systematic facilities planning

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Systematic Facilities PlanningSystematic Facilities Planning

An Overview & PerspectiveAn Overview & Perspective

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SYSTEMATIC FACILITIES SYSTEMATIC FACILITIES PLANNINGPLANNING

SystematicSystematic::Organized, disciplined rational approach to a Organized, disciplined rational approach to a problemproblem

FacilitiesFacilities::Building, production & material handling Building, production & material handling equipment, land, access (supporting equipment, land, access (supporting equipment)equipment)

PlanningPlanning::Decide a course of action based on facts and Decide a course of action based on facts and analysisanalysis

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THE OBVIOUSTHE OBVIOUS““The obvious is that which is never seenThe obvious is that which is never seen

until someone expresses it simply”until someone expresses it simply”

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Obvious?Obvious?

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THE OBVIOUSTHE OBVIOUS

Systematic Facilities Planning fits in this Systematic Facilities Planning fits in this category:category: Common SenseCommon Sense Prior ExperiencePrior Experience Simple Numerical MethodsSimple Numerical Methods Visual RepresentationsVisual Representations

Practical PerceptivenessPractical Perceptiveness

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PRODUCTIVE SYSTEMSPRODUCTIVE SYSTEMSCUSTOMERS

Conversion Process

*Operations

*Transformations

*Activities

*Interrelationships

*Workers*Managers*Equipment*Facilities*Materials*Energy*Information*Environment

INPUTS

*Goods

*Services

OUTPUTS

Information feedback on performance

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FACILITIES PLANNING AND DESIGNFACILITIES PLANNING AND DESIGN

II PROCESSPROCESSConceptualizeConceptualizePlanPlanAnalyzeAnalyzeDesignDesignImplementImplement

Inter-RelationshipsInter-Relationships

ProductiveSystems

PeopleMaterialsInformation FLOWEquipmentMethods

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ModelsModels Physical ModelsPhysical Models Analog ModelsAnalog Models Mathematical ModelsMathematical Models

SYSTEMATIC FACILITIES SYSTEMATIC FACILITIES PLANNINGPLANNING

Modeling ToolsModeling Tools Mathematical ProgrammingMathematical Programming Queuing ModelsQueuing Models Simulation ModelingSimulation Modeling

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WHY PLAN FACILITIESWHY PLAN FACILITIES

The primary causes that trigger new or The primary causes that trigger new or altered facilities are:altered facilities are:1. Expanding production, based on increased demand.

2. Entering a new field of endeavor.

3. Replacing an obsolete or inadequate facility.

4. Reallocating or consolidating production facilities.

5. Improving service to market(s).

LONG TERM STRATEGIC DECISIONS

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THE NEED FOR GOOD FACILITIES PLANNINGTHE NEED FOR GOOD FACILITIES PLANNING

1.1. Plant facilities influence the costs of operating and therefore Plant facilities influence the costs of operating and therefore profits.profits.

2.2. Planning allows facilities to comply with laws ad/or regulations.Planning allows facilities to comply with laws ad/or regulations.3.3. Facilities involve high capital-cost expenditures.Facilities involve high capital-cost expenditures.4.4. Facilities are fixed investments, not readily convertible to money Facilities are fixed investments, not readily convertible to money

or resale.or resale.5.5. Facilities are inflexible (i.e. physically fixed and have limited Facilities are inflexible (i.e. physically fixed and have limited

opportunities to be changed).opportunities to be changed).6.6. Facilities are long term commitments with protracted periods of Facilities are long term commitments with protracted periods of

financial return.financial return.7.7. Facilities planning, design and construction require long lead Facilities planning, design and construction require long lead

times.times.8.8. Sound plans for implementation can avoid disruptions in Sound plans for implementation can avoid disruptions in

production, and discontinuities for shipping or delivery.production, and discontinuities for shipping or delivery.9.9. Operations often produce detrimental wastes that affect entire Operations often produce detrimental wastes that affect entire

communities.communities.

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THE NEED FOR GOOD FACILITIES PLANNINGTHE NEED FOR GOOD FACILITIES PLANNING

10. The safety, convenience, appearance, and comfort of industrial facilities influence the attitudes of and the ability to attract suitable employees.

