Introduction to Facility Design

Arief Rahman, 2021

Lecture Note Series

Laboratorium Ergonomi dan Perancangan Sistem Kerja
Description

• Facilities design is one of the important and complex stages in enterprise strategic
planning. This course will discuss several stages in facilities planning i.e:
• Facilities location analysis
• Material flow design
• Warehouse facilities planning
• Facilities layout design and framework
• Material handling
• Planning for supporting facilities.

• Facilities arrangement in layout and its optimization will be discussed as the main
objectives of this course.
 “ ... One of the oldest activities of the industrial engineer is plant layout
and material handling design. It is the activity that deals with the design of
an arrangement of the physical elements of an activity, and has always been
very closely related to the manufacturing industry ...”
(James M. Apple. Plant Layout and Material Handling, 1977)
 What is Facilities?

Facilities can be broadly defined as

buildings where people utilize material,
machines, and other resources to make
a tangible product or provide a service
(Heragu)

Facilities are include employee,

material, machine, and other
equipment. Facility could be apply for
any tranformation of tangible value of
product in production plant and also on
creating a service (Tomkins)
Facilities Planning

Tompkins, et.al. 2003, 2011]

Facilities planning is a complex and broad subject
that cuts across several specialized disciplines
(civil, electrical, industrial, mechanical, etc)
New hospital
Assembly department
Existing warehouse
Baggage department of an airport.
Facilities planning determines how an activity’s
tangible fixed assets best support achieving the
activity’s objective.
 Facilities Planning as one of Strategic
Planning

▪ Business owner will invest a big money on the project

▪ Developing and procuring several long-term capital assests,
such as: building, machines, equipments, etc.
▪ Treat with uncertainty of demand on business market
▪ Long term maintenance process of production facilities.
▪ The Overall Planning Process. Planning should cover the
input-process-output circle of production.
 The Facilities Planning
Objectives
1. Improve customer satisfaction by being easy to
do business with, conforming to customer
promises, and responding to customer needs.
2. Increase return on assets (ROA) by maximizing
inventory turns, minimizing obsolete inventory,
maximizing employee participation, and
maximizing continuous improvement.
3. Maximize speed for quick customer response. 7. Effectively utilize people, equipment, space,
4. Reduce costs and grow the supply chain and energy.
profitability. 8. Maximize return on investment (ROI) on all
5. Integrate the supply chain through partnerships capital expenditures.
and communication. 9. Be adaptable and promote ease of maintenance.
6. Support the organization’s vision through 10.Provide for employee safety, job satisfaction,
improved material handling, material control, energy efficiency, and environmental
and good housekeeping. responsibility.
11.Assure sustainability and resilience.
Scope of Facilities Planning
 10 Issues May Have A Long-range Impact on The
Strategic Facilities Plan

Centralized versus
decentralized storage
Acquisition of
of supplies, raw
Number, location, existing facilities Flexibility required
materials, working Interface between
and sizes of versus design of because of market
process, and finished storage and
warehouses and/or modern factories and and technological
goods for single- and manufacturing
distribution centers distribution centers uncertainties
multibuilding sites, as
of the future
well as single- and
multisite companies

Changes in customers’
& suppliers’
Control systems, Movement of technology as well as
Level of vertical
including material material between a firm’s own
integration, including
control and buildings and manufacturing Design-to-cost goals
“subcontract versus technology and
equipment control, between sites, both for facilities
manufacture” material movement,
as well as level of inbound and
decisions protection, storage,
distributed processing outbound
and control
technology
 4 Categories of Layout Problem
• Service systems layout problem
The layout of the reception area, dining area, kitchen, and cocktail lounge in a licensed restaurant; an insurance office;
registrar’s office at a university; runways at an airport; emergency facilities in a hospital; and town or county government office
and public library are a few examples of facilities design and layout problems in service systems.

• Manufacturing layout problem

Layout design is an important task when a manufacturing system is redesigned, expanded, or designed for the first time. In the
design of manufacturing layouts, minimizing material-handling costs and providing a safe workplace for employees are major
considerations.

• Warehouse layout problem

Like a machine layout, a good warehouse layout should use available space effectively to minimize storage cost and material-
handling cost. Some factors to be considered in warehouse design are shape and size of aisles, height of the warehouse, location
and orientation of the docking area, types of racks to be used for storage, and the level of automation involved in storage and
retrieval of commodities.

