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Systematic Facilities Planning

Systematic Facilities Planning. An Overview & Perspective. SYSTEMATIC FACILITIES PLANNING. Systematic : Organized, disciplined rational approach to a problem Facilities : Building, production & material handling equipment, land, access (supporting equipment)

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Systematic Facilities Planning

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  1. Systematic Facilities Planning An Overview & Perspective

  2. SYSTEMATIC FACILITIES PLANNING • Systematic:Organized, disciplined rational approach to a problem • Facilities:Building, production & material handling equipment, land, access (supporting equipment) • Planning:Decide a course of action based on facts and analysis

  3. THE OBVIOUS “The obvious is that which is never seen until someone expresses it simply”

  4. Obvious?

  5. THE OBVIOUS • Systematic Facilities Planning fits in this category: • Common Sense • Prior Experience • Simple Numerical Methods • Visual RepresentationsPractical Perceptiveness

  6. PRODUCTIVE SYSTEMS CUSTOMERS INPUTS Conversion Process *Workers*Managers*Equipment*Facilities*Materials*Energy*Information*Environment OUTPUTS *Operations *Transformations *Activities *Interrelationships *Goods *Services Information feedback on performance

  7. FACILITIES PLANNING AND DESIGN I PROCESSConceptualizePlanAnalyzeDesignImplementInter-Relationships ProductiveSystems PeopleMaterialsInformation FLOWEquipmentMethods

  8. SYSTEMATIC FACILITIES PLANNING • Models • Physical Models • Analog Models • Mathematical Models • Modeling Tools • Mathematical Programming • Queuing Models • Simulation Modeling

  9. WHY PLAN FACILITIES The primary causes that trigger new or altered facilities are: • Expanding production, based on increased demand. • Entering a new field of endeavor. • Replacing an obsolete or inadequate facility. • Reallocating or consolidating production facilities. • Improving service to market(s). LONG TERM STRATEGIC DECISIONS

  10. THE NEED FOR GOOD FACILITIES PLANNING • Plant facilities influence the costs of operating and therefore profits. • Planning allows facilities to comply with laws ad/or regulations. • Facilities involve high capital-cost expenditures. • Facilities are fixed investments, not readily convertible to money or resale. • Facilities are inflexible (i.e. physically fixed and have limited opportunities to be changed). • Facilities are long term commitments with protracted periods of financial return. • Facilities planning, design and construction require long lead times. • Sound plans for implementation can avoid disruptions in production, and discontinuities for shipping or delivery. • Operations often produce detrimental wastes that affect entire communities.

  11. THE NEED FOR GOOD FACILITIES PLANNING • The safety, convenience, appearance, and comfort of industrial facilities influence the attitudes of and the ability to attract suitable employees. • Industrial facilities must be planned to meet anticipated future requirements yet compete profitably today. • Facilities need to be planned for an appropriate degree of flexibility, expandability, versatility… • Good planning buys time for making commitments; it minimizes being taken by surprise. • If plans are made, managements can react faster and take advantage of business opportunities that arise. • Good planning, especially if presented well visually, is an aid to obtain financing monies. • The single most important cause of high materials handling costs is “ad hoc” expansion of plant facilities “in the absence of a strategic site-development plan.”

  12. SYSTEMATIC PLANNING OF INDUSTRIAL FACILITIES (SPIF) DEFINED SPIF is an organized, structured system of determining for an industrial plant what its current and future facilities should be. It is an integrated approach to planning the land, buildings, machinery, and equipment for an industrial enterprise, and in so doing, SPIF involves:

  13. SYSTEMATIC PLANNING OF INDUSTRIAL FACILITIES (SPIF) DEFINED • A framework of four planning phases through which each project proceeds. • Five physical components of an industrial facility, each with its distinct sequence of three planning fundamentals. • Certain short-range and long-range inputs. • Appropriate non-physical influences. • A sequential planning pattern that converts the inputs and influences to a facilities plan. • A set of conventions for rating, recording, and visualizing the analyses, work sheets, and planning documents.

