Space Determination

Contents:
Factors for consideration in space planning:
◦ Office
◦ Receiving
◦ Storage
◦ Production
◦ Shipping
◦ Tool room and tool crib
Area allocation factors to be Considered
◦ Expansion
◦ Flexibility
◦ Aisle column
Area allocation procedure
The plot plan
Determination of Space requirements
Factorsfor consideration in space
Planning
A. General
B. Production
C. Building(New or Existing)
D. Cost
A.GENERAL 1. Master Plan
1. Major space occupying 2. Expansion plan
activities 3. Expansion vs new site
2. Production (or equivalent) 4. Flexibility desired
3. Serving production
5. Number of shifts
administration,
6. Total number of
Production, Personnel,
Employees
Plant
7. Male female ratio
4. Sales Forecast
8. Economic Trends
5. Number of Products
Production
6. Foreseeable technological
advances in Product or
Production processes
B.PRODUCTION 1. Material Plow Pattern
1. Production Size 2. Number of Operators
2. Material size, nature 3. Number of Auxiliary and
3. Production Methods-Line, Service Personnel
Job Shop, etc. 4. Handling Methods and
4. Nature of Processes Equipment
5. Number of Operations 5. Storage Requirements
6. Work Methods a) Raw Material
7. Work Standards
b) Supplies
c) In-process Material
8. Production Efficiency
d) Finished Goods
9. Scrap Percentages
e) Inventory Policy
10. Number of Machines f) Storage Methods and
11. Sizes of Machines Equipment
C.BUILDING (New or a) Width
Existing) 1. Size
1. Type 2. Shape
2. Construction 3. Condition
3. Number of Floors 4. Availability
4. Clear Height 5. Column Spacing
5. Floor load Capacity 6. Possible use of
6. Doors Mezzanines Balconies.
7. Stairs: ramps, elevators: Basement, Roof
lifts 7. Utilities
8. Aisles 8. Plot Size
a) Types
b) Location
D.COST

1. Funds Available

2. Interest Rates

3. Economic Trends
This Chapter presents information and procedure
for:

◦ Determining the amount of space needed

◦ Activities requiring significant amount of space

The activities covered here are:

1. Office Facility Planning

2. Receiving

3. Storage

4. Production

5. Employee Services
a) Lockers and Washrooms and Toilets

b) Medical Service

c) Food Service

6. Tool Room. Tool Crib

7. Maintenance

8. Warehousing

9. Shipping

10. Parking
Office Facility Planning
 In case of office planning, the employee focuses on
size, noise, proximity of facilities such as the
 boss,

cafeteria,

elevator,

machines,

windows,

entrance/exit doors and so on.

The starting point for planning office facilities is the
collection of data concerning the objective of the facility.

 The data are collected to determine departmental

interrelationships and departmental area requirements.

 When data gathering is completed a series of

management interviews should be conducted to verify
and refine office requirements.
Approaches to office Planning
Improved communications

Improved supervision

Better access to common files and equipment

Easier to illuminate, heat, cool and equipment

Lower maintenance costs

Reduced space requirements due to space flexibility

Some objections frequently cited
concerning open officer are:

Lack of privacy

Lack of status recognition

Difficulty in controlling noise

Easy access for interruptions and interference

Area requirement:
Area in Sq.ft
Receiving
 factors should be considered for designing the layout of
a receiving department/area for a plant.
1. Type of Carrier
2. Climate/Weather
3. Mechanization
4. Inspection
5. Decentralization
6. Clear Visibility
7. Clear Visibility
 Type of Carrier: Various forms of materials arc received at a plant. The materials

may be in the form of solids or liquids, heavy or small in sizes. The modes of
transportation also depend upon the character of materials.

 Climate / Weather: Whether the climatic conditions might damage the

materials, impair the movement of the vehicles or interfere with the efficiency
of the workers unloading the vehicles.

 Mechanization: Whenever economically justifiable, mechanical handling

equipment for loading and unloading incoming vehicles should be incorporated in
the layout.

 Inspection: When inspection of the material is necessary upon receipt, it is

desirable to conduct the inspection while the material is in transit on its path of
travel to the plant to avoid re-handling.
 Decentralization: Much intermediate handling or storage
can be eliminated whenever the layout permits receiving of
materials at their point of first use. Receiving materials in
this manner might justify the existence of several receiving
point in a plant

Clear Visibility: The materials from incoming vehicle

should be unloaded and set at an area such that it permits
clear visibility of the materials and case of their
identification.
 Quarantine Area
All defective or rejected material or parts should
be placed in a quarantine area until proper
disposition has been made of these rejects.
The quarantine area should be adjacent to, but not
a part of the receiving inspection area.
The rejected material might be disposed of by
returning it to the supplier or by reconditioning it
to bring it up to acceptable quality level.
 STORAGE
 Stores are principally reservoirs to keep the production line
adequately supplied with raw and semi-finished material
required.
 Stores safeguard the material and supplies from losses due
to pilferage, unauthorized use and deterioration due to
weather, moisture, heat, improper handling and
obsolescence.
 The storage function severs the purpose of providing a
means of accounting for materials, checking their qualities,
quantity and types against purchase order.
Topics:

 Functional Requirements of Store Room

 Designing Stores

 Location of Stores

 Temporary Storage

 Factors for Determining storage requirements

Functional Requirements of Store Room:

1) Protection Requirements:
a) Durability of the material
b) Its susceptibility to damage
c) Effect of climatic conditions.
d) d) Exposure to losses through pilferage.

