FACILITIES

MAN AG EM ENT
Session 2. 1
 CONTENTS (1 of 2)
Objective facilities design function
Major elements of facilities design
Importance of facilities design
Facilities design & productivity
Objectives of facilities design (FD)
Functions & activities in FD
Need for FD
Enterprise design process
Sequence of steps in design process
 CONTENTS (2 of 2)
Types of layout and problems expected
Placing a new facility
Desirable characteristics of a good layout
Organization for layout function
Functions of Plant Engineering Department
Inter Department help in layout design
Facilities Design process
Consideration of Facilities Design
 The Facilities Design
Function
OBJECTIVES
 to get the inputs (material, supplies, etc) into
through and out of each facility in the shortest time practicable,
at acceptable cost.

 Facilities Design deals with the design and arrangement of

physical elements of an activity/s related to the manufacturing
industry, whose drawing represents a plant layout.

 Facilities Design analyzes, conceptualizes, designs and

implements systems for the production of goods or services.

 FD is represented as a floor plan, or an arrangement of physical

facilities (equipment, land, buildings, utilities, etc.) 4
 Major Elements of Facilities
Design
S.No Typical Inputs Production Activities Outputs

1. Plant Materials and Conversion of materials to Production and

Supplies parts assemblies, products Scrap!
2. Warehouse Large quantities of Safekeeping and Orders of
Merchandise availability Merchandise
3. Retail Store Orders of Display, convenient access, Individual items for
Merchandise transfers of ownership customers
4. Post Office Letters and Parcels Sorting and accumulating Orderly
arrangement of
letters and parcels
5. Restaurant Food and supplies Preparation of food Meals

6. Hospital Sick Patients, Services required to “cure” Cured Patients

Medicines, Supplies patients
7. Home Food, supplies, Meals and orderly activity Happy people
equipment, e.t.c 5
 Scope of Facilities Design
 Dealing only with the careful and detailed planning of
production equipment arrangement.
 Should include a careful study of at least the following
areas of interest :

1. Transportation 10. Warehousing

2. Receiving 11. Shipping
3. Storage 12. Offices
4. Production 13. External Facilities
5. Assembly 14. Buildings – Canteens
6. Packaging and packing 15. Grounds
7. Material handling 16. Location
8. Personnel Services 17. Safety
9. Auxiliary production activities 18. Scrap 6
 Importance of Facilities
1.
Design
An efficient plan for the flow of material is a primary
requisite for economical production.
2. The material flow pattern becomes the basis for an
effective arrangement of physical facilities.
3. Material handling converts the static flow pattern into a
dynamic reality, providing the means by which
material is caused or permitted to flow.
4. Effective arrangement of facilities around the material
flow pattern should result in efficient operation of the
various related processes.
5. Efficient operation of the various related processes.
6. Minimum production cost should result in maximum 7
profit.
 Facilities Design &
Productivity
 Increasing productivity is usually a desired result of
facilities design or re-design.

 It is accomplished by the design efforts necessary to

carry out the several objectives of the facilities design
process

8
Objectives of Facilities Design
1. Facilitate the manufacturing Process
2. Minimize material handling
3. Maintain flexibility of arrangement and of operation
4. Maintain high turnover of work-in-process
5. Hold down investment in equipment.
6. Make economical use of building cube.
7. Promote effective utilization of manpower.
8. Provide for employee convenience, safety and
comfort in doing the work.

9
Facilitating the Manufacturing
Process
1. Arrange Machines, equipment and work areas so that
material is caused to move smoothly along in as
straight a line as is possible
2. Eliminate all delays possible. It has been said that
during 80% of the time a part is in the plant it is either
being moved or stored – only 20% of the time is
productive.
3. Plan the flow so that the work passing through an area
can be easily identified and counted, with little
possibility of becoming mixed with other parts or
batches in adjacent areas.
4. Maintain quality of work by planning for the
maintenance of conditions that are conducive 10to
quality.
Objectives of Facilities Design
 If a finished layout is to present an effective arrangement
of related work areas, in which goods can be economically
produced, it must be planned with the objectives of layout
well fixed in mind. The major objectives are to :
1. Facilitate the manufacturing process
2. Minimize material handling
3. Maintain flexibility of arrangement and of operation
4. Hold down investment in equipment
5. Make economical use of building cube
6. Promote effective utilization of manpower
7. Provide for employee convenience, safety, and comfort
in doing the work 11
 Functions and Activities in
Facilities Design
 Facilities design & Plant layout group perform a wide
variety of activities.