  14. FACILITIES PLANNING AND DESIGN • Basic Elements of Layout Planning • Product • Quantity • Routing • Supporting Service • Time

  15. THE KEY INPUT DATA: PQRST P PRODUCT-MATERIAL What S SUPPORTING SERVICE R Who ROUTING-PROCESS SEQUENCE When, How T TIME Process Tm PERT Q QUALITY-VOLUME How Much W H Y

  16. OPERATIONS DESIGN Work Meth. & Stds. Manpower Reqts. Equipment Reqts. PRODUCT DESIGN Material & Process Requirements PROCESS DESIGN Tool & Equipment Specifications MARKET RESEARCH AND SALES FORECASTING FACILITIES DESIGN Facility Requirements--Production--Auxiliary--Service COST DETERMINATION FinancialRequirements PROCUREFACILITIES PROCUREFUNDS INSTALLFACILITIES MANUFACTURING PRODUCTION PROCURE MANPOWER RE-CEIVING STO-RAGE PKG FABRICATE PRODUCT OR PERFORM SERVICE WARE-HOUSE SHIP-PING PROCURE MATERIALS ASSY Energy PHYSICAL DISTRIBUTION CUSTOMER SALES AND MARKETING Figure 1-1: The Enterprise Design Process—General Interrelationships among Major System Elements, Functions, and Activities

  17. FOUR PHASES I EXTERNAL I II OVERALL PLAN II III DETAILED PLAN III IV IMPLEMENTATION IV Project Time

  18. FOUR PHASES I EXTERNAL I OK? II OVERALL PLAN II OK? III DETAILED PLAN III IV IMPLEMENTATION IV Project Time

  19. Phase IV III Level of Detail II I Time

  20. MFGBLDG NEW BLDG HIWAY MAINBLDG B D D A C Time The Phases of Systematic Layout Planning I LOCATION II OVERALL LAYOUT III DETAIL LAYOUTS IV INSTALLATION Phase I: Phase II: Phase III: Phase IV:

  21. THE FIVE COMPONENTS(Anatomy)of an Industrial Plant I. LAYOUT(Skeleton, Framework for Operations) II. MATERIAL HANDLING(Muscular System for Movement/Activity) III. PROCEDURES/COMMUNICATIONS(Nervous System for Control of Activity) IV. UTILITIES/AUXILIARIES(Respiratory, Circulatory, & Digestive Systems) V. BUILDING(Skin, Hair, “protective covering”)

