FACILITIES MANAGEMENT

Session 2. 1

CONTENTS (1 of 2)Objective facilities design functionMajor elements of facilities designImportance of facilities designFacilities design & productivityObjectives of facilities design (FD)Functions & activities in FDNeed for FDEnterprise design processSequence of steps in design process

CONTENTS (2 of 2)Types of layout and problems expectedPlacing a new facilityDesirable characteristics of a good layoutOrganization for layout functionFunctions of Plant Engineering DepartmentInter Department help in layout designFacilities Design processConsideration of Facilities Design

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The Facilities Design Function

OBJECTIVES to get the inputs (material, supplies, etc) into

through and out of each facility in the shortest time practicable, at acceptable cost.

Facilities Design deals with the design and arrangement of physical elements of an activity/s related to the manufacturing industry, whose drawing represents a plant layout.

Facilities Design analyzes, conceptualizes, designs and implements systems for the production of goods or services.

FD is represented as a floor plan, or an arrangement of physical facilities (equipment, land, buildings, utilities, etc.)

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Major Elements of Facilities Design

S.No Typical Inputs Production Activities Outputs

1. Plant Materials and Supplies

Conversion of materials to parts assemblies, products

Production and Scrap!

2. Warehouse Large quantities of Merchandise

Safekeeping and availability

Orders of Merchandise

3. Retail Store Orders of Merchandise

Display, convenient access, transfers of ownership

Individual items for customers

4. Post Office Letters and Parcels Sorting and accumulating Orderly arrangement of letters and parcels

5. Restaurant Food and supplies Preparation of food Meals

6. Hospital Sick Patients, Medicines, Supplies

Services required to “cure” patients

Cured Patients

7. Home Food, supplies, equipment, e.t.c

Meals and orderly activity Happy people

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Dealing only with the careful and detailed planning of production equipment arrangement.

Should include a careful study of at least the following areas of interest :

1. Transportation 10. Warehousing2. Receiving 11. Shipping3. Storage 12. Offices4. Production 13. External Facilities5. Assembly 14. Buildings – Canteens6. Packaging and packing 15. Grounds7. Material handling 16. Location8. Personnel Services 17. Safety9. Auxiliary production activities 18. Scrap

Scope of Facilities Design

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1. An efficient plan for the flow of material is a primary requisite for economical production.

2. The material flow pattern becomes the basis for an effective arrangement of physical facilities.

3. Material handling converts the static flow pattern into a dynamic reality, providing the means by which material is caused or permitted to flow.

4. Effective arrangement of facilities around the material flow pattern should result in efficient operation of the various related processes.

5. Efficient operation of the various related processes.

6. Minimum production cost should result in maximum profit.

Importance of Facilities Design

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Increasing productivity is usually a desired result of facilities design or re-design.

It is accomplished by the design efforts necessary to carry out the several objectives of the facilities design process

Facilities Design & Productivity

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1. Facilitate the manufacturing Process

2. Minimize material handling

3. Maintain flexibility of arrangement and of operation

4. Maintain high turnover of work-in-process

5. Hold down investment in equipment.

6. Make economical use of building cube.

7. Promote effective utilization of manpower.

8. Provide for employee convenience, safety and comfort in doing the work.

Objectives of Facilities Design

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1. Arrange Machines, equipment and work areas so that material is caused to move smoothly along in as straight a line as is possible

2. Eliminate all delays possible. It has been said that during 80% of the time a part is in the plant it is either being moved or stored – only 20% of the time is productive.

3. Plan the flow so that the work passing through an area can be easily identified and counted, with little possibility of becoming mixed with other parts or batches in adjacent areas.

4. Maintain quality of work by planning for the maintenance of conditions that are conducive to quality.

Facilitating the Manufacturing Process

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If a finished layout is to present an effective arrangement of related work areas, in which goods can be economically produced, it must be planned with the objectives of layout well fixed in mind. The major objectives are to :

1. Facilitate the manufacturing process

2. Minimize material handling

3. Maintain flexibility of arrangement and of operation

4. Hold down investment in equipment

5. Make economical use of building cube

6. Promote effective utilization of manpower

7. Provide for employee convenience, safety, and comfort in doing the work

Objectives of Facilities Design

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Facilities design & Plant layout group perform a wide variety of activities.