2) Handling: Special facilities are required for

handling and storage of the material.
3) Inventory Control: Degree of accuracy needed
4) Centralization: Comparative advantage of a
large centralized store-room versus a series of
smaller store-rooms located at strategic points.
5) Stores Issues: Operators calling at storeroom for
materials versus delivery of material to
operators.
6) Control Point: Desirability of designing the
storeroom for joint use as a control point for
material quality or cost accounting.
 Designing Stores
While planning the storage facilities we should take care
that:
1) Sufficient storage space is provided so that the items
can be stored properly and are not located at too great
a distance from the point of use of the materials.
2) Maximum use of building cubage is made by stacking
the item to the available height
3) Items scored are easily accessible and one has not to
search them here and there.
4) Movement of man and material in the
storage area is easy and rapid as well as safe.

5) Identification of materials is quick.

6) Materials stored are protected fully.

7) Appearance of the items is neat and orderly

 Location of Stores:
While locating the storage facilities, we should see
that;

1) Storage areas are at convenient locations.

2) Employees have not to move excessive distances

from their work place and excessive time is not

lost due to and fro movement.

3) Location should be such that the receiving and

checking of the incoming material is convenient.

4) Storage area provides full protection to the items from theft or

loss material of high value.

5) Location should be such that it does not require log hauls of large

volume of materials.

6) Maximum use of building cubage is made by slacking the items to

the available height.

7) Arrangement of storage area permits the use of mechanical

handling facilities.

8) Sufficient and proper space for store staff as well as store records.
 Temporary Storage
This is especially in the case in which a certain kind
of material has been bought for a specific job.
It is known that the job will start at a certain
specific point in the plant.
When this material has been used up and the job is
completed, no further need will exist for storage
space for the particular item
 Factors for Determining storage requirements

A. Basic Considerations:

Size of each items - length, width, height and weight of
individual pieces
Size of container - size consists of length, width, height and
weigh of full container in which the pieces are received.
Number of pieces in a full container.
Frequency of issue - quantity of pieces required per year of
month / week and representative number per issue
B. Added Considerations:
1) Market Availability: Scarcity of the material on the
market and length of period between purchased and
delivery.
2) Price Fluctuations: Storage requirements are influenced
directly by price conditions in the market. During period
of rising prices, stocks are frequently increased beyond
normal requirements and depleted when prices are
falling.
3) Maximum and minimum quantities to be stored.
4) Type, size and capacity of binnage, racks and
shelving required in the storeroom.
5) If not stored in racks or bins, the method of
storing to be used.
6) Degree of protection the materials required
from the standpoint of safety against fire,
explosion; water, damage, etc.
7) Method of handling the material in and out of
the storeroom.
8) Inventory control requirements.

9) Protection from pilferage and waste.

10) Physical verification: The need for periodic

physical verification of inventories adds to the

storage problem particularly when the count is

frequent and accuracy required is exacting.

 PRODUCTION
 The determination of space required for productive
activity is dependent to a great extent on the individual
work places.

Work place design:

 A manufacturing operation was defined as a unit process,
or group of related unit process - and related - authorities
- that modifies the material or part, and is usually done at
one location.
Manufacturing Operation Planning Sheet, and
defined in scope to include;

Material e.g. raw, finished, scrap

Tools

Machines and auxiliary equipment

Operator

Auxiliary services (Utilities, etc.)

Considerations in Planning Receiving
Activity
1. Number of track 1. Service roads
sports 2. Space needed
2. Length of dock 3. Doors
3. Depth 4. Lighting
4. Column spacing 5. Ramps
5. Dock height 6. Dock boards
6. Enclosure 7. Dock type
7. Loading area
8. Maneuvering
area
 Planning an efficient work place
1) Determine the direction of general flow of material
2) Determine the desired direction of flow based on
the above, through the workplace: left - to - right,
right - to - left, front - to - back or back - to -front.
3) Determine items to be contained in the work place
such as machine, bench, stock containers, and
conveyors.
4) Make a rough sketch of the major pieces of
equipment in the work place in their approximate
desired positions, and indicate direction of material
flow -from step 2 above - by an arrow.
5) Indicate sources of material used in the work
place, and the directions in which it must go.

6) Indicate the destination of the material from

the work place, and the direction in which it
must go.

7) Indicate method of waste or scrap disposal,

applicable, and direction in which it must go.

8) Sketch in any material handling equipment

serving the work place or area.
9) Check the sketch against the principles of
motion economy and work place planning,
and the factors in Table.
10) Indicate distance between items in the work
place on the sketch.
11) Record work place plan to scale and in detail
on an Operation Analysis and Planning Chart.
12) Indicate method of operation, if appropriate,
at his point in the design process.
 Material handling at the work place
1) The distances involved are relatively short.

2) The number of moves is usually high, that is, it is a function of

the number of cycles performed.

3) The greater portion of the cycle time required at an individual

work place is taken up by material handling.

4) Much of this material handling is commonly classifies as direct

labor

5) Much of the handling activity at the work place is subject to

improvement by traditional material handling techniques.
 Work Standards
 It is necessary to determine the time required to
perform the operation.
 This is usually done by time study personnel, with
the results posted to the Production Routing, in
terms of hours/ piece, or pieces/hour.
 It is this value that is used as the basis for
determining the number of work places, machines,
and operators
 Factors for Consideration in Work Place Design
A. Purpose of the A. Space –related
operation B. Operator – related
B. Production Design C. Working Conditions
C. Material Related Environment
D. Equipment related D. Method Related
E. Quality E. Miscellaneous
Requirements
F. Material Handling
Methods