 The list contain

a. Raw materials
b. Theoretical potential activities
c. Range of facilities design interests

12
Functions and Activities in
Facilities Design
S.No Actions Areas of Interest Nature of Interest
01. Advise (on) Assembly Activities
02. Allocate Auxiliary Services Analysis
03. Analyze Building Appropriation
04. Approve Construction Automation
05. Classify Containers Availability
06. Coordinate Cost Benefits
07. Design Distribution Budgets
08. Determine Equipment Capability
09. Develop Fabrication Capacity
10. Establish Facilities Changes
11. Estimate Flow Contracts
12. Evaluate Grounds Controls
13. Forecast Handling Costs
14. Improve Location Criteria
15. Investigate Maintenance Data 13
16. Measure Manpower Efficiency
Functions and Activities in
Facilities Design…
S.No Actions Areas of Interest Nature of Interest
17. Minimize Manufacturing Equipment
18. Model Material Expansion
19. Modify Office Facilities
20. Monitor Packaging Feasibility
21. Organize Packing Flexibility
22. Plan Plant layout Flow
23. Predict Pollution Functions
24. Promote Process Hazards
25. Provide Production Incentives
26. Qualify Productivity Installation
27. Reduce Repair Interrelationships
28. Review Safety Layout
29. Select Salvage Liason
30. Specify Scrap Location 14
31. Study Security Long range Planning
Functions and Activities in
Facilities Design…
S.No Actions Areas of Interest Nature of Interest
32. Supervise Space Measurements
33. Test Storage Mechanization
34. Up-date Traffic Methods
35. Transportation Modifications
36. Utilities Needs
37. Warehousing Objectives
38. Waste Operations
39. Organization
40. Performance
41. Plans
42. Policies
43. Problems
44. Procedures
45. Processes
15
46. Programs
Functions and Activities in
Facilities Design…
S.No Actions Areas of Interest Nature of Interest
47. Progress
48. Records
49. Regulations
50. Replacements
51. Reports
52. Requirements
53. Resources
54. Schedules
55. Services
56. Sources
57. Specifications
58. Standards
59. Systems
60. Tests
61. Trends 16
62. Utilization
 Need for Facilities Design

1. Design a new plant.

2. Make changes and improvement to present design.
3. Integrate & locate new equipment.
4. Develop future plans.

17
Functions and Activities in
Facilities Design…

Long and Short Term Plans:

10 years ahead Estimate total space by function.

5 years ahead Area allocation diagram by department.
2 years ahead Rough layout of area under
consideration.
1 year ahead Detailed Layout.
6-12 months ahead Appropriation approved.

18
Enterprise Design Process

19
The Enterprise Design Process
 Market Research: Determining what the customer
wants
 Sales Forecasting: Determining how many, or how
much.
 Product Design: Delineating product or service
details
 Process Design: Determining how to make the
product, or provide the service.
 Operation Design: Working out methods for
effecting the processes, and from that, the number
of machines and amount of manpower required.
20
 The Enterprise Design
Process…
 Facilities Design:
Determining the material flow paths, and designing
the arrangement of activities to provide an orderly
and efficient movement of material through the
overall process.
 Equipment Design: (as necessary)
 Building Design: By the architect and his associates.
5. Financing the facility
6. Procurement
a. Building
b. Equipment
c. Manpower
7. Installation of facilities
21
 The Enterprise Design
•
Process…
The actual manufacturing or productive process :
• Manufacturing - the conversion of materials and
supplies into products, such a typewriters, lamps,
foods, automobiles, etc
• The productive process – the organization and use of
human effort to accomplish a desired result, in the
form of a product or a service, ( dry cleaning,
retailing, banking food services, etc).
• Warehousing of the finished goods.
• Distribution of goods.
• Marketing and sales.
• Customer: who use, evaluation, complaints,
suggestions, etc., come back to the enterprise by way22of
Market Research, beginning the whole cycle over again
Sequence of Steps in Design
Process
1. Procure basic data
2. Analyze basic data
3. Design productive process
4. Plan material flow pattern
5. Consider general material handling plan
6. Calculate equipment requirements
7. Plan individual work stations
8. Select specific material handling equipment
9. Coordinate groups of related operations
10. Design activity interrelationships 23
Sequence of Steps in Design
Process…
1. Determine storage requirements
2. Plan service and auxiliary activities
3. Determine space requirements
4. Allocate activities to total space
5. Consider building tyres
6. Construct master layout
7. Evaluate, adjust, and check layout with appropriate
persons
8. Obtain approvals
9. Install layout’
10. Follow-up on implementation of the layout 24
Types Layout Problems
Expected
1. Design change
2. Reduces department
3. Enlarged department
4. Adding a new product
5. Moving a department
6. Adding a new department
7. Replacing obsolete equipment
8. Change in production methods
9. Cost reduction
25
 Planning A New Facility
1. Building not suited to requirements.
2. Failure to apply line production techniques when
applicable.
3. Product design or process changes made without
making necessary changes in the layout.
4. Installation of additional equipment without
considering.
5. Unexplainable delays and idle time.
6. Stock control difficulties.
7. Decreased production in an area.
8. Crowded conditions.
9. Many men moving material. 26
 Planning A New Facility…
1. Bottlenecks in production
2. Backtracking
3. Excessive temporary storage.
4. Obstacles in material flow
5. Scheduling difficulties
6. Wasted “cube”
7. Idle people and equipment
8. Excessive time in process
9. Poor housekeeping
27
 A Good Layout
Desirable Characteristics
1. Planned activity interrelationships
2. Planned material flow pattern
3. Straight-line flow
4. Minimum back-tracking
5. Auxiliary flow lines
6. Straight aisles
7. Minimum handling between operations
8. Planned material handling methods
9. Minimum handling distances
10. Processing combined with material handling
28
 A Good Layout
Desirable Characteristics…
1. Movement progresses from receiving towards
shipping
2. First operations near receiving
3. Last operations near shipping
4. Point-of-use storage where appropriate
5. Layout adaptable to changing conditions
6. Planned for orderly expansion
7. Minimum goods in process
8. Minimum material in process
9. Maximum use of all plant levels
10. Adequate storage space 29
 A Good Layout
Desirable Characteristics…
1. Adequate spacing between facilities
2. Building constructed around planned layout
3. Material delivered to employees and removed from
work areas
4. Minimum walking by production operators
5. Proper location of production and employee service
facilities
6. Mechanical handling installed where practicable
7. Adequate employee service functions
8. Planned control of noise, dirt, fumes, dust, humidity,
etc.
9. Maximum processing time to overall production 30
time
 A Good Layout
Desirable Characteristics…
1. Minimum manual handling
2. Minimum re-handling
3. Partitions don’t impede material flow
4. Minimum handling by direct labor
5. Planned scrap removal
6. Receiving and shipping in logical locations.