• Nontraditional layout problems

Layout problems occur in many situations other than those already discussed. For example, thousands of tiny semiconductor
components must be placed on an integrated circuit chip and connected so that the resulting chip can perform specifi ed
functions. Other example : single-row machine layout, arrangement of books on a shelf, assignment of files to the cylinders of a
disk, and assignment of aircraft to gates in an airport.
Example:

Service Layout : a dentist’s office

Example:
Manufacturing layout problem
3D Layout Modelling

2 mins
Example:

Warehouse layout problem

Example:
Non-traditional layout problems
Typical Design Problem in Automated
Manufacturing Systems

Type and Volume of

Products to be Manufacturing Design of
Type & Qty of
Facility Location manufactured or Process (service) Component Process Planning
Equipment required
services to be processes required (service)
provided

Determining Layout of Determination of

Type, number of Layout of Machines Tooling, fixture
material handling equipment within machine (service)
MHD (service) cell determination
methods (MHD) Each Cells cells

Scheduling and
Determining flow of Overall System Distribution of Quality control and
planning of jobs Inventory control
Products (people) Design goods customer service
(service steps)
Several Problems in Layout Design

▪ Space Availability
▪ Flow of Material
▪ Material Handling
▪ Flexibility (demand and variation of products)
6 Principals on Facilities
Design
1. Total Integration
2. Minimizing the distance of flow
3. Flow of operations
4. Space utilization
5. Employee Safety and Satisfcation
6. Flexibility
FACILITIES
PLANNING
PROCESS
 9 Steps of Facilities Planning Process :
Manufacturing

2. Specify the
1. Define or 3. Determine the 4. Determine
manufacturing 5. Generate
redefine the interrelationships space
processes required alternative
product to be among requirements for
to produce the facilities plans
manufactured department all activities
product(s)

Maintain and 6. Evaluate

8. Implement the 7. Select a
adopt the alternative
plan facilities plan
facilities plan facilities plans
9 Steps of Facilities Planning Process :
Hospital

2. Specify the 4. Determine

1. Define or 3. Determine the
medical services space
redefine the interrelationships
required to satisfy requirements for
health needs for all services
the health needs all services

6. Evaluate 5. Generate
8. Implement the 7. Select a
alternative alternative
plan hospital plan
hospital plans hospital plans

9. Maintain and
adopt the hospital
plan
Millennial Office
Type of Factories 24
• Raw Material/Primary Industries
• Manufacturing Industries (Producer/Consumer Goods)
• Distribution/Transportation Industries
• Service Industries

Type Factories based on product flow

Upstream Industries Downstream Industries
• High Tech • Medium/Low Tech
• Capital Intensive • Finished Goods, Consumer Goods
• Semi-Finished Goods, Producer Goods • Labor Intensive
• Basic processing of material (metal,chemical,electronic,etc)
Type of Production Process

Characteristics Mass Production Job Order Project

1. Final Product Similar Several Product Single/Spesific
2. Quantity Huge numbers Small numbers Only One
3. Type of equipments Specific and Complex General Purposed General Purposed
4. Layout arrangement By Product By Process By Process
5. Material Handling Conveyor Removeable MH and Big Capacity of Portable MH and Big Capacity of
Loader Loader
6. Inventory Level Low High High for main materials
7. Labor Skill Low Moderate High
8. Diffuculity of Jobs Easy Hard Very Hard

9. Flexibility Very low High High

10. Price of per product Low High Very High

Examples : Car Production Machinary Workshop Bridge Construction

Textile production Tools Workshop Highway Construction

Sugar Cane Prduction Apartement Construction

Supply Chain of a Typical Manufacturing Industry

3rd Parties
Manufacturing (Warehouse,
Suppliers Retail Consumer
Company Dealer,
Distributor)
The Levels of Space
Planning

• Layout or space planning involves five

levels - from the global maps of site
location to engineering drawing tools
and workstations
• Level 1: Global site location
• Level 2: Supra-space plan
• Level 3: Macro-space plan
• Level 4: Micro-space plan
• Level 5: Sub-micro-space plan
The Levels of Space Planning

Richard Level Activity Typical of System Area

Muther, 1956 Site Location
Global Plant Sites World/Country
Analysis & Selection
Building or Site
Supra Site Planning Plat/Factory Site
Features
Cell or
Macro Building Layout Building
Departments
Department or Cell Work Station or Cell or
Micro
Layout, MH Design Cell Features Departement
Man-Machine
Sub-Micro Work Station Design Work Station
System
Thank you