it encompass the physical arrangement. Physical arrangement is either installed or in plan. 1. Installed Physical Arrangement of Industrial Facilities. It refers to the existing arrangement wherein all facilities are working , and the activity installation are the bases of how economic activities are to be done. 2. In Plan Physical Arrangement. It identifies the proposed new layout. It is still a plan that is subjected for study or yet to be made as a new arrangement of industrial facilities. Layout planning covers a wide range of industrial settings. It includes the following: 1. Individual Workplace. It is an area or space where an individual worker perform the task or assignment. The workplace design follows the “how” or the process in performing a task that includes “how the body parts move” the way to start and finish the job related to “how the output is to be done” and the placement of materials, tools, machines and equipment. 2. Group Activity Workplace. A workplace where interrelated activities to form a parts of the product or work process is done. A unit section or department for a combined activities that includes the placement of machines and equipment. 3. Total Industry Activities Workplace. A layout that shows the total picture of how the total industry processes are done to complete the long line of material processing. The location of individual and group activities workplaces. Plant and facilities layouting is not only in the perspective of internal work environment of the firm but also the outside part of the structure is situated. It includes other supporting services such as parking spaces, load and unloading area, among others. Competitiveness is the game in this era of modern technology. The latter is one among the concerns of industry players for them to be qualified in a business competition. In any business process, there are three elements that should exist—men, materials, and machineries. These elements are subjected to the process of management for an industry to come up with least cost to contribute to a high level of economic performance of a firm. In profit motive organizations, cost reduction is most sought to realize the projected return on investment (ROI). Alongside with the business process standardization either in service or manufacturing, technology is not left behind to consider in converting or transforming standard materials in which necessary skills is prerequisite to an effective, efficient and economic towards a least cost in business operations.  The technology mentioned in the above paragraph is referring to the machineries and equipment that influence the operation. Managers secure the profit margins. Plant layout or facility design is at the helm towards productivity. Hence, it must be given outmost importance. Often times, operation manager fails to recognize the skills of an Industrial Engineer in this area of concern. It is in which quantitative and qualitative approaches are their tools to come up with ideal plant and facility layout for productive material and work processes. Integrated to the skills of IE/s as plant and facilities engineers are their abilities to identify the problem and varying factors that affects the company’s economic growth. Poor layout leads to losses. Some repercussions are long period of processing that may cause negative effects to materials in process, bottleneck in the line of production, backtree of processes, additional manpower requirements, among other problems. Layout varies according to the nature of industries, procedures, and technology involve in material and work processes, product design, among other concerns. Nature of Plant and Facilities Layout The nature of plant layout and facilities layout evolves on the perspectives of: 1. Grouping similar machines and processes; 2. Providing adequate spaces for machines and processes; 3. Properly allocating spaces for the workers for them to freely move around while performing their tasks; 4. Arranging work areas orderly according to material processes; 5. Providing isles to where workers will pass through and for material movement; 6. Provisions for the installation of material handling; and 7. Orderliness and cleanliness of work environment Layout Objectives The following enumerations are the basic objectives of plant and facility layouting: 1. Economic Operations of the Business. To attain economic business operations, the factors of production and the processes approaches should be effectively and efficiently utilized. It is to avoid bottleneck that causes delays and unacceptable quality of products. There are only some of the concerns for economic operations—the cost they may incur. 2. Workplace that is safe and satisfying to workers. The objective is to benefit the workers for their health and safety—away from harm in accidents. The actual and hidden costs will be disadvantage not only to the workers but also to the firm. Layout Problems Problems are inevitable in the aspects of layout such are: 1. To plan for a complete new layout. The thought is to arrange all the facilities integrated to function as a whole. The approach can be vertical starting from the ground moving upwards. It is in the consideration to the design of the building. Examples are the entrances and exits on top of the concerns is for economic business operations. In this matter, the layouting should be done by a layout engineer who has the expertise with the consideration of knowledgeable layout stuff. 