JurusanTeknik Industri Frame Work for Facilities Planning · JurusanTeknik Industri Frame Work for Facilities Planning ... lSupport the organization’s vision through improved

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Jurusan Teknik Industri

INTRODUCTIONRI-1504

Lecture Notes #1

Stefanus Eko WiratnoDepartement of Industrial Engineering

Sepuluh Nopember Institute of Technology (ITS)[email protected]

2004

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Frame Work for Facilities Planning[Q. Lee, IIE Solution, 1997]

Layout or space planning involves five levels -from the global maps of site location to engineering drawing tools and workstations

§ Level 1: Global site location § Level 2: Supra-space plan § Level 3: Macro-space plan § Level 4: Micro-space plan § Level 5: Sub-micro-space plan

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LEVEL 1: Global site locationl The firm decide where to locate facilities and

determine their missionsl The most strategic impactl Major considerations: labor rates, tax break,

labor skill and attitudes, supporting services, politics,etc.

l Appropriate planning results in facilities optimized for the markets and located near the most important resources

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LEVEL 2: Supra-space planl Site planning, including number, size,

location of buildings, as well as roads, water, gas, and rail

l Involve a series of drawing showing past, present and future configurations

l Planning still has long-term and far reaching consequences

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LEVEL 3: Macro-space planl A macro-layout, plans each building,

structure, or sub-unit of the sitel The designers define and locate operating

departments and determine overall material flow

l Easier to correct than site level decisionsl A poorly planned facility can bring high

handling cost, confusion, and inflexibility

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Level 4: Micro-space planl Department or cell layoutl Location of specific equipment is determinedl Emphasis shifts from gross material flow to

personal space and communicationl Socio-technical considerations dominate

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LEVEL 5: Sub-micro-space plan

l Workstation designl Workstations are designed for efficiency,

effectiveness, and safety l Tools-jig and fixture l Location of materialsl Appropriate material handling aids

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Facilities planning is a complex and broad subject that cuts across several specialized disciplines (civil, electrical, industrial, mechanical, etc)

• new hospital• assembly department• existing warehouse• baggage department of an airport.

Facilities planning determines how an activity’s tangible fixed assets best support achieving the activity’s objective.

Facilities Planning[Tompkins, et.al. 2003]

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Facilities Planning Hierarchy

FacilitiesPlanning

FacilitiesDesign

Handling SystemsDesign

Layout Design

Facility SystemDesign

FacilitiesLocation

It is important to realize that the term facilities planning is not synonyms with facilities location, facilities design, facilities layout, or plant layout.

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Facilities location - placement with respect to customer, suppliers, and other facilities with which it interfaces.

Influences of Plant location : – Proximity to raw material– Markets– Transportation systems– Economic development programs (financial

incentives)

Facilities Location

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Facilities design – consists of the facility systems, the layout, and the handling system§ Facility system – structural systems, the atmospheric

systems, the enclosure system, the lighting/electrical/communication systems, the life safety system and the sanitation system.

§ Layout – consists of all equipment, machinery, and furnishings within the building envelope.

§ Handling system – consists of the mechanisms needed to satisfy the required facility interactions.Material handling is very important to the facility design activity. The choice of material handling equipment will greatly effect the appropriateness of the facility design.

Facilities Design

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Facilities Planningl Facilities planning involves making strategic

decisions concerning the tangible fixed assets used in the production process.

l The difference in the planning horizon for each of the different levels of analysis used in the production process listed in Table 1.1.

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Table 1.1: Planning Horizon Associated with Production Analysis

Machine-level real-time controlSeconds-MinutesQuality controlMinutes-Hours

Production controlHours-WeeksProduction PlanningWeeks-MonthsProduct Design and Process PlanningMonths-YearsFacilities PlanningMonths-Years

Level of AnalysisPlanning Horizon

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Motivation Behind Facility Planning1. One of the most effective methods for increasing

plant productivity and reducing cost is to reduce or eliminate all activities that are unnecessary or wasteful. A facilities design should accomplish this goal in terms of material handling, personnel and equipment utilization, reduced inventories, and increased quality.

2. Employee health and safety 3. Energy conservation4. Community considerations, fire protection, security,

and the ADA of 1989

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Objectives of Facilities Planningl Improve customer satisfaction by being easy to do

business with, conforming to customer promises, and responding to customer needs.l Increase return on assets (ROA) by maximizing

inventory turns, minimizing obsolete inventory, maximizing employee participation, and maximizing continuous improvement.lMaximize speed for quick customer response.l Reduced costs and grow the supply chain profitabilityl Integrate the supply chain through partnership and

communication.

