• What are the generally accepted steps for

successful
– Engineering design
– Facilities Design

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

 Facilities Planning Process
• Steps of scientific method for • Activities included in facilities
engineering design planning process
1. Define the problem 1. Define the objective of the facility
2. Analyze the problem 2. Specify primary and support
3. Generate alternatives activities to be performed
4. Evaluate alternatives 3. Determine the interaction of activities
5. Select the preferred design 4. Determine space requirement for
6. Implement the design each activity
5. Generate alternative facilities plan
6. Evaluate alternatives
7. Select a plan
8. Implement the plan
9. Maintain and adapt the plan
10. Redefine the objective

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

Let’s Design a new Concordia University Campus
▪ Define the objective of the facility
o (There is no single objective; What would be your
objective/expectation)
▪ Specify primary and support activities to be performed
• Operations; Equipment; Personnel; Material flow.
▪ Determine the interaction of activities
▪ Determine space requirement for each activity
▪ Generate alternative facilities plan
▪ Evaluate alternatives
▪ Select a plan
▪ Implement the plan
▪ Maintain and adapt the plan
▪ Redefine the objective

Discuss these steps for the given campus design with your group
members

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

Product, Process and Schedule Design

• Why do we have to know:

– Product design
– Process design
– Schedule design
to solve facilities planning problems?

• What are the relationships between them?

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

Answering these questions will help to
develop the first part of your term projects.
• Product design
• Market analysis
• Vendors selection
• Equipment and personnel requirements
• Location selection
• Plant layouts designs (using CAD) and selection
of the best
• Issues in supply chain management
• Simulation studies
• Life cycle analysis of both product and facility

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

Product, Process and Schedule Design
• Before we start developing
alternative facility plans, we have to
find answers for the following Answers for the first 5
questions questions can be
obtained from:
– What is to be produced
•Product design
– How are the products to be produced •Process design
– When are the products to be produced •Schedule design
– What quantity of each product to be
produced Answer for the last
question might be
– How long the product to be produced searched outside of the
company. Here, the
supply chain concepts
– Where are the products to be produced becomes the
determinant factor

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

Product, Process and Schedule Design
Where are the products to be produced?

• Global sourcing effect

– Today countries are closer-than-ever
– Companies are working together

– Examples:
• Cars are assembled with parts that are
manufactured by several different companies in
several difference countries
• Many food products might be imported from
outside and packed in Canada (Beer, jelly, frozen
vegetables etc.)

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

Product, Process and Schedule Design
Process planners determines:
How the product to be produced
(Machining operations etc)

Product designers determines: Production planners (Schedule

Design) determines:
Shape, size-dimensions of the end
products How many to be produced
Required materials Machine scheduling to optimize
the utilization etc.
Packaging requirements etc.

Facility planners analyze the output/requirements

of each unit to create profitable efficient facilities

These groups work together. Decisions related to each group is not made
independently. To reduce the cycle time, all the decisions are made to comply
withINDU
each group’s
421 individual
- FACILITIES requirements
DESIGN in HANDLING
AND MATERIAL the best possible
SYSTEMSway
Product, Process and Schedule Design
Product Development
• Market is the major factor in the selection
of a product
• Your capabilities
– Financially
– Technologically
– Legally
– etc.
• Finalize the selection process
• In most cases, the final decision is made
by the top management
INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS
 Product Development
•What are the market conditions?
•If you are the manager, how would you select your next product?

– Customer
Bombardier needs?
partially cancelled its plans to build larger aircraft.
– Number ofWhy? Now, itin
customer is this
backcategory?
C-Series

–Boeing decidedsimilar
How many not to go with Airbus
products aretoout
build larger jets?
there?
– Are there
Mirabel was going
needs to be the main
for additional airport?in the
products
marketthought,
Kawasaki for thisit customer group?
could take Honda in motorcycle market
– What would the competitors do against?
– Can you survive? And How?
– Etc. QFD analysis and Benchmarking

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

 Product Development

• Finally, detailed designs take place

– CAD designs
– Prototypes
– Assembly designs
– 2D drawings and dimension determinations
All these can be observed easily in most of the
commercial CAD programs (ProE, CATIA etc)

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

 Product Development

• Concurrent Engineering is a systematic way of

enabling communication between all related
units during the product development
• The aim is to minimize the changes in design
parameters once the design is finalized
• Most of the manufacturing cost is set during the
design phase
• Changing the design later in the process costs
significantly

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

 Product Development

• Once we complete the product design,

usually following documents are provided
for the facilities planning process as inputs
– Exploded assembly drawings
– Exploded parts photographs
– Component part drawings
– Part list, part numbers, part name, number of
parts per product, drawing references
– Bill of materials

