Module 1.

1 • Conceptual Design - overall design concepts or morphologies

Fundamentals of Facilities Planning embedded within the facilities plan.
• Parametric Design - numerical values to the parameters of the
Facilities Planning morphologies
• Detailed Design - final dimensioning, specification of equipment,
• Design, layout, location, and accommodation of people, machines,
materials, finishes, and furnishings, and formal approval of the design
and activities of a system within a physical spatial environment.
concept.

Objectives of Facilities Planning

• It can be divided into to: Objectives of Facilities Location and
Objectives of Facilities Design.
• Objective of Facilities Location– Determine the placement of all
• Activity’s tangible fixed assets best support achieving the activity’s facilities needed to produce a product or service in such a way as to
objective. minimize all the components of the deliver-to-customers cost which
• Placement with respect to customers, suppliers, and other facilities depend on location aspects.
with which it interfaces. • Objectives of Facilities Design
• Consists of the facilities systems, the layout, and the handling – Improve material handling, material control, and housekeeping to
system. enhance and facilitate the manufacturing process
• Consist of the structural systems, the atmospheric systems, the – Effectively utilize people, equipment, space, and energy
enclosure systems, the lighting/electrical/communication systems, the – Minimize capital investment
life safety systems, and the sanitation systems. – Promote flexibility and ease of maintenance
• The layout consists of all equipment, machinery, and furnishings – Promote employee safety and job satisfaction
within the building envelope.
• The handling system mechanisms
Facilities Planning Process

What is Design? 1. Define the problem

– Define or redefine the objective of the facility
• Production plan that, if executed, leads to noun desired or – Specify the primary and support activities to be performed in
unanticipated consequences. accomplishing the objective
• Be logical, rational, and systematic activity. 2. Analyze the problem
– Determine the interrelationships among all activities
Hierarchal Cycle of Facilities Planning 3. Determine the space requirements for all activities
– Generate alternative plans
4. Evaluate the alternatives
 – Evaluate alternative facilities plans • Manufacturing operation are generally classified as forming,
5. Select the preferred design treating, and assembling.
– Select a facilities plan • Material handling is related to systems for moving parts, tools, and
6. Implement the design scrap.
– Implement the facilities plan • Facilities layout physical location of the production processes within
– Maintain and adapt the facilities plan each facility.
– Redefine the objective of the facility • Production planning and control is responsible for integrating
Facilities Planning and Design Constraints marketing information, production capacity, and current inventory
levels to determine production levels that will allow a firm to run
• Building codes and zoning ordinances
smoothly and efficiently.
• Fire, Health, and Safety Considerations
• Structural and environmental constraints
• Utility systems (heating, power, water, and light)
• Environmental and Energy System Constraints
Product design and process planning
• Factors affecting product and process design
Module 1.2 Product Design, Process Planning, and Schedule
Design – Types of products to be manufactured
– Quantities to be produced
Manufacturing Systems
– Specific manufacturing processes
• Manufacturing facilities supply chain interconnecting the raw – Sequence of manufacturing operations to be performed
materials, the manufacturing facility itself, the warehouses, retailers,
and customers. • Several internal functions influence the, the following internal
functions serve as the platform in which facilities planning strategies
• A manufacturing system can be divided into the following essential are developed and coordinated to reach the company’s goals:
functions:
1. Marketing study (why a product is going to be manufactured)
– Product design
2. Product design (what is going to be manufactured)
– Process planning
3. Process planning (how is it going to be manufactured)
– Production operations
4. Schedule design (when and how much is going to be manufactured)
– Material handling and transportation flow/facilities layout
5. Finance and administration (core values, leadership, vision,
– Production planning and control
resources)
• Product Design is responsible from taking input from marketing and
• Integrated strategic plan is a document that formulates functional
for building a product.
courses of action that will be consistent with and supported by the
• Process planning includes specification of operational sequences
internal functions of an organization.
needed to transport raw material into finished product.
• These functional strategies are specific means in which the objectives
of facilities planning are reached in consistency with the main goals of 4. Initial Design and Development
the organization. These strategies are needed for the following - All details of the product are composed.
activities: - Three main factors to take into account during this phase are
a) Product functionality,
1. Selling the product
b) Technical requirements and specifications, and c) economics of
2. Manufacturing
production and distribution.
3. Distribution
- The initial design and development phase is often iterative. First
4. Purchasing
designs and prototypes usually show the opportunities for
improvement and serve as input to a second design cycle.
Product design process
• “What is going to be made?” 5. Prototyping
• Development process focuses on functional requirements and - It is the design verification phase of product development and is used
manufacturability of the product. It can be started once a great idea on to demonstrate or prove aspects of a design.
a new product is available. - It is used to test the product’s physical properties and functions under
1. Idea generation from suppliers, competitors, sales force, actual conditions.
government regulations, research activities, and customer needs.
- A list of product attributes and requirements should be prepared to 6. Final design and production details
address relevant features such as life, functionality, reliability, - All the deficiencies indicated during prototype testing are removed
performance, looks, cost, and usability. The product should be and appropriate changes and modifications are incorporated in the
functional, reliable, and economic design.

