FACILITY DESIGN FOR VARIOUS FACILITIES FUNCTIONS

1. FACILITY DESIGN FOR VARIOUS FACILITIES FUNCTIONS

2. PRESENTATION OUTLINE • WAREHOUSE OPERATIONS • MANUFACTURING SYSTEMS • FACILITIES SYSTEMS

3. WAREHOUSE OPERATIONS

4. MISSION OF A WAREHOUSE To maximize utilizing space To maximize using equipment To maximize manpower To increasing productivity To maximize protection of materials

5. FUNCTION IN THE WAREHOUSE Receiving Identification and sorting Dispatching to storage Placing in the storage Storage Removing from storage Order accumulation Packaging

6. Shipping Record keeping Inspection and quality control Postponement Parts preparation Typical warehouse functions and flows

7. RECEIVING PRINCIPLES Don’t receive Prereceive Cross-dock ‘cross-dockable’ material Put away directly to primary or reserve locations Stage in storage location Complete all necessary steps for efficient load decomposition and movement at receiving.

8. Sort inbound materials for efficient putaway Combine putaway and retrievals when possible Balance the use of resources at receiving by scheduling carries and shifting time-consuming receipt to off-peak hours Minimize or eliminate walking by following inbound material past workstation

9. SHIPPING PRINCIPLES • Select cost and space for effective handling units • Minimize product damage • Eliminate shipping staging, and direct load outbound trailers. • Use storage racks to minimize floor space requirements for shipping staging • Use small-parcel shipping

10. RECEIVING AND SHIPPING PLANNING • Determine what is to be received and shipped Receiving and shipping analysis chart

11. Determine the number and type of docks • Determine internal receiving and shipment requirements • Personnel convenience/offices • A receiving hold area • Trash disposal and recycling bins • Pallet and packaging material storage/palletizing equipment • The truckers’ lounge • Buffer or staging area

12. DOCK OPERATIONS PLANNING The dock equipment needed to perform this interface includes:- • Dock levelers • As the interface between a dock at a given height and variable height carries LO dock levelers

13. Edge dock levelers Dock Plates Dock Lifter

14. Bumper pads • As the interface between a fixed dock and moveable carrier • Dock shelters • As the interface between a heated/air-conditioned dock and an unheated/non-air-conditioned carrier Dock shelters

15. Objectives STORAGE OPERATIONS To maximize : • Space utilization • Equipment utilization • Labor utilization • Material accessibility • Material protection

16. Storage Space Planning • The planned number of unit loads for each material to be stored may be determined by considering the receiving schedule and the method of assigning materials to storage locations. • If materials to be stored in a particular manner to be received together : -the planned number of unit loads stored must be equated to the maximum quantity of unit loads. • If materials to be stored in a particular manner are to arrive over time : -method of assigning materials to storage locations will determine the planned quantity of unit loads stored.

18. There are 2 major material storage philosophies : • Fixed (assigned location storage) - each individual SKU is stored in a specific location - no other SKU may be stored there; even though the location may be empty • Random (floating location storage) - any SKU may be assigned to any available storage location - a SKU stored in location A for one month might be stored in location B the following month, and a different SKU stored in location A

20. Honeycombing • Wasted space that results when a partial row or stack cannot be utilized because adding other materials would result in blocked storage. Ceiling Aisle Floor elevation view Outside wall plan view

22. Storage Layout Planning • Objectives • To use space efficiently. • To allow for the most efficient material handling. • To provide the most economical storage in relation to costs of equipment, use of space, damage to material, handling labor, and operational safety. • To provide maximum flexibility in order to meet changing storage and handling requirements. • To make the warehouse a model of good housekeeping.

23. Storage Area Principles • Popularity • Similarity • Size • Characteristics • Space utilization

24. Popularity • Pareto Law – 85% of the turnover will be a result of 15% of the materials stored. • To maximize throughput, the most popular 15% of the material should be stored such that travel distance is minimized. • Travel distances may be minimized by storing popular items in deep storage areas and by positioning materials to minimize the total distance traveled.