31
 Organization for Layout
Function
Large Organizations :
Plant Layout Department

Small Organizations :
Fireman / Manager / GM

Small Organizations : In many organization the

designations of layout mangers differ widely
32
 Organization for Layout
Function
General
Manager

Finance Purchasing Manufacturing Sales Product Industrial

Engineering Relations

Quality Production Plant Industrial Production

Control Control Production
Engineering Engineering Engineering

Plant OR Plant
Layout Layout
33
Functions of Plant Engineering
Department
1. Construction
2. Housekeeping and custodial service
3. Maintenance
4. Material handling
5. Facilities design
6. Pollution control
7. Safety
8. Transportation
9. Utilities
10. Shops 34
Organization Of Layout
Function

35
 Interdepartmental help in
Layout Design
A. Sales Department
1. Determining quantities for production runs
2. Determining quantities to manufacture for
replacement parts
B. Purchasing Department
1. Finding necessary factory equipment
2. Procuring equipment at lowest practicable cost
C. Product engineering department
1. Providing blueprints and parts lists
2. Offering information on manufacture, as gained 36
in research and development work
 Interdepartmental help in
Layout Design…
A. Industrial Relations Department
1. Helping to design safety into the layout
2. Looking after employee comfort and services in
layout
3. Training personnel for new jobs necessitated by
new layouts
B. Finance Department
1. Aiding in determining cost of layout
2. Aiding in keeping equipment records
37
 Interdepartmental help in
Layout Design…
A. Production Engineering Division
1. Design of processing and production methods
2. Design of special tools and equipment
3. Planning operation sequence
4. Specifying machines and equipment to be used
5. Trying out tools, etc
6. Mechanization and automation
7. Production capability analysis
8. New process and equipment development

38
 Interdepartmental help in
Layout Design…
A. Industrial Engineering Division
1. Determining work methods for each work area
1. Determine production standards for all operation
2. Determining machine capacities and number of
machines needed
3. Aid in comparing effectiveness of methods between
alternate layouts
4. Suggestions on methods
B. Production Control Division
1. Supply routings or operation lists
2. Determine production schedules
3. Aid in planning materials flow 39
 Interdepartmental help in
Layout Design…
• Offer suggestions on materials handling methods
• Plan storage methods and space requirements
A. Production Division
1. Suggestions on machine arrangement
2. Suggestions on human relations problems involved
in layout
3. Ideas on materials handling
• Plant Engineering division ( other than plant layout
group)
1. Aid in planning for utilities
2. Plan for building changes or construction
3. Move machinery and equipment 40
Interdepartmental help in
Layout Design…
1. Install machinery and equipment
A. Quality Control Divisions
1. Help plant layout to maintain quality in processes
2. Assure proper handling to protect product from
damage.
3. Plan scrap disposal

41
Facilities Design Procedure
Plan and design the arrangement of

• Production equipment
• Handling equipment
• Auxiliary equipment
• Space
• Land
• Buildings

42
Considerations in Facilities
Design
1. Collect basic data
2. Analyze basic data
3. Design production process
4. Plan material flow pattern
5. Consider general material handling plan
6. Calculate Equipment requirements
7. Plan individual work areas
8. Select specific material handling equipments
9. Coordinate groups of related operations
10. Design activity relationships 43
 Considerations in Facilities
Design…
1. Determine storage requirements
2. Plan service and auxiliary activities
3. Determine space requirements
4. Allocate activity areas to total space
5. Consider building types
6. Construct master layout
7. Evaluate, adjust and check layout with appropriate
personnel
8. Obtain approvals
9. Install layout
44
10. Follow up implementation of Layout.
 REFERENCES
• “Plant Layout and Material Handling”,
Chapter: 1, Pages 3-24, James M Apple,
John Wiley & Sons

45
46