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS
Product, Process and Schedule Design
Process Design
• During process design phase, following issues are
considered:
– Process identification
• Make/Buy analysis
These are the key inputs we need for
• Part list
the process identification
• Bill of materials
– Process selection
• Define elementary operations
• Identify alternative process for each operations
• Analyze alternative processes
• Standardize process
• Evaluate alternative processes
• Select processes
– Process sequencing
• Information provided in the assembly diagrams
• How components are put together
• Operation process chart

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

 Process Design

• Production methods are the most fundamental

factor affecting the physical layout
• Determination of how the product will be made
– Which part of the products should be made?
– Should we go for subcontracting?
• Supplier
• Contractor
– Make-or-buy analysis?
– Equipment selection for the parts will be made in-
house
– Time is required to make the operations in each
machine

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

 Process Design

• How are the make-or-buy decisions made

– Can the item be purchased?
– Can we make the item?
– Is it cheaper for us to make than to buy?
– Is the capital available in order us to make it?

• These question can be more detailed…

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

 Product, Process and Schedule Design
Process Design

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

Product, Process and Schedule Design
Schedule Design
• Production quantity (lot size)
• Production scheduling (when to produce)
• How long to produce

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

 Schedule Design

• Process Design specifies the type of the

equipment is needed
• Schedule design determines the number of
equipment, personnel, resource requirements
• Most important data comes from marketing
• Schedule design determines the process
requirements

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

Product, Process and Schedule Design
Process Requirements

• We consider three phase process

– Determine the quantity to be manufactured
from each component
• Including scraps
– Identify the equipment required for
accomplishing each operation
– Consolidate equipment requirements when
possible

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

Product, Process and Schedule Design
Process Requirements
Input Process Output
(I) Machining (O)

Scrap (S)

• Based on the given system above, what is the minimum

number of inputs required?
• I = O+S
• If S is a fraction of I, then
• I = O + Ps*I ➔ I = O/(1-Ps)
• Where Ps is the probability of producing scrap items

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

Product, Process and Schedule Design
Process Requirements- Input/Output analysis
Input Machining Machining Machining Machining Final
(I) 1 2 3 4 Product

Scrap Scrap Scrap Scrap

(S1) (S2) (S3) (S4)

• To be able to produce the desired number final product

we have to consider the scraps at the beginning.
• In general term, total needed input can be computed
using the following equation

FinalOutput
Input =
(1 − Ps1 )(1 − Ps2 )...(1 − Psn )
INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS
Product, Process and Schedule Design
Process Requirements- Machine Requirement

• Most of the time facilities need fraction of

machines
– e.g.: 3.5 machine
• How can we determine the number of machines
we need to produce N items (Includes both
required output and scraps).
Where
T *P
N=
N is the required number of machines
T is the time required for per operation (in minutes)
60H * C P is required production per day
H number of hours of production per day
C is the use of equipment (ex. 85 percent of the time,
INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS
it is running)
Product, Process and Schedule Design
Process Requirements- Operator Requirement
• It is conceptually the same as the machine
requirement
T *P To perform the

N= exact manpower
requirement
60H * C analysis, we need
to know how many
Where machine per
N is required number of crews (manpower) operator can run.
For this purpose we
T is the time required for per operation (in minutes) will take a look at
P is required production per day man-machine
assignment
H number of hours of production per day processes.
C Percentage of the total time person is available (utilization)

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

Computer Aided Process Planning
(CAPP)
• Used for automating process planning
• There could be two different CAPP
– Variant:
• Standard process plans are stored in computer
• When needed, they will be called
– Generative:
• Process plans are generated automatically by the
computer
• No initial plan is needed

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

Computer Aided Process Planning
(CAPP)
• Input for the CAPP is CAD designs
• Based on the design specification, CAPP
– can generate a number of alternative routes
– test them to obtain the best route

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

 Route sheet
Data Production Example
Component name and number Plunger housing – 3254
Operation description and number Shape, drill, and cut off – 0104
Equipment requirements Automatic screw machine and
appropriate tooling
Unit times (Per components) Set-up time: 5 hrs.
Operating time: 0.0057 hrs
Raw material requirement 1 in. diameter X 12 ft
aluminum bar per 80
components

Route sheet data requirement

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

 This was
identified in route
sheet already

Sequencing the
Required
Processes
Assemblies

Assembly Charts
Inspection

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

 Sequencing the Required Processes
Operation Process Chart

Route sheets provide

information on production
methods
Assembly charts includes how
components are put together

Combination of route-sheets
and assembly-charts
(Operation Process Chart)
gives an overview of the flow
within the facility

INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS

 Sequencing the Required Processes
Precedence Diagrams
In the operation process charts,
it is not clear if two machining
operations have and
dependency to each other
Observe the part#3254
Operations 0204 and 0304 can
be done at the same time
Yet, the operation 0104 should
be completed before both 0204
and 0304

We cannot observe this How could such

information in operation information
process charts effect ones
decision for job
scheduling?
INDU 421 - FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS