Facility Layout Planning, Part 1

Facility Layout Planning Introduction. Objectives of Plant Layout. Factors affecting Plant Layout. Introduction  Plant layout planning includes decisions regarding the physical allocation of the economic activity centers in a facility.      An economic activity center is any entity occupying space. The objective of plant layout planning is a more effective work flow at the facility, allowing workers and equipment being more productive. Facility layout techniques apply to the case where several physical means have to be located in a certain area, either industrial processes or services. The objective of the chapter is not only Plant layout but re-layout also (most common situation for a company). To carry out an appropriate plant layout, it’s important to take into account the business strategic and tactical objectives  Example: space requirements/cost per m2 in Malls; accessibility/privacy in offices. Introduction  To make a decision about layout planning, 4 different questions must have an answer:   Which centers do we have to consider? How much space and capacity is required for each center?    How must the space be configured at each center?   If there is not enough space, productivity may be reduced. Too much space is expensive and may also reduce productivity. Space quantity, shape and the elements of the work center are related to each other. Where should each center be located at within the facility?  The allocation of the different centers may affect productivity. Introduction   The plant layout process starts at an aggregate level, taking into account the different departments. As soon as we get into the details, the different issues arise, and the original configuration may be changed through a feedback process. Most (if not all of them) layouts are designed properly for the initial conditions of the business, although as long as the company grows and has to be adapted to internal and external changes, a re-layout is GRADO DE DETALLE SEGÚN necessary. AVANCE DEL PROYECTO Fase III Distribución Detallada DETALLE Fase I Localización Fase IV Instalación Fase II Distribución General TIEMPO Introduction  The reasons for a re-layout are based on 3 types of changes:     Changes in production volumes. Changes in processes and technology. Changes in the product. The frequency of the re-layout will depend on the requirements of the process. Introduction  Symptoms that allow us to detect the need for a re-layout:        Congestion and bad utilization of space. Excessive stock in process at the facility. Long distances in the work flow process. Simultaneous bottle necks and workstations with idle time. Qualified workers carrying out too many simple operations. Labor anxiety and discomfort. Accidents at the facility. Difficulty in controlling operations and personnel. Lay Out     Introduction Objectives Factors Affecting Layout Selection and Design Types of Plant Layout    Product Layout Process Layout Layout for Services Facility Layout Definition  A facility layout is an arrangement of everything needed for production of goods or delivery of services. A facility is an entity that facilitates the performance of any job. It may be a machine tool, a work centre, a manufacturing cell, a machine shop, a department, a warehouse, etc. (Heragu, 1997). The layout design generally depends on the products variety and the production volumes. Four types of organization are referred to, namely fixed product layout, process layout, product layout and cellular layout (Dilworth, 1996). Quantity Product Layouts Fixed Position Layouts Mixed Layouts Process Layouts Number of Different Products Objectives of Plant Layout  The main objective consists of organizing equipment and working areas in the most efficient way, and at the same time satisfactory and safe for the personnel doing the work.  Sense of Unity    Minimum Movement of people, material and resources. Safety   The feeling of being a unit pursuing the same objective. In the movement of materials and personnel work flow. Flexibility  In designing the plant layout taking into account the changes over short and medium terms in the production process and manufacturing volumes. Objectives of Plant Layout   These main objectives are reached through the attainment of the following facts:  Congestion reduction.  Elimination of unnecessary occupied areas.  Reduction of administrative and indirect work.  Improvement on control and supervision.  Better adjustment to changing conditions.  Better utilization of the workforce, equipment and services.  Reduction of material handling activities and stock in process.  Reduction on parts and quality risks.  Reduction on health risks and increase on workers safety.  Moral and workers satisfaction increase.  