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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”
3
Obvious?
4
THE OBVIOUS
■ Systematic Facilities Planning fits in this
category:
■ Common Sense
■ Prior Experience
■ Simple Numerical Methods
■ Visual Representations
Practical Perceptiveness
5
PRODUCTIVE SYSTEMS
CUSTOMERS
INPUTS
Conversion Process
*Workers OUTPUTS
*Managers
*Equipment *Operations *Goods
*Facilities *Transformations
*Materials *Services
*Energy *Activities
*Information *Interrelationships
*Environment
Information feedback on
performance 6
FACILITIES PLANNING AND DESIGN
I PROCESS
Conceptualize
Plan Productive
Analyze Systems
Design
Implement
People
Materials
Inter-Relationships Information FLOW
Equipment
Methods
7
SYSTEMATIC FACILITIES
PLANNING
■ Models
■ Physical Models
■ Analog Models
■ Mathematical Models
■ Modeling Tools
■ Mathematical Programming
■ Queuing Models
■ Simulation Modeling
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WHY PLAN FACILITIES
The primary causes that trigger new or
altered facilities are:
1. Expanding production, based on increased demand.
2. Entering a new field of endeavor.
3. Replacing an obsolete or inadequate facility.
4. Reallocating or consolidating production facilities.
5. Improving service to market(s).
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THE NEED FOR GOOD FACILITIES PLANNING
1. Plant facilities influence the costs of operating and therefore
profits.
2. Planning allows facilities to comply with laws ad/or
regulations.
3. Facilities involve high capital-cost expenditures.
4. Facilities are fixed investments, not readily convertible to
money or resale.
5. Facilities are inflexible (i.e. physically fixed and have limited
opportunities to be changed).
6. Facilities are long term commitments with protracted periods
of financial return.
7. Facilities planning, design and construction require long lead
times.
8. Sound plans for implementation can avoid disruptions in
production, and discontinuities for shipping or delivery.
9. Operations often produce detrimental wastes that affect entire
communities.
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THE NEED FOR GOOD FACILITIES PLANNING
1. The safety, convenience, appearance, and comfort of industrial
facilities influence the attitudes of and the ability to attract suitable
employees.
2. Industrial facilities must be planned to meet anticipated future
requirements yet compete profitably today.
3. Facilities need to be planned for an appropriate degree of flexibility,
expandability, versatility…
4. Good planning buys time for making commitments; it minimizes
being taken by surprise.
5. If plans are made, managements can react faster and take advantage
of business opportunities that arise.
6. Good planning, especially if presented well visually, is an aid to
obtain financing monies.
7. 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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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
• A framework of four planning phases through
which each project proceeds.
• Five physical components of an industrial
facility, each with its distinct sequence of three
planning fundamentals.
• Certain short-range and long-range inputs.
• Appropriate non-physical influences.
• A sequential planning pattern that converts the
inputs and influences to a facilities plan.
• A set of conventions for rating, recording, and
visualizing the analyses, work sheets, and
planning documents.
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FACILITIES PLANNING AND DESIGN
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THE KEY INPUT DATA: PQRST
P PRODUCT-MATERIAL
What
S SUPPORTING SERVICE
R ROUTING-PROCESS
Who
SEQUENCE
When, How
T TIME
Process Tm
Q QUALITY-VOLUME
PERT
How Much W H Y
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OPERATIONS DESIGN
PRODUCT DESIGN PROCESS DESIGN
MARKET RESEARCH
AND SALES
FORECASTING Work Meth. & Stds.
Material & Process Tool & Equipment
Manpower Reqts.
Requirements Specifications
Equipment Reqts.
FACILITIES DESIGN
COST DETERMINATION
PROCURE PROCURE
FACILITIES FUNDS
Facility Requirements
Financial
--Production
Requirements
--Auxiliary
INSTALL --Service
FACILITIES
MANUFACTURING
PRODUCTION
PROCURE MANPOWER
RE- STO-
PKG
CEIVING RAGE FABRICATE PRODUCT
OR PERFORM SERVICE
WARE- SHIP-
PROCURE MATERIALS HOUSE PING
ASSY
Energy
PHYSICAL
CUSTOMER SALES AND MARKETING
DISTRIBUTION
Figure 1-1: The Enterprise Design Process—General Interrelationships among Major System
Elements, Functions, and Activities
FOUR PHASES
I EXTERNAL
I
II OVERALL PLAN
II
IV IMPLEMENTATION
IV
Project Time
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FOUR PHASES
I EXTERNAL
I OK?
II OVERALL PLAN
II OK?
