Site Selection & Area Allocation

Maximizing Existing Facilities

Consider the Following Areas for Cube Utilization: Under the floor. Basements are the biggest user of under floor space. Evaluate using for walkways (between buildings) and utility runs. Overhead. Various usages. Roof. The roof could be used for recreational endeavors, central A/C units, silo for material storage, water towers, etc. Get it off the floor.
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Maximizing Existing Facilities

Truss level. A truss is a rafter. Depending on the truss layout; offices, walkways, heaters, utilities, etc. can be located off the floor. Clear Space. Clear space is that space from 8 feet above the floor to the ceiling. Install mezzanines, racks, overhead conveyors, etc. in this area.
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The Shell Game

WAS NOW

OPEN

OPEN
It is easier to move equipment into an open area rather that try and rearrange in place and meet production schedules.
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Site Types

Brown Field A previously developed parcel

Typically have incentives (tax, development, economic growth, etc.) attached to them Existing facility usually present Watch for contamination (chemical, oils, etc.) Allows for new layout Can have incentives attached for their development
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Green Field Untouched parcel of property

Relocation Assistance

Local Economic Development entities State Department of Economic Development Federal programs (Worker training, Welfare to work Program, Enterprise Zones, etc.) Local city assistance (Internal Revenue Bonds IRB, low cost loans, etc.) Missouri Enterprise Business Assistance Center
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Determining Building Size

Determine the total space requirements

Utilize a worksheet (Excel) Include all aspects of the operation Include outside areas (parking, shipping & receiving maneuvering area) on the worksheet 100 x 100, 50 x 50, 40 x 40, and even 25 x 50 feet Size refers to column spacing inside the facility A 2-to-1 length to width ratio is desirable (rectangle)
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Round up to the nearest standard size

Total Space Requirement Worksheet

Stations X W X L Manufacturing A. Fabrication Strip Shear 2 X 9.5 X 12 Chop Shear 4 X 7 X 13 Punch press 3 X 8 X 11 Press break 6 X 8 X 11 Roll former 1 X 6 X 18 Fabrication Total: B. Spot weld 1 X 26 X 30 C. Paint 1 X 28 X 100 D. Assembly & P.O. 1 X 16 X 38 Subtotal 50 percent allowance (mostly aisles) Manufacturing Total: II. Production Services Receiving--steel 13 X 25 Receiving--cartons 17 X 19 Stores 18 X 25 Warehouse 64 X 68 Shipping 20 X 20 Maintenance & tool room (two people @ 400 sq ft each) Utilities (estimate only)* 100 Production Services Area Total: (aisles are included in each layout in this area) III. Employee Services Employee entrance 10 X 20 Locker room (3.5 sq ft/employee x 50 employees) Toilets 10 X 20 Cafeteria (10 sq ft/employee X 50 employees) Drinking fountain (6 fountains X 15 sq ft each) Medical Services (first aid room only 10 X 10 feet) Services Area Required Total: IV. Office area (11 people from organizational chart) (11 people X 200 sq ft each) Total Building Space V. Outside Areas Receiving, parking, and maneuvering area Shipping, parking and maneuvering area Employee parking (50 employees) 1.5 employees per parking space 250 sq ft/parking place (9-2) 50 employees 1.5 employees/spaces = 34 spaces 34 spaces X 250 sq ft/space = 8,500 sq ft I. Square Feet 228 364 264 528 108 1,492 780 2,800 608 5,680 2,840 8,520 325 323 450 4,352 400 800 6,750

200 175 200 500 90 100 1,265 2,200 18,735

* I didn't size it properly, but the error will be minimized by an educated guess. This is a very minor use of area.

Building Size Determination

Our example building needs to be 18,735 sq. ft. No one would build this size building due to cost. We need to establish the 2-to-1 ratio first.
Step 1Divide by 2 Step 2Square root Step 3Round to a multiple of 25 & 50 ft.

18,735 / 2 = 9367.5 sq. ft. 9367.5 sq. ft. = 97 ft.

97 ft. = 100 ft therefore (2-to-1) = 100 ft. x 200 ft.

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Building Size Determination

At 100 x 200 ft., this is essentially two 100 x 100 ft. areas. Total area is 20,000 sq. ft. A comparable square building would need to be 137 x 137 ft., rounded to 150 x 150 or 22,500 sq. ft. The 2-to-1 rule yields a space savings of 2,500 sq. ft. Additionally, a square building tends to put an employee farther from an emergency exit.

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Dimensionless Block Diagram

With the starting size of the building known, begin by developing the dimensionless block diagram. Maintain the relationships between the block diagrams and the final layout.

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Area Allocation Procedure

1.

Establish the 100 x 200 ft. grid using graph paper. Start with the walls and columns only.
I I I I

100 ft.

200 ft.

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Area Allocation Procedure

2. Calculate the number of squares (400 square feet) needed by each department.

Department
Fabrication Spot weld Paint Assembly

Sq. Ft.
2,238 1,170 4,200 912

Blocks
6 3 11 3
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Area Allocation Procedure

3. Place the blocks into the area allocation layout using the dimensionless block diagram as a guide.
R S F
F F F O

F
F F F O

F
F F F O

F
F F
Assy

Util

W
W W W

W
W
Ship

SW F SW F P
RR LR

TR W TR W PO W O O

F C

1,300 sq. ft.

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Area Allocation Procedure

4.

Layout the internal walls or area boundaries. Present the layout and receive a final approval. Begin the detailed layout. Show all equipment and utility requirements.

5.

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Office Area Allocation

Procedure is similar to the manufacturing layout Use the organizational chart as a guide

Use 200 sq. ft. of space per person as a guide i.e. 36 employees x 200 sq. ft. = 7,200 sq. ft. 7,200 sq. ft. / 2 = 3,600 sq. ft. 3,600 sq. ft. = 60 ft. 2-to-1 ratio = 60 ft. x 120 ft.
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