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) Planning: Decide a course of action based on facts and analysis
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THE OBVIOUS
The obvious is that which is never seen until someone expresses it simply

Obvious?

THE OBVIOUS

Systematic Facilities Planning fits in this category:

Common Sense Prior Experience Simple Numerical Methods Visual Representations

Practical Perceptiveness
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PRODUCTIVE SYSTEMS
CUSTOMERS

INPUTS
*Workers *Managers *Equipment *Facilities *Materials *Energy *Information *Environment Conversion Process OUTPUTS *Operations *Transformations *Activities *Interrelationships

*Goods
*Services

Information feedback on performance

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FACILITIES PLANNING AND DESIGN

I PROCESS Conceptualize Plan Analyze Design Implement
Inter-Relationships

Productive Systems

People Materials Information Equipment Methods

FLOW

SYSTEMATIC FACILITIES PLANNING

Models
Physical Models Analog Models Mathematical Models

Modeling Tools
Mathematical Programming Queuing Models Simulation Modeling

WHY PLAN FACILITIES

The primary causes that trigger new or altered facilities are:
1. 2. 3. 4. 5. 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
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THE NEED FOR GOOD FACILITIES PLANNING

1.

2.
3. 4.

5.
6. 7. 8. 9.

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.
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THE NEED FOR GOOD FACILITIES PLANNING

10. 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.
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11.
12. 13. 14. 15. 16.

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:

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SYSTEMATIC PLANNING OF INDUSTRIAL FACILITIES (SPIF) DEFINED

1. A framework of four planning phases through which each project proceeds. 2. Five physical components of an industrial facility, each with its distinct sequence of three planning fundamentals. 3. Certain short-range and long-range inputs. 4. Appropriate non-physical influences. 5. A sequential planning pattern that converts the inputs and influences to a facilities plan. 6. A set of conventions for rating, recording, and visualizing the analyses, work sheets, and planning documents.
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FACILITIES PLANNING AND DESIGN

Basic Elements of Layout Planning

Product Quantity Routing Supporting Service Time

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THE KEY INPUT DATA: PQRST

P
PRODUCT-MATERIAL

What
S
SUPPORTING SERVICE

ROUTING-PROCESS SEQUENCE

Who
T
TIME

When, How
Q
QUALITY-VOLUME

Process Tm PERT
W H Y
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How Much

MARKET RESEARCH AND SALES FORECASTING

PRODUCT DESIGN

PROCESS DESIGN

OPERATIONS DESIGN

Material & Process Requirements

Tool & Equipment Specifications

Work Meth. & Stds. Manpower Reqts. Equipment Reqts.

COST DETERMINATION PROCURE FACILITIES PROCURE FUNDS Financial Requirements INSTALL FACILITIES

FACILITIES DESIGN

Facility Requirements --Production --Auxiliary --Service

MANUFACTURING
PRODUCTION PROCURE MANPOWER RECEIVING STORAGE FABRICATE PRODUCT OR PERFORM SERVICE PKG WAREHOUSE SHIPPING

PROCURE MATERIALS Energy CUSTOMER

ASSY

SALES AND MARKETING

PHYSICAL DISTRIBUTION

Figure 1-1: The Enterprise Design ProcessGeneral Interrelationships among Major System Elements, Functions, and Activities

FOUR PHASES
I EXTERNAL I

II OVERALL PLAN

II

III DETAILED PLAN

III

IV IMPLEMENTATION

IV

Project Time
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FOUR PHASES
I EXTERNAL I OK?

II OVERALL PLAN

II

OK?

III DETAILED PLAN

III

IV IMPLEMENTATION

IV

Project Time
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Phase IV Level of Detail III

II
I

Time
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The Phases of Systematic Layout Planning

I LOCATION II OVERALL LAYOUT III DETAIL LAYOUTS Time
Phase I:
MFG BLDG HIWAY

IV INSTALLATION
Phase II: Phase III: Phase IV:

NEW BLDG

B A C

MAIN BLDG

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THE FIVE COMPONENTS (Anatomy) of an Industrial Plant

I. II. III. IV. LAYOUT (Skeleton, Framework for Operations) MATERIAL HANDLING (Muscular System for Movement/Activity) PROCEDURES/COMMUNICATIONS (Nervous System for Control of Activity) UTILITIES/AUXILIARIES (Respiratory, Circulatory, & Digestive Systems) BUILDING (Skin, Hair, protective covering)

V.

