1 The facility planning process for manufacturing facilities: 1. Define the products to be manufactured 2. Specify the manufacturing processes and related activities required to produce the products. 3. Determine the interrelationships among all activities 4. Determine the space requirements for all activities 5. Generate alternative facilities plans 6. Evaluate the alternative facilities plans 7. Select the preferred facilities plan 8. Implement the facilities plan 9. Maintain and adapt the facilities plan 10. Update the products to be manufactured and redefine the objective of the facility.
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1
The facility planning process for manufacturing facilities:
1. Define the products to be manufactured2. Specify the manufacturing processes and related
activities required to produce the products.3. Determine the interrelationships among all activities4. Determine the space requirements for all activities5. Generate alternative facilities plans6. Evaluate the alternative facilities plans7. Select the preferred facilities plan8. Implement the facilities plan9. Maintain and adapt the facilities plan10. Update the products to be manufactured and redefine the
objective of the facility.
Systematic Layout PlanningInput Data and Activities
1. Flow of materials 2. Activity Relationships
6. Space Relationship Diagram
5. Space Available4. Space Requirements
3. Relationship Chart
8. Practical Limitations7. Modifying Considerations
9. Develop Layout Alternatives
10. Evaluation
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Chapter 3 IT 392 (Tompkins) 3
Space Requirements
Perhaps the most difficult determination in facilities planning is the amount of space required in the facility.
In manufacturing and office environments, space
requirements should be determined first for individual workstations; next, department requirements should be determined, based on the collection of workstations in the department.
Chapter 3 IT 392 (Tompkins) 4
Space Requirements
For the workstationThe equipmentMachine travelMachine maintenancePlant services
The sum of the machinery areas for all machines within a workstation gives the machinery area requirement for the workstation.
Chapter 3 IT 392 (Tompkins) 5
Space RequirementsFor the materials areas for a workstation
Receiving and storing materialsIn-process materialsStoring and shipping materialsStoring and shipping waste and scrapTools, fixtures, jigs, dies, and maintenance materials
Space for tools, fixtures, jigs, dies, and maintenance materials. This decision will depend on if central storage is utilized of storage at the workstation.
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Space Requirements
For the personnel area for a workstation
The operator – determined from motion & ergonomic studyMaterial handling – Operator ingress and egress – a minimum of a 30in. aisle is needed for operator travel past stationary objects.Minimum operator space is 24”X36”.
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Production-center methodConverting method – the present space requirements are converted to those required for the proposed layoutRoughed-out layout method – using templates or models on the layout to obtain an estimate of configuration and space requirementsRatio trend projection method – for general space requirements e.g. square feet per direct labor hour, square feet per unit produced, etc.
Space Determination
Space RequirementsWarehousing Equipment Inventory levels Storage units Storage methods Personnel
Requirements Building constraints
Manufacturing Equipment Space for work-in-
process inventory Operator
(Personnel area) Aisles for material
handling
Workstation Space Requirements
Three components Equipment, materials, and personnel
WSPACE = workstation space (square ft)MSPACE = machine space (square ft)OMSPACE = operator and maintenance spaceSTSPACE = storage space
WSPACE = MSPACE + OMSPACE + STSPACE
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Departmental SpecificationOnce the space requirements for the
workstations have been determined then the next is the department space requirements. This includes:Equipment maintenancePlant servicesHousekeeping itemsStorage areas,Etc.
Department Space Requirements
NWORKS = # of workstationsDSPACE = department spaceTSPACE = transportation space
DSPACE = NWORKS * WSPACE + TSPACE
Add at least 5-10% allowance for aisles within department.
Manufacturing Space Requirements ExampleEquipments:
5 Turret Lathes (4 x 12 ft.)6 Automatic Screw Machines ( 4 x 14 ft.)2 Chucker ( 5 x 6 ft.)
Personnel space:4 x 5 ft. per operator
Materials storage:20 ft2 per turret lathe40 ft2 per screw mach.50 ft2 per chucker
Aisle space allowance : 13% of the net area requirement
WS Quan. Equipment Material Personnel Total
Turret lathe 5 5*4*12=240 20*5=100 4*5*5=100 440
Screw mach. 6 6*4*14=336 40*6=240 4*5*6=120 696
Chucker 2 2*5*6= 60 50*2=100 4*5*2=40 200
Net area required 1336 Aisle allowance
174Total area req. 1510
Solution Sheet
Chapter 3 IT 392 (Tompkins) 15
Chapter 3 IT 392 (Tompkins) 16
Aisle Arrangement
Departmental aisle and main aisles.
Planning aisles that are too narrow may result in congested facilities having high levels of damage and safety problems.
Curves, jogs, or nonright angle intersections should be avoided in planning for aisles.
Service and Manufacturing Facilities
Organization Parking spaces
Restaurants (with drive- through facilities)
One space per 75 square feet of floor area or 1.5 persons (whichever is greater)
Theaters, Arenas, and Assembly areas
One space per 8 feet of bench length or 4 seats (whichever is greater)
Secondary schools and Colleges
One space per 8 students, one-and-a-half spaces per classroom, and number of spaces for gymnasium/assembly hall seating
Factories One space per 1000 square feet of area plus number of spaces for offices
Hospitals Two spaces per bed
Churches One space per three persons
Hotels One space per guest room plus number of spaces for accessory uses
Warehouses One space per 2000 square feet of floor area
Table 5.1. Minimum dimensions for parking stalls
Parking Angle Aisle-width (two-way)
Aisle-width (one-way)
Stall width Stall length
76-90o 25 feet 15 feet 9 feet 20 feet
30-75o 25 feet 12 feet 9 feet 22 feet
0-29o 18 feet 12 feet 9 feet 25 feet
fig_04_03
fig_04_02
Service and Manufacturing Facilities
Organization Showers Lavatories Water Closets Water Fountain
Others
Restaurants - 1 per 200 1 per 75 1 per 500 1service sink
Arenas (capacity more than 3000)
- 1 per 200 (male); 1 per 150 (female)
1 per 120 (male); 1 per 60 (female)
1 per 1000 1 service sink
Churches - 1 per 200 1 per 150 (male); 1 per 75 (female)
1 per 1000 1 service sink
Schools - 1 per 50 1 per 50 1 per 100 1 service sink
Airports - 1 per 750 1 per 500 1 per 1000 1 service sink
Factories - 1 per 100 1 per 100 1 per 1000 1 service sink
Hospitals 1 per 15 1 per room 1 per room 1 per 100 1 service sink
Prisons 1 per 15 1 per cell 1 per cell 1 per 100 1 service sink
Hotels 1 per room
1 per room 1 per room - 1 service sink
Dormitories 1 per 8 1 per 10 1 per 10 1 per 100 1 service sink
table_04_02
table_04_05
Table 5.2 Accessible spaces for persons with disability
Total spaces in parking lot
1-25 26-50 51-75 76-100 101-150
151-200
201-300
301-400
401-500
501-1000
Minimum Accessible spaces
1 2 3 4 5 6 7 8 9 2%
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