FACILITIES MANAGEMENT Session 2. 1
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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