The list contain

a. Raw materials

b. Theoretical potential activities

c. Range of facilities design interests

Functions and Activities in Facilities Design

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Functions and Activities in Facilities Design

S.No Actions Areas of Interest Nature of Interest

01. Advise (on) Assembly Activities

02. Allocate Auxiliary Services Analysis

03. Analyze Building Appropriation

04. Approve Construction Automation

05. Classify Containers Availability

06. Coordinate Cost Benefits

07. Design Distribution Budgets

08. Determine Equipment Capability

09. Develop Fabrication Capacity

10. Establish Facilities Changes

11. Estimate Flow Contracts

12. Evaluate Grounds Controls

13. Forecast Handling Costs

14. Improve Location Criteria

15. Investigate Maintenance Data

16. Measure Manpower Efficiency

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S.No Actions Areas of Interest Nature of Interest

17. Minimize Manufacturing Equipment

18. Model Material Expansion

19. Modify Office Facilities

20. Monitor Packaging Feasibility

21. Organize Packing Flexibility

22. Plan Plant layout Flow

23. Predict Pollution Functions

24. Promote Process Hazards

25. Provide Production Incentives

26. Qualify Productivity Installation

27. Reduce Repair Interrelationships

28. Review Safety Layout

29. Select Salvage Liason

30. Specify Scrap Location

31. Study Security Long range Planning

Functions and Activities in Facilities Design…

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S.No Actions Areas of Interest Nature of Interest

32. Supervise Space Measurements

33. Test Storage Mechanization

34. Up-date Traffic Methods

35. Transportation Modifications

36. Utilities Needs

37. Warehousing Objectives

38. Waste Operations

39. Organization

40. Performance

41. Plans

42. Policies

43. Problems

44. Procedures

45. Processes

46. Programs

Functions and Activities in Facilities Design…

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S.No Actions Areas of Interest Nature of Interest

47. Progress

48. Records

49. Regulations

50. Replacements

51. Reports

52. Requirements

53. Resources

54. Schedules

55. Services

56. Sources

57. Specifications

58. Standards

59. Systems

60. Tests

61. Trends

62. Utilization

Functions and Activities in Facilities Design…

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1. Design a new plant.

2. Make changes and improvement to present design.

3. Integrate & locate new equipment.

4. Develop future plans.

Need for Facilities Design

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Functions and Activities in Facilities Design…

Long and Short Term Plans:

10 years ahead Estimate total space by function.

5 years ahead Area allocation diagram by department.

2 years ahead Rough layout of area under consideration.

1 year ahead Detailed Layout.

6-12 months ahead Appropriation approved.

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Enterprise Design Process

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1. Market Research: Determining what the customer wants

2. Sales Forecasting: Determining how many, or how much.

3. Product Design: Delineating product or service details

4. Process Design: Determining how to make the product, or provide the service.

5. Operation Design: Working out methods for effecting the processes, and from that, the number of machines and amount of manpower required.

The Enterprise Design Process

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6. Facilities Design:Determining the material flow paths, and designing the arrangement of activities to provide an orderly and efficient movement of material through the overall process.

7. Equipment Design: (as necessary)8. Building Design: By the architect and his associates.9. Financing the facility10. Procurement

a. Building b. Equipmentc. Manpower

11. Installation of facilities

The Enterprise Design Process…

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12. The actual manufacturing or productive process :a. Manufacturing - the conversion of materials and

supplies into products, such a typewriters, lamps, foods, automobiles, etc

b. The productive process – the organization and use of human effort to accomplish a desired result, in the form of a product or a service, ( dry cleaning, retailing, banking food services, etc).

13. Warehousing of the finished goods.14. Distribution of goods.15. Marketing and sales. 16. Customer: who use, evaluation, complaints,

suggestions, etc., come back to the enterprise by way of Market Research, beginning the whole cycle over again

The Enterprise Design Process…

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1. Procure basic data

2. Analyze basic data

3. Design productive process

4. Plan material flow pattern

5. Consider general material handling plan

6. Calculate equipment requirements

7. Plan individual work stations

8. Select specific material handling equipment

9. Coordinate groups of related operations

10. Design activity interrelationships

Sequence of Steps in Design Process

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11. Determine storage requirements

12. Plan service and auxiliary activities

13. Determine space requirements

14. Allocate activities to total space

15. Consider building tyres

16. Construct master layout

17. Evaluate, adjust, and check layout with appropriate persons

18. Obtain approvals

19. Install layout’

20. Follow-up on implementation of the layout

Sequence of Steps in Design Process…

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1. Design change

2. Reduces department

3. Enlarged department

4. Adding a new product

5. Moving a department

6. Adding a new department

7. Replacing obsolete equipment

8. Change in production methods

9. Cost reduction

Types Layout Problems Expected

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1. Building not suited to requirements.2. Failure to apply line production techniques when

applicable.3. Product design or process changes made without

making necessary changes in the layout.4. Installation of additional equipment without

considering.5. Unexplainable delays and idle time.6. Stock control difficulties.7. Decreased production in an area.8. Crowded conditions.9. Many men moving material.

