UVA 2005/02

ENGINEERING PRODUCTION FACILITY PLANNING

Office Layout
Rating Proximity to Development Layout Service Facilities You have been hired by
the company XXX Architectural Design and Engineering. As a first task, your bos
s asks you to draw the layout of the new office to be installed in Barra da Tiju
ca. You made the lifting of all activities related to a project office and Archi
tectural Engineering, XXX and some features especially relevant. Based on this l
ist, you discussed with key people from XXX and finally defined the following li
st: Reception Local Activities / Features relevant Input / Output Receipts from
Customers Receive correspondence office manager Daylight Input / Output Study cu
stomer requirements Planning the scope of the project building's design with Aut
oCad Computer Printers Input / Output Daylight structural design hydraulic and e
lectrical design computers with MS Project and AutoCad Printers Input / Output D
aylight Design Architectural Design plant electrical and hydraulic structure des
ign with AutoCad Computer Printers and Plotters Input / Output Calculation of st
ructural design, hydraulic design specifications and electrical design specifica
tions and work computers with Excel software for structural input / output and f
ile a copy of plans and designs Input / Output
Management
Architecture
Engineering
Design
Calculation
calculation
Reprographics
1 / 7
UVA 2005/02
ENGINEERING PRODUCTION FACILITY PLANNING
Activities / Features relevant input / output Registration Guest Registration Re
ceivables from suppliers and banks Payables Management accounting reports and fi
nancial statements Computers with Excel, Word, Money Printers and Input / Output
Licenses Works at City Hall Shuttle service document Administrative support Reg
istry Entry / Departure Café, snack service, machine input / output Bathroom Ba
throom male female Input / Output Input / Output Window Door Consumer Products O
ffice Phone Fax Servers Computer Networking Internet communications, printing an
d data Hubs Router
Local Accounting Hall elevator
Support
Bathrooms kitchen pantry
Circulation Daylight Input / Output Communication Warehouse
Laboratory Informatics
WORK: (a) Draw the flow within the office, (2) Using the grading scale neighborh
ood below, suggests the layout to be deployed in the office of the Foo Bar: Rati
ng 1 2 3 4 5 6 7 Meaning Very important Absolutely necessary Unwanted Trashy Lit
tle Important Extremely important undesirable
2 / 7
UVA 2005/02
ENGINEERING PRODUCTION FACILITY PLANNING
(3) To explain the choice to add to the array of proximity, reasons for the degr
ee of closeness used: Code 1 2 3 4 5 6 7 Ratio (*) Contact Personal Convenience
Noise, disturbance Light Using common equipment Access Client
(*) Complete the table as needed. (4) Upon completion of the layout by proximity
, draw the layout of the office according to the data below the area required fo
r each section: Section Front Engineering Calculus Accounting Warehouse Manageme
nt Movement Area (m2) 16 30 16 25 20 June 12% of the total Section Architecture
Design Laboratory Computer Support Reprographics Cup Kitchen Area (m2) 30 20 9 1
2 24 20
Here are the restrictions of the site: Foyer 5x6
Bathroom masc. 4x3
Ladies room 4x3
windows
Free area (320 m2)
windows
windows
windows
3 / 7
UVA 2005/02
ENGINEERING PRODUCTION FACILITY PLANNING
CHECK YOUR LAYOUT
Author: Reinaldo A. Moura, Director of IMAM Consultoria Ltda., São Paulo. Tel (
11) 5575 1400 imam@imam.com.br http://www.guialog.com.br/ARTIGO67.htm
With the amount producing, planning the overall flow of materials, methods of wo
rk planned, the more work the specified pattern, we can determine and plan the r
esources needed: â ¢ â ¢ â ¢ how equipment will be needed, how many people / shift, ho
w much space will be necessary, etc..