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Objectives of Facilities Planningl Support the organization’s vision through improved

material handling, material control, and good housekeeping.l Effectively utilize people, equipment, space, and

energy.lMaximize return on investment (ROI) on all capital

expendituresl Be adaptable and promote ease of maintenance.l Provide for employee safety and job satisfaction.l Provide flexibility to adapt to changing conditions

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Significance of Facility Design

l Material handling costs:§ 30-75% of a product’s cost (Sule 1991)§ 20-50% of a manufacturing company’s

operating budget (Tompkins & White, 1994)

l Optimal Layout Design can reduceproduction costs

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Facilities Planning ProcessBy applying the engineering design approach, a systematic approach can be developedl Define the problem

– Define (or redefine) the objective of the facility– Specify the primary and support activities to be

performed in accomplishing the objectivel Analyze the problem

– Determine the interrelationships among all activitiesl Determine the space requirements for all activities

– Generate alternative facilities plans

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Facilities Planning Processl Evaluate the alternatives

– Evaluate alternative facilities plansl Select the preferred design

– Select a facilities planl Implement the design

– Implement the facilities plan– Maintain and adapt the facilities plan– Redefine the objective of the facility

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Developing Facilities Planning StrategiesProduct

development and design decisions

Processing & Material

Requirements

Layout & Material Handling

Production Planning &

Inventory Control

# & Location

Storage, movement, protection & control of material

Space & Flow

Size & Design

Human Resources & Finance

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Sources of Information For Manufacturing Facilities Design

l All the information that is used must come from different sources.

l The larger the company is, the less data actually produced by the facility designer.

l Some companies have several sub-departments within manufacturing/industrial engineering. But, in smaller organizations you are responsible for producing the information.

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Sources Of Information For Manufacturing Facilities Design

l Marketing

l Product design

l Management policy

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Marketing

l Selling pricel Volume, how many can we sell?l Seasonality, summer or winter productl Replacement parts, older products

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Product Designl Product design

– blueprints– bill of material (part list)

• indented BOM• buyouts/fabricate

– assembly drawings• Part and assembly drawings are especially helpful in

visualization of how parts will fit together

– model shop samples (prototypes)l Relationship between FD and product design is

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Management Policyl Management policy - refers to the upper-level

employees – inventory policy (Just in Time, Kanban, WIP)– lean thinking– investment policy (ROI)– startup schedule – make or buy decision (new or old facility, capital

investment, and mission)– feasibility studies (what product or process

proposal is the most profitable for the company

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Types of Layout Problems

l Service systems layout problems

l Manufacturing layout problems

l Warehouse layout problems

l Nontraditional layout problems

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Service Systems Layout Problemsl Examples: layouts of the tables, kitchen, and cocktail

lounge in licensed restaurant; an insurance office; runway at an airport; emergency facilities in a hospital and town; public library

l To develop service systems layout, designers must know the number of entities or facilities that are to be located, the area that will likely be occupied by each, the interaction between facilities, and special layout restrictions for any facility or pair of facilities

l General office structures: 1) Closed, 2) Semiclosed, 3) Open, and 4) Semiopen

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Service Systems Layout Problems

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Service Systems Layout Problems

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Manufacturing layout problemsl Layout design is an important task when a

manufacturing systems is redesign, expanded, or designed for the first time

l The layout problems involves determining the location of machines, workstations, rest areas, inspection stations, clean rooms, heat treatment station, supervisor or manager offices, tool cribs, and other facilities to achieve these five objectives:§ Minimize cost of transportation between

facilities

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Manufacturing layout problems§ Minimize cost of transportation between facilities§ Facilitate the traffic flow§ Increase employee morale§ Minimize the risk of injury to personnel and

damage to property§ Provide for supervision and face-to-face

communication

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Manufacturing layout problems

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Warehouse layout problemsl A good warehouse layout should use

available storage space effectively to minimize storage and material handling cost

l Some factors to be considered in warehouse design are shape and size of aisles, height of the warehouse, location and orientation of the docking area, types of racks to be used for storages, and the level of automation involved in the storage and retrieval of commodities

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Warehouse layout problems

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Nontraditional layout problemsl The ability to design and operate manufacturing

facilities that can quickly and effectively adapt to changing technological and market requirements is becoming increasingly important to the success of any manufacturing organization

l Manufacturing facilities must be able to exhibit high levels of flexibility and robustness despite significant changes in their operating requirements.

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Nontraditional layout problems

l Due to the large variety of parts usually produced in jobshops, none of traditional layouts by itself provides a satisfactory layout solution

l Examples: Dynamic Layout, Flexible Layout.

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Classification of Traditional and Non–traditional Layout

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Focused Factories/Plants within Plants (PWP)

Types of Facility Layouts

Product ResponsibilityNetworksProject Parts

(Components) Remanufacturing

Types of Manufacturing Focus• A single product• A family of products• Products ordered by a single customer• Products ordered by many customer (MTO)• Prototypes

Assembly Line Product-based Cells

Point of Use Modular Multi -Channel Manufacturing

B

A

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Linked Cells

A

A – Plant T – Plant V – Plant Combination ofV, A, and/or T Plant

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Flowline Layout

Types of Manufacturing Focus• Single part• Family of parts with similar raw material properties• Family of parts with similar geometry• Family of parts with similar routings• Family of parts with common tools and fixtures• Dissimilar parts that can be produced in a flexible cell• Identical parts in a range of sizes• Rework• Spare parts

Transfer Line Cascading Flowlines

Classification of Flowlines

B

C

Cellular Layout*

* Each cell is dedicated to a part family

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Hybrid Cellular LayoutsFractal Cells Modular Layout

C

Virtual Cells

Distributed LayoutFunctional Layout Holonic Layout

D

Holographic Layout

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Robust Layouts suitable for Multiple Product Mixes and/or Production Periods

D

Robust/Flexible Layout Reconfigurable/Dynamic Layout

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JurusanTeknik Industri Frame Work for Facilities Planning · JurusanTeknik Industri Frame Work for Facilities Planning ... lSupport the organization’s vision through improved