Planning A New Facility

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10. Bottlenecks in production

11. Backtracking

12. Excessive temporary storage.

13. Obstacles in material flow

14. Scheduling difficulties

15. Wasted “cube”

16. Idle people and equipment

17. Excessive time in process

18. Poor housekeeping

Planning A New Facility…

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1. Planned activity interrelationships2. Planned material flow pattern3. Straight-line flow4. Minimum back-tracking 5. Auxiliary flow lines6. Straight aisles7. Minimum handling between operations8. Planned material handling methods9. Minimum handling distances10. Processing combined with material handling

A Good Layout Desirable Characteristics

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11. Movement progresses from receiving towards shipping

12. First operations near receiving13. Last operations near shipping 14. Point-of-use storage where appropriate15. Layout adaptable to changing conditions16. Planned for orderly expansion17. Minimum goods in process18. Minimum material in process19. Maximum use of all plant levels20. Adequate storage space

A Good Layout Desirable Characteristics…

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21. Adequate spacing between facilities22. Building constructed around planned layout23. Material delivered to employees and removed from

work areas24. Minimum walking by production operators25. Proper location of production and employee service

facilities 26. Mechanical handling installed where practicable27. Adequate employee service functions28. Planned control of noise, dirt, fumes, dust, humidity,

etc.29. Maximum processing time to overall production

time

A Good Layout Desirable Characteristics…

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30. Minimum manual handling 31. Minimum re-handling32. Partitions don’t impede material flow33. Minimum handling by direct labor34. Planned scrap removal35. Receiving and shipping in logical locations.

A Good Layout Desirable Characteristics…

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Organization for Layout Function

Large Organizations :

Plant Layout Department

Small Organizations :Fireman / Manager / GM

Small Organizations : In many organization the

designations of layout mangers differ widely

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Organization for Layout Function

GeneralManager

Finance Purchasing Manufacturing Sales ProductEngineering

IndustrialRelations

QualityControl

ProductionControl Production Plant

EngineeringIndustrial

EngineeringProductionEngineering

PlantLayout

PlantLayout

OR

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1. Construction

2. Housekeeping and custodial service

3. Maintenance

4. Material handling

5. Facilities design

6. Pollution control

7. Safety

8. Transportation

9. Utilities

10. Shops

Functions of Plant Engineering Department

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Organization Of Layout Function

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A. Sales Department

1. Determining quantities for production runs

2. Determining quantities to manufacture for replacement parts

B. Purchasing Department

1. Finding necessary factory equipment

2. Procuring equipment at lowest practicable cost

C. Product engineering department

1. Providing blueprints and parts lists

2. Offering information on manufacture, as gained in research and development work

Interdepartmental help in Layout Design

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D. Industrial Relations Department

1. Helping to design safety into the layout

2. Looking after employee comfort and services in layout

3. Training personnel for new jobs necessitated by new layouts

E. Finance Department

1. Aiding in determining cost of layout

2. Aiding in keeping equipment records

Interdepartmental help in Layout Design…

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F. Production Engineering Division1. Design of processing and production methods2. Design of special tools and equipment3. Planning operation sequence4. Specifying machines and equipment to be used5. Trying out tools, etc6. Mechanization and automation7. Production capability analysis8. New process and equipment development

Interdepartmental help in Layout Design…

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G. Industrial Engineering Division1. Determining work methods for each work area

1. Determine production standards for all operation2. Determining machine capacities and number of

machines needed3. Aid in comparing effectiveness of methods between

alternate layouts4. Suggestions on methods

H. Production Control Division1. Supply routings or operation lists2. Determine production schedules3. Aid in planning materials flow

Interdepartmental help in Layout Design…

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1. Offer suggestions on materials handling methods2. Plan storage methods and space requirements

I. Production Division1. Suggestions on machine arrangement2. Suggestions on human relations problems involved

in layout3. Ideas on materials handling

J. Plant Engineering division ( other than plant layout group)

1. Aid in planning for utilities2. Plan for building changes or construction3. Move machinery and equipment

Interdepartmental help in Layout Design…

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4. Install machinery and equipmentK. Quality Control Divisions

1. Help plant layout to maintain quality in processes2. Assure proper handling to protect product from

damage.3. Plan scrap disposal

Interdepartmental help in Layout Design…

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Plan and design the arrangement of

• Production equipment• Handling equipment• Auxiliary equipment• Space• Land• Buildings

Facilities Design Procedure

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1. Collect basic data

2. Analyze basic data

3. Design production process

4. Plan material flow pattern

5. Consider general material handling plan

6. Calculate Equipment requirements

7. Plan individual work areas

8. Select specific material handling equipments

9. Coordinate groups of related operations

10. Design activity relationships

Considerations in Facilities Design

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11. Determine storage requirements

12. Plan service and auxiliary activities

13. Determine space requirements

14. Allocate activity areas to total space

15. Consider building types

16. Construct master layout

17. Evaluate, adjust and check layout with appropriate personnel

18. Obtain approvals

19. Install layout

20. Follow up implementation of Layout.

Considerations in Facilities Design…

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REFERENCES

• “Plant Layout and Material Handling”, Chapter: 1, Pages 3-24, James M Apple, John Wiley & Sons

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