  22. A B C D FUNDAMENTALS OF FIVE COMPONENTS I. LAYOUT 3 Fundamentals Relationships Flow and Non-flow A B D C B A D C

  23. A B C D FUNDAMENTALS OF FIVE COMPONENTS I. LAYOUT 3 Fundamentals A B D Space C B A D C

  24. A B C D FUNDAMENTALS OF FIVE COMPONENTS I. LAYOUT 3 Fundamentals A B D C B A D Adjustments C

  25. FUNDAMENTALS OF FIVE COMPONENTS II. MATERIAL HANDLING 3 Fundamentals Materials

  26. FUNDAMENTALS OF FIVE COMPONENTS II. MATERIAL HANDLING 3 Fundamentals Moves

  27. FUNDAMENTALS OF FIVE COMPONENTS II. MATERIAL HANDLING 3 Fundamentals Methods

  28. FUNDAMENTALS OF FIVE COMPONENTS III. PROCEDURES/COMMUNICATIONS 3 Fundamentals Information

  29. FUNDAMENTALS OF FIVE COMPONENTS III. PROCEDURES/COMMUNICATIONS 3 Fundamentals Transmission Timelines

  30. FUNDAMENTALS OF FIVE COMPONENTS III. PROCEDURES/COMMUNICATIONS 3 Fundamentals Means

  31. FUNDAMENTALS OF FIVE COMPONENTS IV. UTILITIES/AUXILIARIES 3 Fundamentals Substance

  32. FUNDAMENTALS OF FIVE COMPONENTS IV. UTILITIES/AUXILIARIES 3 Fundamentals Destination/Routing

  33. FUNDAMENTALS OF FIVE COMPONENTS IV. UTILITIES/AUXILIARIES 3 Fundamentals Conductors/Means

  34. FUNDAMENTALS OF FIVE COMPONENTS V. BUILDING 3 Fundamentals Form/Shape

  35. FUNDAMENTALS OF FIVE COMPONENTS V. BUILDING 3 Fundamentals Materials

  36. FUNDAMENTALS OF FIVE COMPONENTS V. BUILDING 3 Fundamentals Design

  37. FIVE COMPONENTS LAYOUT HANDLING COMMUNICATION UTILITIES BUILDING I P,Q,R PHASES Block Diagram II Detailed Layout III Train/ Install IV

  38. FIVE COMPONENTS LAYOUT HANDLING COMMUNICATION UTILITIES BUILDING I P,Q,R,S PHASES Type and Size of Equipment II Make of Equip. III Train/ Install IV

  39. PROJECTING KEY INPUT DATA Long-Range Facilities Planning should be based on Long-Range projection of Key Input Data FUTURE TIME N 0 W P INPUT DATA Q R S T

  40. PQRST PROJECTIONS TIME PROJECTION Key Elements Last Year CurrentYear Plus 2Years Plus 4Years Plus 6Years Pa 412# 410# 380# 350# 275# Pb C.I. Steel Alum. Stainless Plastic Coat P1 Pc “Other Physical Characteristics” Pd Qa $ or $ or $ or Qb Units Units Units Q1 Qc Qd Ra (Man. Ovens) Semi Auto Elect. Ovens (Heat Treating) Rb Manual N/C(1/10) (1/2)N/C Fully Auto N/C (Machining) R1 Rc Rd Sa Cafeteria S1 Sb Parking Sc Tool Rm Sd Ta 8 hrs/day 8 7 6 6 (Labor) Tb T1 Tc Td 48 hrs 48 36 24 12 (Delivery Time)

  41. SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING SYSTEM P Q R S T 1 2 3 I II 4 III IV 5 Layout Handling Communication Utilities 6 Building

  42. SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING SYSTEM P Q R S T Key Input Data 1 2 3 I II 4 III IV 5 Layout Handling Communication Utilities 6 Building

  43. SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING SYSTEM P Q R S T Key Input Data 1 Projection in Time 2 3 I II 4 III IV 5 Layout Handling Communication Utilities 6 Building

  44. SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING SYSTEM P Q R S T Key Input Data 1 Projection in Time 2 Fundamentals 3 I II 4 III IV 5 Layout Handling Communication Utilities 6 Building

  45. SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING SYSTEM P Q R S T Key Input Data 1 Projection in Time 2 Fundamentals 3 I Phases II 4 III IV 5 Layout Handling Communication Utilities 6 Building

  46. SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING SYSTEM P Q R S T Key Input Data 1 Projection in Time 2 Fundamentals 3 I Phases II 4 III IV 5 Components Layout Handling Communication Utilities 6 Building

  47. SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING SYSTEM P Q R S T Key Input Data 1 Projection in Time 2 Fundamentals 3 I Phases II 4 III IV 5 Components Layout Handling Communication Utilities 6 Time Schedule Building

  48. APPLE: FACILITIES DESIGN PROCEDURE-20 STEPS- • Procure Data • Analyze Data • Design Production Process • Design Material Flow Pattern • Design/Select Material Handling Plan • Calculate Equipment Requirements • Plan Work Areas • Select Material Handling Equipment • Plan Groups of Related Operations • Design Activity Relationships

  49. APPLE: FACILITIES DESIGN PROCEDURE-20 STEPS- (Continued) • Calculate Storage Requirements • Plan Service (Auxiliary) Activities • Calculate (Total) Space Requirements • Allocate Activities to Space • Consider Building Types • Construct Layout (Model) • Evaluate, Adjust, Check Layout • Justify, (Approval ?) • Install Layout • Nurture Layout

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