11. Industrial facilities must be planned to meet anticipated future requirements yet compete profitably today.

12. Facilities need to be planned for an appropriate degree of flexibility, expandability, versatility…

13. Good planning buys time for making commitments; it minimizes being taken by surprise.

14. If plans are made, managements can react faster and take advantage of business opportunities that arise.

15. Good planning, especially if presented well visually, is an aid to obtain financing monies.

16. The single most important cause of high materials handling costs is “ad hoc” expansion of plant facilities “in the absence of a strategic site-development plan.”

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SYSTEMATIC PLANNING OF INDUSTRIAL SYSTEMATIC PLANNING OF INDUSTRIAL FACILITIES (SPIF) DEFINEDFACILITIES (SPIF) DEFINED

SPIF is an organized, structured system of SPIF is an organized, structured system of determining for an industrial plant what its determining for an industrial plant what its current and future facilities should be. It is an current and future facilities should be. It is an integrated approach to planning the land, integrated approach to planning the land, buildings, machinery, and equipment for an buildings, machinery, and equipment for an industrial enterprise, and in so doing, SPIF industrial enterprise, and in so doing, SPIF involves:involves:

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SYSTEMATIC PLANNING OF INDUSTRIAL SYSTEMATIC PLANNING OF INDUSTRIAL FACILITIES (SPIF) DEFINEDFACILITIES (SPIF) DEFINED

1. A framework of four planning phases through which each project proceeds.

2. Five physical components of an industrial facility, each with its distinct sequence of three planning fundamentals.

3. Certain short-range and long-range inputs.4. Appropriate non-physical influences.5. A sequential planning pattern that converts the

inputs and influences to a facilities plan.6. A set of conventions for rating, recording, and

visualizing the analyses, work sheets, and planning documents.

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FACILITIES PLANNING AND DESIGNFACILITIES PLANNING AND DESIGN

Basic Elements of Layout PlanningBasic Elements of Layout Planning Product Product Quantity Quantity RoutingRouting Supporting ServiceSupporting Service Time Time

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THE KEY INPUT DATA: PQRSTTHE KEY INPUT DATA: PQRST

PRODUCT-MATERIALP

QUALITY-VOLUMEQ

ROUTING-PROCESS SEQUENCE

R

TIMET

SUPPORTING SERVICES

W H Y

WhatWhat

When, HowWhen, How

How MuchHow Much

WhoWho

Process Tm Process Tm PERTPERT

Figure 1-1: The Enterprise Design Process—General Interrelationships among Major System Elements, Functions, and Activities

MARKET RESEARCH AND SALES

FORECASTING

PRODUCT DESIGN

Material & Process Requirements

PROCESS DESIGN

Tool & Equipment Specifications

OPERATIONS DESIGN

Work Meth. & Stds. Manpower Reqts. Equipment Reqts.

COST DETERMINATION

FinancialRequirements

FACILITIES DESIGN

Facility Requirements--Production--Auxiliary--Service

PROCUREFUNDS

INSTALLFACILITIES

PROCUREFACILITIES

PROCURE MANPOWER

PROCURE MATERIALS

CUSTOMER SALES AND MARKETINGPHYSICAL

DISTRIBUTION

MANUFACTURING

PRODUCTION

RE-CEIVING

STO-RAGE

WARE-HOUSE

SHIP-PING

PKG

ASSY

FABRICATE PRODUCT OR PERFORM SERVICE

Energy

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FOUR PHASESFOUR PHASESI EXTERNAL

II OVERALL PLAN

III DETAILED PLAN

IV IMPLEMENTATION

I

II

III

IV

Project Time

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FOUR PHASESFOUR PHASESI EXTERNAL

II OVERALL PLAN

III DETAILED PLAN

IV IMPLEMENTATION

I

II

III

IV

Project Time

OK?OK?

OK?OK?

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Time

Lev

el o

f D

etai

l

Phase

I

II

III

IV

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The Phases of Systematic Layout PlanningThe Phases of Systematic Layout Planning

I LOCATION

II OVERALL LAYOUT

III DETAIL LAYOUTS

IV INSTALLATIONTime

NEW BLDG

MFGBLDG

MAINBLDG

HIW

AY

BD

CA

D

Phase I: Phase II: Phase III: Phase IV:

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THE FIVE COMPONENTSTHE FIVE COMPONENTS(Anatomy)(Anatomy)

of an Industrial Plantof an Industrial PlantI.I. LAYOUTLAYOUT

(Skeleton, Framework for Operations)(Skeleton, Framework for Operations)II.II. MATERIAL HANDLINGMATERIAL HANDLING