2. Initial Screening
Product design tools
- All fundamental and sweeping ideas are evaluated. Aim is to
eliminate ideas that do not appear to have high potential for success. 1. Concurrent engineering
- Market criteria determine whether there is market for the product, - It is systematic approach that develops products and their related
whether this market is expected to grow and by how much, and what is manufacturing and support processes in parallel (simultaneously).
the size of competition in the market.
- Technical screening determines the feasibility of a product from the 2. Quality Function Deployment
point of view of manufacturability. - Identifies and links customer requirements to a diversity of functions,
including design, manufacturing, and service.
3. Economic Analysis
3. Value Analysis
- It encompasses a diversity of financial and engineering economy
- Supports cost-reduction activities by relating the costs of components
calculations to evaluate the product proposal from an economic point
to their functional contributions in a product.
of view, in which the time value of money is usually considered.
 Process Selection
Process Planning • The next step in process planning is to select a production process for
- A process is a group of related tasks with specified inputs and those items that will be produced in-house.
outputs. Processes exists to create value for the customer, the • Process classification
shareholder, or society. • Project
- Design defines what tasks need to be done and how they are to be • Batch production
coordinated among functions, people, and organizations. • Mass production
- Process strategy is an organization’s overall approach for physically • Continuous production
producing goods and providing services.
- Process Strategy
- Vertical integration: firm will produce the inputs and
control the outputs of each stage of the production process. It is
also the degree to which a firm produces the parts that go into
its products.
- Capital intensity: The mix of capital and labor resources
used in the production process
- Process Flexibility: The ease with which resources can be Process Classification
adjusted in response to changes in demand, technology, • Project takes a long time to complete, involves a large investment of
product or services, and resource availability. funds and resources, and produce one item at a time to consumer
- Customer involvement: The role of the customer in the order.
production process • Batch production processes many different jobs through the
production system at the same time in groups and batches. Products
are typically made to customer order, volume is low, and demand
- Process Planning determines how a product will be produced or a fluctuates.
service provided. It decides which components will be made in-house
and which will be purchased from a supplier, select processes, • Mass production produces large volumes of a standard product for a
develops and documents the specifications for manufacture and mass market. Product demand is stable, and product volume is high.
delivery. • Continuous production is used for very high-volume commodity
- It converts designs into workable instructions for manufacture or products that are very standardized. The system is highly automated
delivery. and is typically in operation continuously 24 hours a day.
Process Types
• Intermittent production is normally a process where multitude of
products or parts are produced, each necessitating a certain sequence
of operations. Examples are woodworking and furniture industries, and
machine shops.
• Repetitive production or sometimes called continuous production,
consists of operations where one or a few products pass through a
sequence of operation to produce the desired finished product of
products

Schedule Design
• “How many parts are going to be made in a specified time period?”
• Determines the process requirements in terms of the number of units
of each type of equipment needed to meet the production schedule.
• Activities in schedule design:
1. Determination of the quantity to be manufactured for each
component
2. Identification of equipment required by each operation
3. Consolidation of all equipment requirements