These data provide the basis for a layout correction. Thus, plant-layout (layout
of the plant) can be defined as: analysis, conceptualization and design of an a
rrangement of physical facilities (land, buildings, equipment and utilities), co
vering also all its interrelations with involved in the manufacture of a product
or provide a service efficiently, economically and safely. Therefore, the mater
ial should flow smoothly from one job to another. In this article, we will evalu
ate the productivity through small individual improvements in specific areas€or
 by developing a completely new layout that can be implemented gradually. It wil
l be a responsibility of the role plant-layout assemble it all into a new, modif
ied and more productive physical arrangement (layout). ANALYSIS The analysis con
sists of a general procedure for developing a new layout based on comparison wit
h the current. If it is not feasible a complete redesign of the layout, then: 1
- Consider how just some of the design phases of the development complete; 2 - R
efuse suggestions for improvement that are based only on "hunches", 3 - Try the
ideas of all . And if your "problem" is as specific as: A project of expansion o
r layout changes, without expansion, see the guidelines below for specific ways
to accomplish each one:
GUIDELINES P / PLANNING OR EXPANSION OF FACILITIES 1 - Plan for the future layou
t with all the details. 2 - Design the expansions in at least two directions. 3
- Locate the activities most likely to expand in the best position to facilitate
the expansion. 4 - Locate the equipment in such a way that allows the insertion
of new equipment. 5 - Use aisles wide enough for efficient material flow. 6 - L
ocate the large equipment or special fixed positions, if necessary, due to found
ations and special facilities.
4 / 7
UVA 2005/02
ENGINEERING PRODUCTION FACILITY PLANNING
7 - Plan spaces with clearance required and appropriate. 8 - Use the minimum num
ber of partitions and walls. 9 - Plan an appropriate modulation to facilitate ex
pansion. 10 - Plan the location, arrangement and capacity to facilitate the expa
nsion of water facilities, power, steam, sewage, etc.. 11 - Plan activities for
receiving, forwarding, parking, streets and other utilities to the minimum reloc
ation or changes in the expansions. 12 - Create a gallery for the movement of pi
pes of utilities. 13 - Design a model of modular construction. 14 - Plan at appr
opriate times for the installation of suspended platforms or mezzanines. 15 - Pl
an external doors large enough to serve corridor in case of expansions. 16 - Pla
n for External walls become firewalls after expansions. 17 - Make or has referen
ce to a Master Plan is complete, even if you will deploy a first step only a par
t of that plan. 18 - Plan services and facilities necessary for manpower sized (
for classes or total): dining room, cloakroom, toilets, outpatient, lighting, ad
ministrative area, etc.. 19 - Idem, about the materials and equipment. 20 - Desi
gn a solution that optimizes the flow and logistics of materials and items that
move, also considering expansions. 21 - Check if the project includes the rules,
regulations and legislation, including special programs of the Company (eg ISO-
14000). GUIDELINES P / LAYOUT CHANGES WITHOUT EXPANSION OF 1 - Relocate the corr
idors. 2 - Refine policy materials with reduced in-process inventories. 3 - Stoc
ks materials that resist weather areas outside the building. 4 - Make the most o
f the height of the building, according to needs. 5 - Bring your machines as muc
h as possible (creating cells). 6 - Remove the walls to increase space and flexi
bility. 7 - Add mezzanines and platforms suspended if necessary. 8 - Eliminate p
roducts whose sales do not justify the production, provided that the time saved
is transferred to other products (ie, do not be idle). 9 - Use stents collapsibl
e to save space when empty. 10 - rearrange materials and obsolete equipment. 11
- Foster a right foot approximately 4-6 m for manufacturing areas and 70-10 m fo
r storage areas. 12 - Provide uniform illumination on all areas of the factory.
13 - Design the floor with a load capacity sufficient for future needs (producti
on or storage). 14 - Use pallets four entries instead. 15 - Analyze whether they
are adequate services and facilities for manpower, material and equipment, and
promotes the necessary adjustments.