25. Outside wall Aisle Outside wall Aisle Storage depth of 3 units Storage depth of 2 units Outside wall Aisle Storage depth of 1 unit

26. Slow moving Medium moving Fast moving Entrance and exit

27. Similarity • Items that are received and/or shipped together should be stored together. • Exception :- - items are so similar that storing them together might result in order picking and shipping errors.

28. Size • Heavy, bulky, hard-to-handle goods should be stored close to their point of use. • Heavy items should be stored in areas with low ceiling. • Lightweight, easy-to-handle items should be stored in areas with high ceiling. • Size of storage location should fit the size of the material to be stored. • Total quantity of items to be stored must also be considered.

29. Characteristics • Perishable materials • Oddly shaped and crushable materials • Hazardous materials • Security items • Compatibility

30. Space utilization • Space conservation • Space limitations • Accessibility • Orderliness

31. ORDER PICKING OPERATIONS • Most critical function in distribution operations. • Where customer expectations are actually filled. • Highest-priority activity in the warehouse for productivity improvements. • Most costly activity. • Increasingly difficult to manage.

32. Principles • Apply Pareto’s Law • Use a clear, easy-to-read picking document • Use a pre-routed, pre-posted picking document • Maintain an effective stock-location document • Batch orders to reduce total travel time • Assign the most popular items to the most easily accessed locations in the warehouse • Eliminate paperwork

33. MANUFACTURING SYSTEMS

34. MANUFACTURING SYSTEMS Facilities design for manufacturing systems is extremely important because of the economic dependence of the firm on manufacturing performance. The effectiveness of the facility layout and material handling in these facilities will be influenced by a number of factors, including changes in • Product mix and design • Processing and materials technology • Handling, storage, and control technology • Production volumes, schedules, and routings • Management philosophies

35. FIXED AUTOMATION SYSTEMS Transfer Line •In a transfer line, material flow from one workstation to the next in a sequential manner. •Transfer lines often used for high-volume production and are highly automated. •In highly automated lines, the processing rates of individual machines are matched so that there is usually no need for buffer storage between machines. Disadvantages: •Very high equipment cost •Inflexible in the number of products manufactured •Inflexible Layout •Large deviation in production rates in case of equipment failure in the line.

36. Straight-line flow

37. U-flow

38. Circular-flow

39. FLEXIBLE MANUFACTURING SYSTEMS Flexible manufacturing systems are designed for small-batch (low volume) and high variety conditions. The word “flexible” is associated with such a system since it is able to manufacture a large number of different part types. The components of flexible manufacturing systems are: •Processing equipment •The material handling equipment •Computer control equipment Cellular Manufacturing-A working definition of a cell is a product centred grouping of machines and workers with all the resources to meet defined objectives.

40. FMS with external centralized layout

41. FMS with internal centralized layout

42. Guidelines for physical cell layout •Keep operator inside cell and in full view of others •Aim for high reliability in all machines and equipment •Minimize space available for inventory •Minimize operator and part travel distance •Provide for easy maintenance and housekeeping •Place cell function above appearance.

43. FMS based on cellular manufacturing

44. JUST-IN-TIME MANUFACTURING Just in time production aims to give customers exactly what is needed, when it is needed but with the minimum possible stock. There are many concepts and techniques related to the JIT production system that impact building design, facility layout, and the material handling systems. •Reduction of inventories •Deliveries to point of uses •Quality at the source •Better communication, line balancing, and multifunctional workers.

45. FACILITIES SYSTEM

46. Facilities Systems Atmospheric System Enclosure System Lighting & Electric System Life Safety Systems Sanitation Systems Building Automation Systems Facility Maintenance Management Systems

47. INTRODUCTION • Provide unified picture of the building technology and the interrelationship. • Overview of how the systems’ elements impact the overall process of facilities planning, • Effect of the facilities systems • Cost of constructing, operating & maintaining. • Employee performance, morale and safety. • Fire protection, maintenance, and security.

48. ENCLOSURE SYSTEMS • Consists of floor, walls, and roof. • Provide the facilities with a specific comfort level (thermal performance & water exclusion) • Provides a barrier against the effects of extreme cold or heat, lateral forces, water and undesirable entries.

49. Controlling solar transmission

50. Membrane layer – prevent water penetration. Insulation layer – thermal comfort. Vapor check – stop vapor migration. Roof design