IV IMPLEMENTATION
IV
Project Time
18
Phase
IV
Level of Detail
III
II
Time
19
The Phases of Systematic Layout Planning
I LOCATION
II OVERALL LAYOUT
III DETAIL LAYOUTS
Time IV INSTALLATION
MFG
BLDG
NEW BLDG
B
D D
HIWAY
A
MAIN
BLDG C
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THE FIVE COMPONENTS
(Anatomy)
of an Industrial Plant
I. LAYOUT
(Skeleton, Framework for Operations)
II. MATERIAL HANDLING
(Muscular System for Movement/Activity)
III. PROCEDURES/COMMUNICATIONS
(Nervous System for Control of Activity)
IV. UTILITIES/AUXILIARIES
(Respiratory, Circulatory, & Digestive
Systems)
V. BUILDING
(Skin, Hair, “protective covering”) 21
FUNDAMENTALS OF FIVE COMPONENTS
I. LAYOUT
3 Fundamentals
A B
D
C
Relationships
A B D
C
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FUNDAMENTALS OF FIVE COMPONENTS
I. LAYOUT
3 Fundamentals
A B
D
C
A B
D
C Space
A B D
C
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FUNDAMENTALS OF FIVE COMPONENTS
I. LAYOUT
3 Fundamentals
A B
D
C
A B
D
A B D
C
Adjustments
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FUNDAMENTALS OF FIVE COMPONENTS
Materials
25
FUNDAMENTALS OF FIVE COMPONENTS
Moves
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FUNDAMENTALS OF FIVE COMPONENTS
Methods
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FUNDAMENTALS OF FIVE COMPONENTS
III. PROCEDURES/
3 Fundamentals
COMMUNICATIONS
Information
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FUNDAMENTALS OF FIVE COMPONENTS
III. PROCEDURES/
3 Fundamentals
COMMUNICATIONS
Transmission
Timelines
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FUNDAMENTALS OF FIVE COMPONENTS
III. PROCEDURES/
3 Fundamentals
COMMUNICATIONS
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
32
FUNDAMENTALS OF FIVE COMPONENTS
IV. UTILITIES/AUXILIARIES
3 Fundamentals
Conductors/Means
33
FUNDAMENTALS OF FIVE COMPONENTS
V. BUILDING
3 Fundamentals
Form/Shape
34
FUNDAMENTALS OF FIVE COMPONENTS
V. BUILDING
3 Fundamentals
Materials
35
FUNDAMENTALS OF FIVE COMPONENTS
V. BUILDING
3 Fundamentals
Design
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FIVE COMPONENTS
LAYOUT HANDLING COMMUNICATION UTILITIES BUILDING
I P,Q,R
P
H Block
II Diagram
A
S
E III Detailed
S Layout
IV Train/
Install
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FIVE COMPONENTS
LAYOUT HANDLING COMMUNICATION UTILITIES BUILDING
I P,Q,R,S
P
H Type and
II Size of
A
S Equipment
E III Make of
S Equip.
IV 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 P
N
P Q
U
T
R
D
A S
T
A T
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PQRST PROJECTIONS
TIME PROJECTION
Key Last Current Plus 2 Plus 4 Plus 6
Elements Year Year Years Years Years
Sa Cafeteria
S1 Sb Parking
Sc Tool Rm
Sd
Ta 8 hrs/day 8 7 6 6 (Labor)
Tb
T1 Tc
Td 48 hrs 48 36 24 12 (Delivery Time)
SYSTEMATIC FACILTIES
PLANNING AS AN INTEGRATED
PLANNING SYSTEM
P Q R S T 1
2
3
I
II
III 4
IV
Layout
Handling
5
Communication
Utilities
Building 6
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SYSTEMATIC FACILTIES
PLANNING AS AN INTEGRATED
PLANNING SYSTEM
3
I
II
III 4
IV
Layout
Handling
5
Communication
Utilities
Building 6
42
SYSTEMATIC FACILTIES
PLANNING AS AN INTEGRATED
PLANNING SYSTEM
Layout
Handling
5
Communication
Utilities
Building 6
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SYSTEMATIC FACILTIES
PLANNING AS AN INTEGRATED
PLANNING SYSTEM
Layout
Handling
5
Communication
Utilities
Building 6
44
SYSTEMATIC FACILTIES
PLANNING AS AN INTEGRATED
PLANNING SYSTEM
Layout
Handling
5
Communication
Utilities
Building 6
45
SYSTEMATIC FACILTIES
PLANNING AS AN INTEGRATED
PLANNING SYSTEM
Layout
Handling
5 Components
Communication
Utilities
Building 6
46
SYSTEMATIC FACILTIES
PLANNING AS AN INTEGRATED
PLANNING SYSTEM
Layout
Handling
5 Components
Communication
Utilities
Building 6 Time Schedule
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APPLE: FACILITIES DESIGN PROCEDURE
-20 STEPS-
1. Procure Data
2. Analyze Data
3. Design Production Process
4. Design Material Flow Pattern
5. Design/Select Material Handling Plan
6. Calculate Equipment Requirements
7. Plan Work Areas
8. Select Material Handling Equipment
9. Plan Groups of Related Operations
10. Design Activity Relationships
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APPLE: FACILITIES DESIGN PROCEDURE
-20 STEPS- (Continued)
1. Calculate Storage Requirements
2. Plan Service (Auxiliary) Activities
3. Calculate (Total) Space Requirements
4. Allocate Activities to Space
5. Consider Building Types
6. Construct Layout (Model)
7. Evaluate, Adjust, Check Layout
8. Justify, (Approval ?)
9. Install Layout
10. Nurture Layout
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