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Facility planning and Design Lecture 1 A– introduction

Facility planning and Design Lecture 1 A– introduction. Dr. Husam Arman. Outline. Syllabus Course contents ILOs Text book Grading Subjects detail Introduction to the course. Syllabus.

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Facility planning and Design Lecture 1 A– introduction

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  1. Facility planning and Design Lecture 1 A– introduction Dr. Husam Arman

  2. Outline • Syllabus • Course contents • ILOs • Text book • Grading • Subjects detail • Introduction to the course

  3. Syllabus This course covers various areas related to facility planning and design. The materials covered include mainly three parts; facility location, plant layout and material handling. The first two parts will be discussed extensively, while little emphasis on the materials handling part (see detail subjects).

  4. ILOs Understand the importance of facility planning as an IE. Be able to formulate quantitative and qualitative models to address facilities planning problems Be able to analyze practical problems considering the fundamental principles of material handling Be able to design a factory layout incorporating product, process, and schedule. Be able to work in a team and confident in presenting and defending his work

  5. Text book • Text book: • Facilities Planning, J.A. Tompkins et al., John Wiley & Sons, Inc., New York, 2010 • Additional references; • Facility layout and location, Francis, McGinnis & White, Prentice Hall NJ, 1992. • Facilities Planning and Design, Alberto Garcia-Diaz and J. MacGregor Smith, Prentice Hall, 2007

  6. Assessment criteria

  7. Subjects detail

  8. Group Project • Study a real location or layout problem and try to improve upon the current situation using analytical tools developed in the course. • You are free to suggest a project that interests you • More information will be provided duly!

  9. Project Planning • Group Project will incorporate: • Course content • Teamwork • Data collection and analysis (will use software) • Project Presentation • Project Report

  10. Our ground rules • Please switch off/silent our phones when in class. • Arrive on time • Keep our presentations to agreed upon lengths • In general be courteous to others • …. • Do you want to add anything!

  11. Ok, shall we start now!

  12. Facility location and plant layout • The location of facilities and also determination of the configuration at certain types of facilities • Also called Facilities planning! • Facilities planning is complex and broad subject cuts across several disciplines (engineering, civil, electrical, architecture, etc) • However, here we’ll focus on industrial engineer’s role in developing effective and efficient facilities plans.

  13. Facilities Planning Viewpoints • Civil engineering • Electrical • Mechanical engineering • Architectural • Real estate • Urban planning • Industrial engineering • What is the role of each in facility planning?

  14. IE Viewpoint of Facilities Planning • IEs are focusing on requirements, resource allocation, and efficient use of resources. • Facilities are the integration of many lower level systems • Space requirements with respect to flow and operations control • Personnel requirements • Equipment requirements • System design/layout with respect to flow and operations control • The use of information systems and technology to increase effectiveness • Movement within a facility • Movement between facilities – Location • …

  15. Definitions • Facilitylocation refers to the choice of region and the selection of a particular site for setting up a business or factory • Plant layout Plant layout refers to the arrangement of physical facilities such as machinery, equipment, furniture etc. within the factory building in such a manner so as to have quickest flow of material at the lowest cost and with the least amount of handling in processing the product from the receipt of material to the shipment of the finished product

  16. Definitions • Facilities Planning determines how an activity’s tangible, fixed assets should contribute to meeting the activity’s objectives . • This course will focus on facilities planning. • Emphasis on location and layout. • Some coverage of materials handling.

  17. Facilities planning Facilities location Facilities planning Facilities design

  18. f01_02

  19. Why matters? • To stimulate your thought, think of the following questions: • What impact does facilities planning have on handling and maintenance costs? • What impact does facilities planning have on employee moral? • What impact does facilities planning have on management of a facility? • What impact does facilities planning have on a facility’s capability to adapt to change and satisfy future requirements?

  20. Why matters?

  21. Why matters?

  22. Inventory Strategy Inventory Strategy • • Forecasting Forecasting Transport Strategy Transport Strategy • • Inventory decisions Inventory decisions • • Transport fundamentals Transport fundamentals • • Purchasing and supply Purchasing and supply • • Transport decisions Transport decisions Customer Customer scheduling decisions scheduling decisions service goals service goals • • Storage fundamentals Storage fundamentals ORGANIZING ORGANIZING • • The product The product CONTROLLING CONTROLLING • • Storage decisions Storage decisions PLANNING PLANNING • • Logistics service Logistics service • • Ord Ord . proc. & info. sys. . proc. & info. sys. Location Strategy Location Strategy Location decisions Location decisions • • • • The network planning process The network planning process Facility Location in Location Strategy .

  23. Why matters? All the facilities in the supply chain should have the following characteristics: • Flexibility • Modularity • …

  24. f01_07 Why matters? f01_07

  25. Strategic Planning • Def.: • High level of planning: • Identify a process to obtain an objective • Identify and utilize resources (physical aspects) • Identify and execute processes (time aspects) • Identify and coordinate methods (control aspects) • Longer term (Strategic) vs. shorter term (Tactical) • Plan a trip from Nablus to London – (map?) • Resources • Timing • Control • Strategic and Tactical relationship • Objective of strategic plan doesn’t change!

  26. Strategic Planning • Applied to Facilities Planning: • Requires an understanding of feasibilities: • Marketing • Product development • Manufacturing / Processing • Production / Inventory control • Human resources • Finance • Impacts the performance of each, too • Concurrent design process seems best • Facilities planning occurs simultaneously • Evolving requirements • Multiple alternatives • Design iterations probable

  27. f01_08 f01_08

  28. Steps in Engineering Design • Ideal Sequence: • Defining the Problem • Gathering Pertinent Information • Generating Multiple Solutions • Analyzing and Selecting a Solution • Testing and Implementing the Solution • Actual process is iterative… • Frequently back-track to a previous stage

  29. Facilities Planning Process Steps • Defining the Problem • Define • Gathering Pertinent Information • Specify • Determine • .

  30. Facilities Planning Process Steps • Generating Multiple Solutions • Generate … • Analyzing and Selecting a Solution • Evaluate … • Select … • Testing and Implementing the Solution • Implement the facilities plan • Maintain and update the facilities plan

  31. Facilities Planning Process Steps • Frequently back-track to a previous stage • Update the products and redefine the objective of the facility

  32. f01_04 f01_04

  33. Data for Strategic Facility Design • What is to be produced? • How are the products to be produced? • When are the products to be produced? • How much of the product is to be produced? • How long will the product be produced? • Where are the products to be produced?

  34. Example Data for Strategic Facility Design • What is to be produced? 1/16 scale models of new and old tractors • How are the products to be produced? Die & sand casting, trimming/drilling, painting, assembling, direct shipping • When are the products to be produced? Within 1/2 month prior to introduction, and 2 months after order • How much of the product is to be produced? Batch production runs of 100 to 1000, ~ 8 new & 20 total models/yr • How long will the product be produced? 2 – 3 yrs/model, product lifecycle of 15 – 30 yrs, facility life >50 yrs • Where are the products to be produced? Small, rural Iowa town (~ 3000 pop.; supplied from Chicago, WI; adjacent to rail, near major U.S. highway; OEMs in IL, WI, IA

  35. Issues Impacting a Strategic Facilities Plan: • Number, location, sizes of warehouse/distribution centers • Centralized vs. decentralized storage / manufacturing • Acquire existing (brownfield) vs. build new (greenfield) • Flexibility required for marketing & technology • Interfacing storage and manufacturing • Level of vertical integration • Control of materials and equipment • Inbound and outbound material movement • Technology changes for suppliers, firm, customers • Financial goals for the design of the facility

  36. HW – next time

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