KIOT

Plant Layout and Facility Design

Course code: Greg 4181
Target group: 4th year GED
Chapter one
MANUFACTURING FACILITY PLANNING
By: Endashaw Yohannes
Kombolcha/Ethiopia
Nov, 2019

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 Course Objectives
• The objectives of the course are

• To understand the importance of facility design in general and

manufacturing unit in particular.

• To analyze the basic principles of effective plant layout and design as

these apply to the apparel industry.

• To develop understanding of building typology and indoor environment

• To draw upon specialized knowledge from a number of disciplines

including engineering, architecture, business management, and
economics, as these relate to plant engineering.

• To learn the planning of layout using simulation exercises in classroom.

• To understand principles of material system and equipments

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CHAPTER ONE: OUTLINE

o Introduction to Facility Planning

o why facility planning is important?

o Objectives of Facility Planning

o Classification of Facility Planning

o Facility planning process steps

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 1. Introduction to facility planning
What is Facility ?

• A facility is an entity(object) that facilitates

the performance of any job.

• Example Machine, tool, work center,

manufacturing cell, warehouse, land, buildings,
equipment, furnishings and etc.

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 What is Facility Planning?

Facility Planning determines how an activity’s tangible fixed assets

best support in achieving the activity’s objectives.

Examples:

a. In manufacturing, the objective is to support production.

(manufacturing facility Planning)

b. In an airport, the objective is to support the passenger airplane

interface.

c. In a hospital, the objective is to provide medical care to

patients.

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Facility plan

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Hierarchy of Facility Planning

Facility Structural
Location Design

Facility
Layout
Planning Facility
Design
Design
Handling System
Design

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1. Facility location : is the placement of a facility
with respect to customers, suppliers,
and other facilities with which it
interfaces.

2. Structure Design: consists of the building

and services (e.g., gas, water system,
lighting system, air conditioning system,,
sewage system, safety system, etc. )

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3. Layout Design: consists of all equipment,
machinery, and furnishings within the
structure.

4. Handling System Design: consists of the

mechanism by which all interactions
required by the layout are satisfied
(e.g., materials, personnel, information,
and equipment handling systems).

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Plant lay out

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 Why is Facility planning important?
1) Facility planning must be a continuing activity to be
competitive and keep developments in its field.

• Economic considerations of existing systems,

personnel and equipment

• New machines and processes

• Rapid changes in production techniques in the

present and future

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 Why is Facility planning important?
Cont..
2) Facility planning can increase plant productivity and
reduce costs by reducing or eliminating all activities
that are unnecessary and wasteful.

3) By incorporating vital health and safety measures

the employer may avoid unsafe conditions and losses
in both money and manpower resulting from industrial
accidents.

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 Why is Facility planning important?
Cont..
4) Energy conservation incorporating new methods of
energy to reduce the cost of energy

5) Other factors that requires investment in new facilities

Example

• Fire protection ,Security, Disability act

• Community rules and regulations regarding noise ,air

pollution, liquid and solid waste disposal.

6) Pilferage- stealing merchandise from manufacturing

companies etc…
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 2. Objectives of Facility planning

o Minimize capital investment & increase productivity

o Improve customer satisfaction

o Effectively utilize people, equipment ,Space and energy

o Improved material handling, material control and good

house keeping.

o Promote flexibility & increase speed to customer

response (shorten lead time)

o Provide for employee safety and job satisfaction

o Improve productivity and reduce costs

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 3. Classification of Facility Planning
• It is important to organize and classify facility planning
into manageable sub-projects based on their Levels of
Detail.

• Each sub-project has a series of tasks that the design

team must complete.

• The tasks and their sequence differ for each level

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 Facility planning levels of details
I. Global (Site Location)
This involves factors such as freight cost, labor cost, skill
availability and site focus.

II. Supra (Site Planning)

This includes number, size, and location of buildings. It includes
infrastructure such as roads, water, gas and rail.

III. Macro (Building Layout)

Operating departments are defined and located at this level.
Frequently, this is the most important level of planning. A Macro-
Layout institutionalizes the fundamental organizational structure
in steel and apparel industry.
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Facility planning levels of details cont..

IV. Micro (Work cell/Department

Layout)
determines the location of specific equipment and
furniture

V. Sub-Micro (Workstation Design)

focuses on individual workers. Here we design
workstations for efficiency, effectiveness and
safety. Ergonomics is key.
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 4. Facility planning process steps
1) Define or redefine the objective of the facility

2) Specify the primary and support activities to be performed in

accomplishing the objective

3) Determine the interrelationships among all activities

4) Determine the space requirement for all activities

5) Generate alternative facility plans

6) Evaluate alternative facility plans

7) Select a facilities plan

8) Implement the facilities plan

9) Maintain and adapt the facility plans

10) Redefine the objective of the facilities

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1) Define or redefine the objective of the facility

• May be planning for new facility or improvement of

existing facility.

• Products to be produced or services to be provided

must be specified quantitatively

• Volumes or levels of activities are to be identified

when possible.

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2) Specify the primary and support activities to be
performed in accomplishing the objective

• Primary and support activities to be performed and

should be specified in terms of operations ,equipment
,personnel and material flow involved.

• Support activities allow primary operations to

function properly with out interruptions.

e.g Maintenance function is a support activity for

manufacturing.

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3) Determine the interrelationships among all activities

• Define both quantitatively and qualitatively how

activities interact and support one another with in the
boundaries of the facility.

4) Determine the space requirement for all activities

• All equipment , material, and personnel requirements

must be considered while considering space
requirements for each activity.

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5) Generate alternative facility plans
• Alternative facility plans will include both alternative
facility locations and alternative facility designs.

• Alternative facility designs will include alternative

layout design, structural designs and material handling
system designs.

• Depending on the situation the facility location decision

and facility designs may be decoupled

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6) Evaluate alternative facility plans

• Determine the factors, set an accepted criteria and

rank the plans.

7) Select a facility plans

• Select the most acceptable in satisfying the goals and

objectives of the organizations.

• Most often cost is not the only major considerations

when evaluating a facility plans.

• Use the information generated in step 6.

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8) Implement the facility plans

• After selection, considerable amount of planning must

precede before the actual construction of the facility.

• Supervising installation of layout, getting ready to

start up, actual starting up, running and correction
activities are all part of implantation phase of facility
planning.

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9) Maintain and adapt facilities plans.

• When new requirements are placed on the facility, the

facility plan must be modified accordingly.

• Changes in product design, new machines ,material

handling equipments or flow patterns require an
updated facility plan.

10) Redefine the objective of the facility

• In case of potential modifications ,expansion and so on

for existing facilities, all recognized changes must be
considered and the objective of the facility should be
redefined in quantifiable terms 26
 Brainstorming

• Think about your role as a facility

planner and what kind of
improvements would you like to
suggest for garment industries.

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