2. Expanding the business by occupying an existing layout. The layout engineer must bear in mind that the existing building and services complicate the layout. Hence, there are limitation in such workplace. The problem goes with the adaptation of the economic resources to a different but existing plant. Thus, leaving behind old practice and technology and improving work methods. 3. New arrangement for an existing layout. Layout engineer should look into the limits of an existing layout in consideration to new methods and technology products’ model or style in nature that has to be integrated into whole. The problem will be on existing size or dimensions, shape, and the installations of the present building. 4. Adjustments to an existing layout. Problems occur when minor changes has done in the operating aspects such as: a. Engineering in some parts of work process and material flow; b. Increasing sales that need to wider the space of the storeroom to carry the increase in volume of items to be kept; c. Increased of materials to be processed due to increase in demand; d. Improved work method due to new type of equipment; e. Installation of hard equipment; f. Additional internal service to improve the quality of production. The rearrangements of work areas for material and workers movement. These are the considerations that a layout engineer has to build in the existing arrangement such improvements without changing the overall layout. Types of Plant Layout In the aspect of production arrangement or layouts are essential. In this matter, an understanding on what production is in its essence. The factors of production—man, material and machinery that includes tools and equipment are the fundamental concern of plant and facilities layouting towards productivity gains. ASSIGNMENT NO. 1: Indicate examples based on the definition given in the spaces provided.  FACTORS DESCRIPTION EXAMPLE Man Workers move around the workplace to perform work assignments following the work process design and material flow—from one work station to the next. Material Input materials are brought from one machine to another machine or from one workplace to the next— following the production process in accordance to product design and methodology of production. Machinery Tools and moveable equipment/ machines are brought to the workplace where the machines/ equipment are stationed Man and Material Workers and materials are brought to the workplace where the machines/ equipment are stationed. Material and Machinery Input materials and machines/ tools are brought to the workplace where the worker is stationed to perform his task following the operation process. Man and Machinery Workers and machines/ tools are brought to the workplace where the materials are stationed for processing. Man, Material and Workers input materials and Machinery equipment/ tools are brought to the place where the  production is to be undertaken. TABLE 1 Traditional Layout During early years when factory system in Europe was in its height of success, layout has a great contribution to the enterprises economic success. Before we identify the classic types of layout, it is necessary to know the three material processes: ASSIGNMENT NO. 2: Indicate examples based on the definition given in the spaces provided. TABLE 2 Material Process PROCESS NATURE EXAMPLE Changing the form It is known as forming. Forming is to produce semi-manufactures which disparately fabricated goods passing from producer to producer, and finished goods sold for ultimate consumption. Changing the It is called treatment or characteristics processing. A component to It is called assembly. In become a part of the garment factory, the whole or total process is done. product. ASSIGNMENT NO. 3: Indicate examples based on the definition given in the spaces provided. TABLE 3 Traditional Types of Layout TYPES OF LAYOUT DESCRIPTION EXAMPLE Fixed Position The materials and/or material component remains in fixed location. All the factors in production are brought to it. Layout-by-process All operations of the or same process or type of Layout-by-function process are grouped together. Line Production or One product or one type Layout-by-product of product is produced in one area, and the material moves all machines/ equipment used in processing the materials to form a product are arranged according to sequence of operation Table 3 shows the differentiated description of the nature of functions that will ultimately lead to productivity gains of the firm. Bear in mind that most layouts adopted by business enterprises are on combinations. Certain factors influence the layout that they are combined. 1. Nature of the Product 2. Characteristics of the Product 3. Material Processing 4. Work Systems Design The enumerated items are determined to consider the following:  1. Cost involves in producing the product that includes direct and indirect costs. 2. Time involves in processing the materials-in-process. 3. The volume of the output to produce. 