Facility Layout Planning, Part 3

University:
California State University, Northridge
Course:
MSE 403 | Facilities Planning and Design
Academic year:

2024
Views:

33

Pages:

17
Author:

Harley Phelps

Facility Layout Planning Systematic Layout Planning P-Q Analysis Definition Diagram activity relationships Product Flow Chart relationship (flow, functional) Establish space requirements Analysis Space Availability Diagram space relationships Synthesis Practical Limitations Evaluation Selection Adjustment Project A Project B Project C Evaluate alternative arrangements Detail selected layout, install Implementation Space Availability Maintenance QC Mat. Handling INSTALACION SLP Method Muther (1973) Types of Plant Layout  Process oriented plant layout   It’s essential to design a flexible plant layout, taking into account as well the need of flexibility for the material handling equipment to be used. Main disadvantage of this layout:    Low operations and material handling efficiency when comparing to a plant layout oriented to the product. On the other hand, technology development is facilitating getting over this disadvantage (i.e.- CNC Equipment). Analysis   Decision to be made: Relative location of the different working areas (same type of equipment). Criteria: reduction of distance and material handling costs: Increase of operations efficiency. Types of Plant Layout  Process oriented plant layout  Analysis    If it exists a clear material flow that carries out more volume than anyone else, the layout could be similar to a Product oriented plant layout. The main factor for the analysis is the material handling and transportation costs among the different working areas. Sometimes, quantitative information relative to material handling flows is not available, or it’s not the main factor to be considered, being the qualitative factors the most important ones in this case. Types of Plant Layout  Process oriented plant layout  Analysis  Process:      Information gathering. Plan development. Quantitative criteria: transportation costs. Qualitative criteria: closeness priorities. Information gathering  We have to know the space requirements by working area.  Demand forecast – production plan – working hours – number of workers and equipment.  Consider demand and production fluctuations. Types of Plant Layout  Process oriented plant layout  Analysis  Information gathering  Working area space.  Static area (Se): Physical space for equipment and workstations.  Gravitation area (Sg): Allocation of tools and materials. Area where operators develop their work.  Evolution area (Sv): Space to allow operators and material movements. St=Se+Sg+Sv Sg=Se*n n=number of accessible sides Sv=(Se+Sg)*k k=industry coefficient (0,05-3) Types of Plant Layout  Process oriented plant layout  Analysis  Information gathering   Available space.  Total available area at the plant.  Divide the area at a first approach to estimate each section.  When performing the detailed layout, it’s required to have more accurate shapes adjusted to the reality. When the objective is the reduction of material handling costs, we can solve the problem in quantitative terms:  It’s required to know the material flow among departments or areas, distances among them and means of transportation. Types of Plant Layout  Process oriented plant layout  Analysis  Information gathering  When the objective is the reduction of material handling costs, we can solve the problem in quantitative terms:  Traffic intensity matrix: Number of material handling moves among departments (information provided by historical data, route sheets and production plans).  Distance matrix: Distances among areas at the plant and places where the different working areas could be allocated.  Cost matrix: Cost of material transportation.- It depends on the type of equipment to be used. Types of Plant Layout  Process oriented plant layout  Analysis  Information gathering   Sometimes, quantitative information is not available, or the importance of distance among areas depends on qualitative factors (i.e.- a hospital X-ray room may be close to the trauma medicine room). Plan development   Once the size of the different areas have been determined, the next step is to organize the different areas within the existent facility, or to determine the desired shape for the facility construction. There are multiple possible solutions, so the selected one will be the a good one that complies with the max. number of constraints. P-Q Analysis Quantity Product Layouts Fixed Position Layouts Mixed Layouts Number of Different Products Process Layouts DIRTY EMPTY BOTTLES QC WAREHOUSE WASHER UNCASER FILLER/ CROWNER PASTEURIZER MANUAL SIGHTING EBI COMPLEMENTARY ACTIVITIES BI-DIRCTIONAL TABLE MANUAL SIGHTING FGI LABELLER COMPLEMENARY ACTIVITIES LABELLER MANUAL PACKING PALLETIZER PACKER PACKER WAREHOUSE DISTRIBUTOR CUSTOMERS Types of Plant Layout  Process oriented plant layout  Analysis  Quantitative criteria: Transportation costs.   With the information gathered in the previous 3 matrixes, the objective is to minimize the transportation costs. Total Transportation Cost: TTC=   ΣΣ tij dij cij Objective: Finding the combination of dij that minimizes TTC. This formula is complicated for common cases, due to the number of different possibilities (i.e.- for 10 sections, the alternatives would be 3,628,000). Types of Plant Layout  Process oriented plant layout  Analysis  Quantitative criteria: Transportation costs.  Use of heuristics: Algorithm of basic transposition  Initial arbitrary layout: base permutation.  Transportation cost calculation for this layout.  Generation of all possible permutations among activities, interchanging the ones in the initial arbitrary layout 2 to 2: Number of permutations =(n*(n-1))/2  Transportation cost calculation for each of the generated permutations: If we get one with a lower cost than the base, this last one becomes the base permutation and the process starts again until there is no one with a lower cost. Types of Plant Layout  Process oriented plant layout  Analysis  Quantitative criteria: Transportation costs.   In practice, we have to take into account certain constraints and circumstances that have to be considered, apart from the quantitative criteria of the transportation costs. Once this information is taken into account, the next step will be to perform the spatial design of the different departments. Types of Plant Layout  Process oriented plant layout  Analysis  Qualitative criteria: Closeness priorities.  Technique: Systematic Layout Planning (SLP)  Closeness priorities have a letter code: Types of Plant Layout  Process oriented plant layout  Detailed layout   Equipment and machinery layout within each area or department, getting a detailed layout of installations and all elements. There could appear some issues like scales, elevators, columns, floor resistance, roof height, etc. not considered in previous stages, that could make necessary the review of the solution.

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