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FUNDAMENTALS OF FIVE COMPONENTS

I. LAYOUT
A B
D C

3 Fundamentals

Relationships Flow and Non-flow

D

B C

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FUNDAMENTALS OF FIVE COMPONENTS

I. LAYOUT
A B
D C

3 Fundamentals

B D C

Space
B C

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FUNDAMENTALS OF FIVE COMPONENTS

I. LAYOUT
A B
D C

3 Fundamentals

B D C

B C

Adjustments
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FUNDAMENTALS OF FIVE COMPONENTS

II. MATERIAL HANDLING 3 Fundamentals

Materials

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FUNDAMENTALS OF FIVE COMPONENTS

II. MATERIAL HANDLING 3 Fundamentals

Moves

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FUNDAMENTALS OF FIVE COMPONENTS

II. MATERIAL HANDLING 3 Fundamentals

Methods
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FUNDAMENTALS OF FIVE COMPONENTS

III. PROCEDURES/ COMMUNICATIONS 3 Fundamentals

Information

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FUNDAMENTALS OF FIVE COMPONENTS

III. PROCEDURES/ COMMUNICATIONS 3 Fundamentals

Transmission Timelines

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FUNDAMENTALS OF FIVE COMPONENTS

III. PROCEDURES/ COMMUNICATIONS 3 Fundamentals

Means
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FUNDAMENTALS OF FIVE COMPONENTS

IV. UTILITIES/AUXILIARIES 3 Fundamentals

Substance

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FUNDAMENTALS OF FIVE COMPONENTS

IV. UTILITIES/AUXILIARIES 3 Fundamentals

Destination/Routing

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FUNDAMENTALS OF FIVE COMPONENTS

IV. UTILITIES/AUXILIARIES 3 Fundamentals

Conductors/Means
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FUNDAMENTALS OF FIVE COMPONENTS

V. BUILDING 3 Fundamentals

Form/Shape

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FUNDAMENTALS OF FIVE COMPONENTS

V. BUILDING 3 Fundamentals

Materials

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FUNDAMENTALS OF FIVE COMPONENTS

V. BUILDING 3 Fundamentals

Design
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FIVE COMPONENTS
LAYOUT HANDLING COMMUNICATION UTILITIES BUILDING

P,Q,R

P Block H II Diagram A S E III Detailed Layout S IV Train/ Install

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FIVE COMPONENTS
LAYOUT HANDLING COMMUNICATION UTILITIES BUILDING

I
P H II A S E III S IV

P,Q,R,S
Type and Size of Equipment Make of Equip. Train/ Install

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PROJECTING KEY INPUT DATA

Long-Range Facilities Planning should be based on Long-Range projection of Key Input Data FUTURE TIME N0 W
I N P U T D A T A

P
Q R S T
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PQRST PROJECTIONS
Key Elements Pa Pb Pc Pd Qa Qb Qc Qd Ra Rb Rc Rd Sa Sb Sc Sd Ta Tb Tc Td Last Year TIME Current Year PROJECTION Plus 2 Plus 4 Years Years 380# Alum. 350# Stainless Plus 6 Years 275# Plastic Coat

P1

412# 410# C.I. Steel Other Physical Characteristics $ or Units $ or Units

Q1

$ or Units

R1

(Man. Ovens) Semi Auto Elect. Ovens Manual N/C(1/10)

(1/2)N/C

Fully Auto N/C

(Heat Treating) (Machining)

S1

Cafeteria Parking Tool Rm

8 hrs/day

6 (Labor)

T1

48 hrs

48

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24

12 (Delivery Time)

SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING SYSTEM

P Q R S T
1 2 3
I II III IV Layout Handling Communication Utilities Building

5
6
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SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING SYSTEM

P Q R S T
1 2 3
I II III IV Layout Handling Communication Utilities Building

Key Input Data

5
6
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SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING SYSTEM

P Q R S T
1 2 3
I II III IV Layout Handling Communication Utilities Building

Key Input Data Projection in Time

5
6
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SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING SYSTEM

P Q R S T
1 2 3
I II III IV Layout Handling Communication Utilities Building

Key Input Data Projection in Time Fundamentals

5
6
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SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING SYSTEM

P Q R S T
1 2 3
I II III IV Layout Handling Communication Utilities Building

Key Input Data Projection in Time Fundamentals Phases

5
6
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SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING SYSTEM

P Q R S T
1 2 3
I II III IV Layout Handling Communication Utilities Building

Key Input Data Projection in Time Fundamentals Phases

5
6

Components

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SYSTEMATIC FACILTIES PLANNING AS AN INTEGRATED PLANNING SYSTEM

P Q R S T
1 2 3
I II III IV Layout Handling Communication Utilities Building

Key Input Data Projection in Time Fundamentals Phases

5
6

Components
Time Schedule
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APPLE: FACILITIES DESIGN PROCEDURE -20 STEPS1.

2.
3. 4. 5. 6. 7. 8. 9. 10.

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
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APPLE: FACILITIES DESIGN PROCEDURE -20 STEPS- (Continued)

11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 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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