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Traditional Approaches to Facility Layout

Traditional Approaches to Facility Layout. Chapter 4. Significance of Facilities Planning. 20-50% of all manufacturing costs are related to material handling FP can reduce MH costs by 10-30% Therefore…

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Traditional Approaches to Facility Layout

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  1. Traditional Approaches to Facility Layout Chapter 4

  2. Significance of Facilities Planning • 20-50% of all manufacturing costs are related to material handling • FP can reduce MH costs by 10-30% • Therefore… • 2-15% reductions in overall manufacturing costs could be achieved by effective facilities planning. • Annual productivity would increase 3x more than it has in the past 15 years. • Hard to make similar projections to other areas of our economy • FP continues to be one of the most promising fields

  3. Objectives • Minimize material handling costs • Utilize space efficiently • Utilize labor efficiently • Eliminate bottlenecks • Facilitate communication and interaction between workers, between workers and their supervisors, or between workers and customers • Reduce manufacturing cycle time or customer service time

  4. Objectives (continued) • Eliminate waste or redundant movement • Facilitate the entry, exit, and placement of material, products, or people • Incorporate safety and security measures • Promote product and service quality • Encourage proper maintenance activities • Provide a visual control of operations or activities • Provide flexibility to adapt to changing conditions • Increase capacity

  5. The Nature of FP Objectives • As you can see, there are MANY! • They are conflicting. How? • There are constraints. Can you list some?

  6. The Facility Planning Problem • It is a constrained multi-objective optimization problem with many non-quantifiable costs and benefits. • There is NO OPTIMAL SOLUTION! • The best we can hope for is a “GOOD” solution. • Effective designs must consider all stakeholders • Owners • Customers • Suppliers • Employees • Neighbors

  7. Layout Problems • Design or Optimization?

  8. Facility Design Process • Combination of art and engineering • Many techniques available • Muther’s SLP Approach (1973) • Optimization based approaches • We will focus on both

  9. Systematic Layout Planning • Phase I - Determination of the location of the area where departments are to be laid out • Phase II - Establishing the general overall layout • Phase III - Establishing detailed layout plans • Phase IV - Installing the selected layout

  10. Systematic Layout Planning Input Data and Activities 2. Activity Relationships 1. Flow of materials ANALYZE 3. Relationship Chart 4. Space Requirements 5. Space Available 6. Space Relationship Diagram SEARCH 7. Modifying Considerations 8. Practical Limitations 9. Develop Layout Alternatives SELECT 10. Evaluation

  11. Systematic Layout Planning • P Product: Types of products to be produced • Q Quantity: Volume of each part type • R Routing: Operation sequence for each part type • S Services: Support services, locker rooms, inspection stations, and so on • T Timing: When are the part types to be produced ? What machines will be used during this time period?

  12. Sample relationship diagram

  13. Special Considerations in Office Layout • Minimizing distance traveled by employees • Permitting flexibility so that the current layout can be changed, expanded or downsized easily • Providing a safe and pleasant atmosphere for people to work in • Minimizing capital and operational costs of the facility

  14. Aesthetics

  15. Aesthetics

  16. Aesthetics

  17. Aesthetics

  18. Aesthetics

  19. Aesthetics

  20. SLP for MortAmerica, Inc. • Evaluation • Planning • Site selection • Design and layout

  21. SLP for MortAmerica, Inc. • Review current space utilization • Determine space projections • Determine level of interaction between departments • Identifying special consideration

  22. Current and Future Space Requirements

  23. Current and Future Space Requirements

  24. Relationship diagram for MortAmerica, Inc.

  25. Activity relationship diagram for MortAmerica, Inc.

  26. Space relationship diagram for MortAmerica, Inc.

  27. Engineering design approach

  28. OSHA, ADA and Local Codes

  29. OSHA, ADA and Local Codes

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