THE NEED FOR GOOD FACILITIES PLANNING

1. Plant facilities influence operating costs and profits. 2. Planning allows facilities and its operations (OSHA, ISO 14001, etc.) to comply with laws and/or regulations. 3. Facilities are fixed investments involving high capital-cost expenditures. 4. Facilities are inflexible and long term commitments. 5. The planning, design and construction of facilities require long lead times. 6. Good planning helps to avoid disruptions in production and shipping or delivery.

THE NEED FOR GOOD FACILITIES PLANNING

7.

8. 9. 10. 11.

12.

The quality of facilities influences the attitudes of and the ability to attract suitable employees. Industrial facilities must be planned to meet anticipated future requirements yet compete profitably today. Facilities need to be planned for an appropriate degree of flexibility, expandability, versatility Good plans help management to take advantage of business opportunities that arise. Good planning is an aid to obtain approval and financing monies. Good planning reduces the high materials handling $ resulting from ad hoc expansion of plant facilities.

Planning the Conversion System

Successful operations depend on
Physical layout facility Flows of material Productivity

Planning the Conversion System

Types of manufacturing and service operations
Intermittent operations
For made to order products Low product volume General purpose equipment Labour intense operations Interrupted product flow Frequent schedule changes Large product mix

Planning the Conversion System

Continuous operation
Standardized product made to store inventory High product volume Special purpose equipment Capital intense operation Continuous product flow Small product mix

Planning the Conversion System

Basic layouts:
Layout : physical configuration of departments, workstations and equipment in the conversion process. The spatial arrangement of physical resources used to create the product

Type
Process oriented Product oriented Fixed position

Plant Layout
A Systematic Layout Planning (SLP) Approach

Planning the Conversion System

Product layout
For producing one standardized product Usually large in volume Each unit of output requires the same sequence of operation from beginning to end Work centers and equipment are ideally arranged in a line to afford a specialized sequence of tasks Examples
Automatic car washes, cafeterias, automobile makers, beverage bottlers

TYPES OF MANUFACTURING LAYOUT CONFIGURATIONS

I. Product Line Layout
Product A B C Lathe Lathe Lathe Mill Drill Seal Grind wash Wash

CHARACTERISTICS
High volume production Special purpose machines and material handling equipment
Throughput rates--high Work-in-process--low Setup/Run time ratio--low

System is very inflexible Control is relatively simple

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TYPES OF MANUFACTURING LAYOUT CONFIGURATIONS

II. Flow Line Workcell

M
D SG

M
D CG

T
M CG SG

M
D D

T = turning D = drilling M = milling CG = center grinding SG = surface grinding

GOAL:

GAIN the advantages and efficiency of high volume production in a LOW/MEDIUM VOLUME (FLEXIBLE) ENVIRONMENT.

Planning the Conversion System

Process layout
For intermittent operations Work centers or departments are grouped together according to their functional type Examples
Distribution warehouses Hospitals Universities Office buildings Job shops

Planning the Conversion System

Fixed position layout is appropriate when because of size shape or any other characteristic it is not feasible to move the product eg ship building home plumbing repair business etc Often a combination of layouts may be used . Most typically a process layout is combined with aproduct layout