Reduction on delays and manufacturing time, as well as increase in production capacity. All these factors will not be reached simultaneosly, so the best solution will be a balance among them. Lay Out     Introduction Objectives Factors Affecting Layout Selection and Design Types of Plant Layout    Product Layout Process Layout Layout for Services Factors affecting Plant Layout   The final solution for a Plant Layout has to take into account a balance among the characteristics and considerations of all factors affecting plant layout, in order to get the maximum advantages. The factors affecting plant layout can be grouped into 8 categories:         Materials Machinery Labor Material Handling Waiting Time Auxiliary Services The building Future Changes Factors affecting Plant Layout  The factors affecting plant layout can be grouped into 8 categories:  Materials    The layout of the productive equipment will depend on the characteristics of the product to be managed at the facility, as well as the different parts and materials to work on. Main factors to be considered: size, shape, volume, weight, and the physical-chemical characteristics, since they influence the manufacturing methods and storage and material handling processes. The sequence and order of the operations will affect plant layout as well, taking into account the variety and quantity to produce. Factors affecting Plant Layout  The factors affecting plant layout can be grouped into 8 categories:  Machinery     Having information about the processes, machinery, tools and necessary equipment, as well as their use and requirements is essential to design a correct layout. The methods and time studies to improve the processes are closely linked to the plant layout. Regarding machinery, we have to consider the type, total available for each type, as well as type and quantity of tools and equipment. It’s essential as well to know about space required, shape, height, weight, quantity and type of workers required, risks for the personnel, requirements of auxiliary services, etc. Factors affecting Plant Layout  The factors affecting plant layout can be grouped into 8 categories:  Labor     Labor has to be organized in the production process (direct labor, supervision and auxiliary services). Environment considerations: employees’ safety, light conditions, ventilation, temperature, noise, etc. Process considerations: personnel qualifications, flexibility, number of workers required at a given time as well as the type of work to be performed by them. Material Handling   Material handling does not add value to the product; it’s just waste. Objective: Minimize material handling as well as combining with other operations when possible, eliminating unnecessary and costly movements. Factors affecting Plant Layout  The factors affecting plant layout can be grouped into 8 categories:  Labor     Labor has to be organized in the production process (direct labor, supervision and auxiliary services). Environment considerations: employees’ safety, light conditions, ventilation, temperature, noise, etc. Process considerations: personnel qualifications, flexibility, number of workers required at a given time as well as the type of work to be performed by them. Material Handling   Material handling does not add value to the product; it’s just waste. Objective: Minimize material handling as well as combining with other operations when possible, eliminating unnecessary and costly movements. Factors affecting Plant Layout  The factors affecting plant layout can be grouped into 8 categories:  Waiting time - Stock   Objective: Continuous Material Flow through the facility, avoiding the cost of waiting time and demurrages that happen when the flow stops. On the other hand, the material waiting to flow through the facility not always represents a cost to avoid. As stock sometimes provides safety to protect production, improving customer service, allowing more economic batches, etc.   It’s necessary then to consider space for the required stock at the facility when designing the layout. Resting time to cool down or heating up… Factors affecting Plant Layout  The factors affecting plant layout can be grouped into 8 categories:  Auxiliary Services  Support the main production activities at the plant:      Related to labor: Accessibility paths, fire protection installations, supervision, safety, etc. Related to material: quality control. Related to machinery: maintenance and electrical and water lines. The auxiliary services represent around 30% of the space at a facility. The space dedicated to auxiliary services is usually considered as waste.  It’s important to have efficient services to insure that their indirect costs have been minimized. Factors affecting Plant Layout  The factors affecting plant layout can be grouped into 8 categories:  The building   If it has been already selected, its characteristics will be a constraint at the moment of designing the layout, which is different if the building has to be built. Future changes     One of the main objectives of plant layout is flexibility. It’s important to forecast the future changes to avoid having an inefficient plant layout in a short term. Flexibility can be reached keeping the original layout as free as possible regarding fixed characteristics, allowing the adjustment to emergencies and variations of the normal process activities. Possible future extensions of the facility must be taken into account, as well as the feasibility of production during re-layout.