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Systematic Facilities Planning

An Overview & Perspective

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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”

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Obvious?

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THE OBVIOUS
■ Systematic Facilities Planning fits in this
category:
■ Common Sense
■ Prior Experience
■ Simple Numerical Methods
■ Visual Representations

Practical Perceptiveness

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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
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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).

LONG TERM STRATEGIC DECISIONS

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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

■ Basic Elements of Layout Planning


■ Product
■ Quantity
■ Routing
■ Supporting Service
■ Time

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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

III DETAILED PLAN


III

IV IMPLEMENTATION
IV

Project Time

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FOUR PHASES
I EXTERNAL
I OK?

II OVERALL PLAN
II OK?

III DETAILED PLAN


III

IV IMPLEMENTATION
IV

Project Time

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Phase
IV
Level of Detail

III

II

Time
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The Phases of Systematic Layout Planning
I LOCATION

II OVERALL LAYOUT
III DETAIL LAYOUTS

Time IV INSTALLATION

Phase I: Phase II: Phase III: Phase IV:

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 Flow and Non-flow


D

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

II. MATERIAL HANDLING


3 Fundamentals

Materials

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FUNDAMENTALS OF FIVE COMPONENTS

II. MATERIAL HANDLING


3 Fundamentals

Moves

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FUNDAMENTALS OF FIVE COMPONENTS

II. MATERIAL HANDLING


3 Fundamentals

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

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FUNDAMENTALS OF FIVE COMPONENTS

IV. UTILITIES/AUXILIARIES
3 Fundamentals

Conductors/Means
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FUNDAMENTALS OF FIVE COMPONENTS

V. BUILDING
3 Fundamentals

Form/Shape

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FUNDAMENTALS OF FIVE COMPONENTS

V. BUILDING
3 Fundamentals

Materials

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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

Pa 412# 410# 380# 350# 275#


Pb C.I. Steel Alum. Stainless Plastic Coat
P1 Pc “Other Physical Characteristics”
Pd
Qa $ or $ or $ or
Qb Units Units Units
Q1 Qc
Qd

Ra (Man. Ovens) Semi Auto Elect. Ovens (Heat Treating)


Rb Manual N/C(1/10) (1/2)N/C Fully Auto N/C (Machining)
R1 Rc
Rd

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

P Q R S T 1 Key Input Data


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

P Q R S T 1 Key Input Data


2 Projection in Time
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

P Q R S T 1 Key Input Data


2 Projection in Time
3 Fundamentals
I
II
III 4
IV

Layout
Handling
5
Communication
Utilities
Building 6

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SYSTEMATIC FACILTIES
PLANNING AS AN INTEGRATED
PLANNING SYSTEM

P Q R S T 1 Key Input Data


2 Projection in Time
3 Fundamentals
I
II
III 4 Phases
IV

Layout
Handling
5
Communication
Utilities
Building 6

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SYSTEMATIC FACILTIES
PLANNING AS AN INTEGRATED
PLANNING SYSTEM

P Q R S T 1 Key Input Data


2 Projection in Time
3 Fundamentals
I
II
III 4 Phases
IV

Layout
Handling
5 Components
Communication
Utilities
Building 6

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SYSTEMATIC FACILTIES
PLANNING AS AN INTEGRATED
PLANNING SYSTEM

P Q R S T 1 Key Input Data


2 Projection in Time
3 Fundamentals
I
II
III 4 Phases
IV

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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