EVALUATE YOUR LAYOUT (DIAGNOSIS) Answer with Yes or No. In Part 1 - The layout h
as been designed from a master plan? 2 - The layout includes areas non-manufactu
ring (office support, etc.).? 3 - The layout provides for expansion into new pro
ducts, changes in volume, etc..? 4 - The storage areas for raw materials, proces
s materials, auxiliary materials, packaging materials, etc.. were adequately siz
ed?
5 / 7
UVA 2005/02
ENGINEERING PRODUCTION FACILITY PLANNING
5 - There was a location study for the current manufacturing facility? 6 - The c
urrent facilities include the needs of the environment? 7 - The internal distrib
ution of resources in the principles of the cells and minifábricas? 8 - The mat
erial flow is the result of a standard adopted in the company? 9 - The movement
of materials found all ways to make the material move efficiently on the general
pattern? 10 - The working methods established the best ways to perform each ope
ration as well as your space needs? 11 - The layout considered the possibility o
f new processes? 12 - The layout of the store gets the same treatment plant layo
ut? 13 - The layout has been analyzed with respect to NR's - Rules Regulating He
alth and Safety at Work? 14 - Is there a master plan showing the physical growth
of dwellings? 15 - The layout looked all storage facilities in external areas?
16 - The material flows without the need for verbal instructions? 17 - Machinery
and equipment are located to allow full use of its capacity? 18 - All resources
are correlated close to each other? 19 - The layout meets the floor load capaci
ty, height of the building and emergency doors? 20 - The layout drawings are upd
ated with the facilities? Number of Responses Yes - 16-20: Its layout is excelle
nt. Keep performance. - 10-15: Make improvements throughout your layout. - Below
10: Your layout is probably the cause of many problems in your company. promote
s an urgent redesign.
REVIEW YOUR LAYOUT 1 - Analyze the relationship x Product Quality and / or Quant
ity. 2 - Evaluate production processes for improvement. 3 - Calculate the needs
of production equipment. 4 - Evaluate the flow of basic materials. 5 - Review th
e materials handling systems. 6 - Calculate the areas for storage needs. 7 - Rev
iew the activities related to the material flow. 8 - Check the area (space) are
meeting the needs. 9 - Develop the proposed new layout and compare it with the c
urrent. 10 - Identify and evaluate the differences and meaningful alternatives.
11 - Design plans and procedures for implementing changes. 12 - Check the flows
of raw materials, materials in process and finished components throughout the pr
oduction process. 13 - There is need for transfer during the production process
to other companies for processing (eg heat treatment)? 14 - Review the policy on
supply of raw materials in order to try to reduce inventory in the warehouse. 1
5 - Review the policy for finished goods inventory in order to try to reduce the
ir inventories and make room on the expedition. 16 - Try to gain vertical space,
especially in deposits of raw materials, auxiliary matetriais, semi-finished pr
oducts, trying to stack them to the fullest. 17 - Hire assistants deposits to st
ock raw materials and finished products. 18 - Place of supervisors offices and t
oilets on mezzanines, taking the floor area beneath them.
6 / 7
UVA 2005/02
ENGINEERING PRODUCTION FACILITY PLANNING
TIPS FOR PERFECT LAYOUT 1 - Review the interrelationship of the activities invol
ved with the material flow. 2 - Rearrange the layout of equipment for reduction
of the drive. 3 - Predict the stream for better efficiency. 4 - Locate the first
operations near the reception. 5 - Locate the operations related next to each o
ther. 6 - Preview flexibility to changing situations. 7 - Remove or minimize the
 partitions and walls. 8 - Predict the movement mechanized-automated to ensure a
continuous flow. 9 - Use mezzanines to release the floor area. 10 - Remove the
equipment they are not very usdos in order to free up more space. 11 - Preview o
f emergency exits. 12 - Combine processing activities with the handling. 13 - Pr
edict the frequent removal of scrap. 14 - Preview spaces suitable for estocagens
materials. 15 - Find support activities (services, utilities, etc.)..
7 / 7