(Muscular System for Movement/Activity)(Muscular System for Movement/Activity)III.III. PROCEDURES/COMMUNICATIONSPROCEDURES/COMMUNICATIONS

(Nervous System for Control of Activity)(Nervous System for Control of Activity)IV.IV. UTILITIES/AUXILIARIESUTILITIES/AUXILIARIES

(Respiratory, Circulatory, & Digestive Systems)(Respiratory, Circulatory, & Digestive Systems)V.V. BUILDINGBUILDING

(Skin, Hair, “protective covering”)(Skin, Hair, “protective covering”)

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FUNDAMENTALS OF FIVE COMPONENTSFUNDAMENTALS OF FIVE COMPONENTS

I. LAYOUT 3 Fundamentals

A B

C

D

C

A

A B

CD

D

B

RelationshipsRelationships

Flow and Non-flowFlow and Non-flow

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FUNDAMENTALS OF FIVE COMPONENTSFUNDAMENTALS OF FIVE COMPONENTS

I. LAYOUT 3 Fundamentals

A B

C

D

C

A

A B

CD

D

B

Space Space

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FUNDAMENTALS OF FIVE COMPONENTSFUNDAMENTALS OF FIVE COMPONENTS

I. LAYOUT 3 Fundamentals

A B

C

D

C

A

A B

CD

D

B

AdjustmentsAdjustments

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FUNDAMENTALS OF FIVE COMPONENTSFUNDAMENTALS OF FIVE COMPONENTS

II. MATERIAL HANDLING 3 Fundamentals

MaterialsMaterials

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FUNDAMENTALS OF FIVE COMPONENTSFUNDAMENTALS OF FIVE COMPONENTS

II. MATERIAL HANDLING 3 Fundamentals

MovesMoves

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FUNDAMENTALS OF FIVE COMPONENTSFUNDAMENTALS OF FIVE COMPONENTS

II. MATERIAL HANDLING 3 Fundamentals

MethodsMethods

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FUNDAMENTALS OF FIVE COMPONENTS

III. PROCEDURES/COMMUNICATIONS

3 Fundamentals

InformationInformation

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FUNDAMENTALS OF FIVE COMPONENTS

III. PROCEDURES/COMMUNICATIONS

3 Fundamentals

Transmission Transmission

TimelinesTimelines

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FUNDAMENTALS OF FIVE COMPONENTS

III. PROCEDURES/COMMUNICATIONS

3 Fundamentals

MeansMeans

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FUNDAMENTALS OF FIVE COMPONENTS

IV. UTILITIES/AUXILIARIES 3 Fundamentals

SubstanceSubstance

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FUNDAMENTALS OF FIVE COMPONENTS

IV. UTILITIES/AUXILIARIES 3 Fundamentals

Destination/RoutingDestination/Routing

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FUNDAMENTALS OF FIVE COMPONENTS

IV. UTILITIES/AUXILIARIES 3 Fundamentals

Conductors/MeansConductors/Means

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FUNDAMENTALS OF FIVE COMPONENTS

V. BUILDING 3 Fundamentals

Form/ShapeForm/Shape

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FUNDAMENTALS OF FIVE COMPONENTS

V. BUILDING 3 Fundamentals

MaterialsMaterials

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FUNDAMENTALS OF FIVE COMPONENTS

V. BUILDING 3 Fundamentals

DesignDesign

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FIVE COMPONENTSFIVE COMPONENTSLAYOUT HANDLING COMMUNICATION UTILITIES BUILDING

I

II

III

IV

PHASES

P,Q,RP,Q,R

Block Block DiagramDiagram

Detailed Detailed LayoutLayout

Train/ Train/ InstallInstall

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FIVE COMPONENTSFIVE COMPONENTSLAYOUT HANDLING COMMUNICATION UTILITIES BUILDING

I

II

III

IV

PHASES

Train/ Train/ InstallInstall

P,Q,R,SP,Q,R,S

Type and Type and Size of Size of EquipmentEquipment

Make of Make of Equip.Equip.

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PROJECTING KEY INPUT DATAPROJECTING KEY INPUT DATA

Long-Range Facilities Planning should be based on Long-Range projection of Key Input Data

P

Q

R

S

T

FUTURE TIMEN0W

INPUT

DATA

PQRST PROJECTIONSPQRST PROJECTIONS

Key Elements

Last Year

CurrentYear

Plus 2Years

Plus 4Years

Plus 6Years

P1

Pa

Pb

Pc

Pd

Q1

Qa

Qb

Qc

Qd

S1

Sa

Sb

Sc

Sd

T1

Tb

Tc

Td

Ta

412#C.I.“Other Physical Characteristics”

410#Steel

380#Alum.