4. The flow of work involving workers. The Type of Layout to the Work Processes The type of layout to use is dependent on the work processes in a particular business enterprise in consideration to the following items: 1. Product to produce 2. Services process to render relating to industry 3. Technology integrated to production 4. Materials to be processed Factors Influencing Plant and Facilities Layout 1. Material Factor As a layout engineer, the following features should be put into account because any of them may influence the layout one could establish. a. Materials. These input in production are categorized according to features in layouting for productivity, nature and characteristics. b. Raw Materials. This refers to the direct production inputs to form a product. Textile materials used to produce a piece of garment such as outer wear and underwear. Leather for the production of shoes and bags. c. Incoming Materials. These are the deliveries of direct and indirect materials. Direct materials are those described above and basis in designating a drop off place to maintain its quality and for purposes of keeping the workers healthy and safe. Hence, a proper location for this type of materials. d. Materials-in-process. These type of materials are those that are already in the production line passing through the various stages of material transformation into product parts. And, to be integrated to form a useful product as part of another product or for ultimate or final consumption. The process design is necessary for estimating the allocation of spaces and location of the equipment. e. Finished products. These products are those that are for shipment or distribution to wholesales, retailers, outlets and to other companies needing for such to further process their products. But, before finally transporting them, safekeeping is necessary—storekeeping and/or warehousing. The features, characteristics, nature and volume of the finished products are consideration in determining the size of the warehouse/storeroom, handling  equipment and location of exit points where the finished products are to temporarily stored for shipment. f. Outgoing packed materials. These items are those placed in pallets, cartons, in bundle among other form of packaging ready for shipment. Same with the finished products, place or location in the plant where they are to be loaded is needed to be accounted for safekeeping and reducing cost of transportation. g. Supplier and process-used materials. These kinds of materials are the “left overs” which are to be kept safe near the production area for retrieval once it is needed for use again. The location and size of the storeroom in consideration to the volume and emergence of use of supplies and process-used materials are of its importance in layouting. h. Rejects, repairs and rework items. A location near the production area that the rejects, for repairs, and for rework or “back-job” items should be stationed. The layout should indicate the place where in the processing area those items are temporarily kept. The reason is for immediate action—to avoid delays that will deteriorate the quality of the said items. i. Salvage Materials. These materials can be saved for future use. Although it will not compromise a full recovery of the cost involved in processing the previously used materials, the salvage items can still be useful for other purposes. A separate area for salvage items should be included in the layout. j. Scrap, Trim, Cuttings and Wastes. These items are of have no value at all for business output. For safety and health of the workers and for protection of the environment and the community, the items are already declared no value at all and should be in a secluded place. k. Packing Materials. Proper layouting of the place for these materials are to kept is necessary to maintain the packing materials’ quality. l. Materials and tools for maintenance and services. These materials need to keep safe, maintain their functionality and for safety purposes. Considerations in Material Factor as basis for Layouting: 1. Products’ design and specification The plant layout work follows the production design. And, the latter is based in product design. Hence, a layout plan has something to do with required quality in a product. This is a standard process and it is associated to installing quality into the product. 2. Material’s physical and chemical characteristics Layouting in consideration to physical and chemical characteristics of the material will be cost effective. Accurate dimensions on the space requirements will be attained. Such considerations is on size, shape, bulk, weight, condition and other special characteristics. 3. Quantity of varying products and materials A layout engineer must look into the quantity of production output of each of the  items produced. Thus, a kind of production equipment should be arranged as to the type of layout suited to the type and kind of product and production system. 4. Component Materials and Sequence of Operation Layout for the arrangement of production equipment should be in accordance to the sequence of operations. 2. Machinery Factor Next to material is the machine that is being used in processing the materials in various stages until the materials became a final output. There are features, that a machine have. It includes the following 1. Production machines 2. Process or treating equipment 3. Special attachments 4. Tools, jigs, fixtures, dies, forms, patterns 5. Gauges, measuring machinery, test units 6. Hand and hand-operated power tools 7. Controls or control items 8. Idle or dead machinery items 9. 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