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OPERATIONS MANAGEMENT

O P M By: ZAHID HUSSAIN
O
P
M
By: ZAHID HUSSAIN
OPERATIONS MANAGEMENT O P M By: ZAHID HUSSAIN
OPERATIONS MANAGEMENT O P M By: ZAHID HUSSAIN
OPERATIONS MANAGEMENT O P M By: ZAHID HUSSAIN

Facilities Planning

Facilities Planning

  • 1. What is Facility Planning?

  • 2. Need for Facility Planning

  • 3. The objectives of Facility Planning

  • 4. Types of Layout

  • 5. Product versus Process Layout

  • 6. Developing the Process layout

  • 7. Conventional approach for developing process layout.

  • 8. Conventional approach for developing product layout.

Facilities Planning

Introduction

Facility planning, layout planning, Plant layout,

Facilities design, Optimum allocation of space to the components

of system Determine the best arrangement of facilities and

equipment capable to satisfying anticipated demand ( qty, qly, time) at lower cost. All elements of processes are integrated to gain

high productivity and satisfaction of social and psychological needs of all people at work. Experience, good judgment, suitable tools are required for facility planning.

Facilities Planning

Need for Facility Planning

Need to reduce handling and maintenance cost

which is 20-50% of operating cost. It can be reduced to 10-30%. Better maintenance cost can reduce downtime.

Economic consideration forces a constant

evaluation and reevaluation of existing system, personnel and equipment. Changes in production methods, better

materials and equipments can be achieved. Change in level of demand, design of product,

technology. Employees moral- health safety, environment issue, employee turnover.

Facilities Planning

Need for facility Planning

Layout designed efficiently, but with growth and changing environment layout becomes less efficient.

Certain indicators for re layout study.

  • 1. Congestion in aisles and storage area and poor utilization of space.

  • 2. Excessive inventory.

  • 3. Process bottleneck in some locations.

  • 4. Skilled worker doing some unskilled work

  • 5. Long operation cycle and delivery delay

  • 6. Workers anxiety and strain.

  • 7. Accidents and near accidents,

Facilities Planning

Objectives of facility Planning

It support organization mission through

improved material handling, control and good housekeeping. Effective utilization of people, equipment, space

and energy. Minimize capital investment.

Be flexible and promote case of maintenance.

Provide employees safety and job satisfaction.

Facilities Planning

Types of Layouts Process or functional Layout.

Facilities' and equipments in groups according to function

performed. Different orders follow different paths depending on their special processing requirements.

  • 1. Job shop batch type production facilities.

  • 2. Loss of time, cost of moving materials.

Facilities Planning

Process or functional Layout. Milling Lathe Department Department Drilling Department M M D D D D
Process or functional Layout.
Milling
Lathe Department
Department
Drilling Department
M
M
D
D
D
D
L
L
M
M
D
D
D
D
L
L
G
G
G
P
L
L
G
G
G
P
L
L
Painting Department
Grinding
Department
L
L
A
A
A
Receiving and
Shipping
Assembly

Facilities Planning

Types of Layouts

Advantages of Process or Functional Layout.

Less duplication of equipment

Lower investment in equipment

Greater flexibility of production like design

change, production volume change, mew product and new machines induction. Capability to handle breakdown of equipment

by transferring the work to other machines. Better and efficient supervision.

Greater incentives to efficient individual workers.

Facilities Planning

Developing the process layout

Analyze the product to be produced.

-

Design drawings, parts lists ( to produce, to purchase, assembly charts showing sequences of assembling.

Determine the process required to manufacture the

product through study of route sheets and operation process charts. Prepare layout planning charts keeping in view the following.

-

Flow process showing all operations, moves storage and inspection in sequence.

-

Standard times for each operation

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Machine selection

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Manpower requirement for all activties.

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Material handling loads, methods and equipment requirements.

Facilities Planning

Developing the process layout

Convert the layout planning chart data to physical plant area. Determine the work station and develop the layout after

considering the machine, material, service area. Analyze the storage area requirement, raw material, in

process material and finished goods. Establish the minimum aisle width.

Establish the office requirement.

Consider personnel facilities and services like first aid,

lunch & refreshment centers, lockers, rest rooms, parking etc. Survey plant services like utilities, waste disposal,

maintenance, heating, ventilation etc. Provide for future expansion, i.e. additional product line, increase in sales demand

Facilities Planning

Types of Layouts Product and line Layout.

Arrangement of facilities' and equipments in same sequence that of operations needed to complete each unit of product.

Automobile assembling , domestic appliances

Facilities Planning

Types of Layouts

Advantages of Product Layout.

Lower total material handling cost.

Lower total production time.

Less work in process.

Simple prod control, fewer control needed.

Better incentive plan for group of workers.

Facilities Planning

When to use product and process layouts?

Product layout

Process layout

One & fewer standard products

Many types & styles of product

Large volume of production of each item over a considerable time period.

Low volume of production of individual items.

Possibility of carrying out effective motion and time studies.

Adequate motion and time study difficult or impossible to make.

Scope of getting good labor and equipment balance

Difficult to achieve good labor and equipment balance.

Minimum inspection required during processing

Many inspections are required during sequence of operations.

Facilities Planning

Fixed Position Layout.

Typical Typical of of projects projects

Equipment,

Equipment,

workers, materials,

workers,

materials,

other

other resources

resources

brought toto the

brought

the site

site

Highly skilled

Highly

skilled labor

labor

Often lowlow fixed

Often

fixed

Cost

Cost

Typically

Typically high

high

variable

variable costs

costs

Facilities Planning Fixed Position Layout.  Typical Typical of of projects projects  Equipment, Equipment, workers,

Facilities Planning

Types of Layouts Fixed Position Layout.

Arrangement of facilities and equipments so

that the resources as workers, equipments materials flow to the item being produced. Maintenance of steel mills or power plant or building.

Effective scheduling, coordination and control are required.

Process Process A B Product Process Process C D
Process
Process
A
B
Product
Process
Process
C
D

Facilities Planning

Types of Layouts Combination Layout.

Process layout and product layout are

combined. Parts of refrigerators are prepared through

process layout All parts are assembled at assembly line.

QUESTIONS

QUESTIONS