350#Stainless

275#Plastic Coat

$ orUnits

$ orUnits

$ orUnits

CafeteriaParkingTool Rm

8 hrs/day

48 hrs

8

48

7

36

6

24

6 (Labor)

12 (Delivery Time)

R1

Ra

Rb

Rc

Rd

(Man. Ovens)Manual

Semi Auto Elect. OvensN/C(1/10) (1/2)N/C Fully Auto N/C

(Heat Treating)(Machining)

TIME PROJECTION

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SYSTEMATIC FACILTIES SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING AS AN INTEGRATED

PLANNING SYSTEMPLANNING SYSTEM

1

2

3

4

5

6

I

II

III

IV

LayoutHandling

CommunicationUtilities

Building

P Q R S TP Q R S T

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SYSTEMATIC FACILTIES SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING AS AN INTEGRATED

PLANNING SYSTEMPLANNING SYSTEM

1

2

3

4

5

6

I

II

III

IV

LayoutHandling

CommunicationUtilities

Building

P Q R S TP Q R S T Key Input DataKey Input Data

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SYSTEMATIC FACILTIES SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING AS AN INTEGRATED

PLANNING SYSTEMPLANNING SYSTEM

1

2

3

4

5

6

I

II

III

IV

LayoutHandling

CommunicationUtilities

Building

P Q R S TP Q R S T Key Input DataKey Input Data

Projection in TimeProjection in Time

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SYSTEMATIC FACILTIES SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING AS AN INTEGRATED

PLANNING SYSTEMPLANNING SYSTEM

1

2

3

4

5

6

I

II

III

IV

LayoutHandling

CommunicationUtilities

Building

P Q R S TP Q R S T Key Input DataKey Input Data

Projection in TimeProjection in Time

FundamentalsFundamentals

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SYSTEMATIC FACILTIES SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING AS AN INTEGRATED

PLANNING SYSTEMPLANNING SYSTEM

1

2

3

4

5

6

I

II

III

IV

LayoutHandling

CommunicationUtilities

Building

P Q R S TP Q R S T Key Input DataKey Input Data

Projection in TimeProjection in Time

FundamentalsFundamentals

PhasesPhases

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SYSTEMATIC FACILTIES SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING AS AN INTEGRATED

PLANNING SYSTEMPLANNING SYSTEM

1

2

3

4

5

6

I

II

III

IV

LayoutHandling

CommunicationUtilities

Building

P Q R S TP Q R S T Key Input DataKey Input Data

Projection in TimeProjection in Time

FundamentalsFundamentals

PhasesPhases

ComponentsComponents

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SYSTEMATIC FACILTIES SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING AS AN INTEGRATED

PLANNING SYSTEMPLANNING SYSTEM

1

2

3

4

5

6

I

II

III

IV

LayoutHandling

CommunicationUtilities

Building

P Q R S TP Q R S T Key Input DataKey Input Data

Projection in TimeProjection in Time

FundamentalsFundamentals

PhasesPhases

ComponentsComponents

Time ScheduleTime Schedule

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APPLE: FACILITIES DESIGN PROCEDUREAPPLE: FACILITIES DESIGN PROCEDURE-20 STEPS--20 STEPS-

1.1. Procure DataProcure Data

2.2. Analyze DataAnalyze Data

3.3. Design Production ProcessDesign Production Process

4.4. Design Material Flow PatternDesign Material Flow Pattern

5.5. Design/Select Material Handling PlanDesign/Select Material Handling Plan

6.6. Calculate Equipment RequirementsCalculate Equipment Requirements

7.7. Plan Work AreasPlan Work Areas

8.8. Select Material Handling EquipmentSelect Material Handling Equipment

9.9. Plan Groups of Related OperationsPlan Groups of Related Operations

10.10. Design Activity RelationshipsDesign Activity Relationships

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APPLE: FACILITIES DESIGN PROCEDURE-20 STEPS- (Continued)

11. Calculate Storage Requirements

12. Plan Service (Auxiliary) Activities

13. Calculate (Total) Space Requirements

14. Allocate Activities to Space

15. Consider Building Types

16. Construct Layout (Model)

17. Evaluate, Adjust, Check Layout

18. Justify, (Approval ?)

19. Install Layout

20. Nurture Layout