• Schedule design decisions impact machine selection, number of

machines, number of shifts, number of employees, space requirements,
storage equipment, material handling equipment, personnel
requirements, storage policies, unit load design, building size, etc.
M2.1: LAYOUT PLANNING PROCEDURE - As a general rule, planning departments may be
determined by combining workstations that
Introduction
perform “like” functions. “Like” could refer to
- Planning departments are groups of workstations performing operations on similar
workstations out together in a facilities layout. A products or components or to workstations
workstation consists of fixed assets added to performing similar processes.
perform specific operations.
- It can be subdivided into the following: (1)
Types of Production Planning Departments
Product or production line departments (2) Fixed
materials location department (3) Product family 1. Production line department - a large, stable
department (4) Process department demand exists for a standardized product, that
results to the combination of workstations into a
Layout Planning means space planning
planning department so that all workstations
- This is the main focus of facilities design. As required to produce the product are combined.
indicated by Lee, every layout has four 2. Fixed materials location department - consists of
fundamental elements: space planning units, low, sporadic demand for a product that is very
affinities, space, and constraints. large and awkward to move.
- Space planning units are separate physical 3. Product family department - there exists a
components to be arranged on a layout. Typical medium demand for a moderate number of
examples are a production or service similar components. Similar components form a
department, a warehouse, a building feature, or family of components that, in group technology,
a single workstation requiring a fixed location. may be produced via a group of workstations.
4. Process department - these are departments
Affinities based on the combination of workstations
- This represents relationships that demand containing similar processes.
closeness among the space planning units. All
these relationships fall into five general
classifications: (1) Organizational relationships Product Family Departments
(2) Flow relationships (3) Control relationships
- Group technology departments aggregate
(4) Environmental relationships (5) Process
medium volume-variety parts into families based
relationships
on similar manufacturing operations or design
Each SPU has its own space requirement. When space is attributes.
added, it transforms the relationship diagram into a - Machines required to manufacture the part
preliminary space plan or space relationship diagram. family are grouped together to form a “cell”- thus
the label cellular manufacturing.
Constraints
Cellular Manufacturing
- The conditions, assumptions, policies, or
requirements that restrict a physical - This involves the use of manufacturing cells – can
arrangement or space plan. Typical constraints be formed in a variety of ways, involving the
are floor loading, columns in a building and grouping of machines, employees, materials,
required location of the receiving and shipping tooling, and material handling storage
area in a factory layout. equipment to produce families of parts.
- Production flow analysis, first proposed by
Departmental Planning Burbidge is a procedure for forming part families
- Production planning departments are collections by analyzing the operation sequences and the
of workstations to be grouped together during production routing of a part or component
the facilities layout process. through the plant.
 - Clustering methodologies are often used to bring the flow, and (c) the communications that
group parts together so they can be processed as coordinate the resources.
a family. This methodology lists parts and
machines in rows and columns and interchanges
them based on some criterion such as similarity Categories of Flow Systems: Logistics System
coefficients
- Singh and Rajamani present a wide range of 1. Materials management system – It is the flow of
algorithms for forming manufacturing cells. materials into a manufacturing facility. The
Among those they consider are: subjects are the materials, parts, and supplies
o bond energy (BEA) purchased by a firm and required for the
o rank-order clustering (ROC and ROC2) production of its product.
o modified rank-order clustering 2. Material flow system – It is the flow of materials,
(MODROC) parts, and supplies within a manufacturing
o Direct clustering algorithm (DCA) facility. The subjects are the materials, parts, and
o cluster identification (CIA) supplies used by a firm in manufacturing
o Single linkage clustering (SLC) products and components within its facility.
o Linear cell clustering (LCC) 3. Physical distribution system – it is the flow of
products from a manufacturing facility. The
DCA Methodology subjects are the finished goods produced by a
firm.
- It is a simple procedure but clearly illustrates the
important features of the cell clustering Material Flow System: Flow patterns and structures
problem.
- It is based on a machine-part matrix in a which a 1. Flow within workstations - should be
1 indicates that the part requires processing by simultaneous, symmetrical, natural, rhythmical,
the indicated machine; a blank indicates the and habitual
machine is not used for the particular part. 2. Flow within departments - it is dependent on the
type of department.
Procedure of DCA Methodology: (1) Order the rows and 3. Flow between departments - it is a criterion
columns. Find its Sum (2) Sort the columns (3) Sort the often used to evaluate overall flow within a
rows (4) Form cells facility. An important consideration if the
location of the pickup and delivery stations for
Flow System
each department.
- Flow depends on production and transfer lot
Material Flow System: Flow patterns and principles
sizes, unit load sizes, material handling systems,
layout arrangement, and building configuration. 1. Flow Principles - maximization of directed flow
Measuring flow involves the calculation of path, Minimization of total flow, Minimization of
activity relationships between machines and the costs of flow
departments. 2. Directed flow path: an uninterrupted flow path
- Space is a function of lot sizes, storage systems, progressing directly from origination to
production equipment type and size, layout destination, it has no backtracking
arrangement, building configuration, 3. Uninterrupted flow path - a flow path that does
housekeeping and organization policies, material not intersect with the other path
handling equipment, office design, cafeteria
design, and restroom design Minimizing total flow: Work Simplification Approach
- Flow systems are very important to the facilities • Eliminating flow by planning for the delivery of
planner, who views flow as the movement of materials, information, or people directly to the
goods, materials, energy, information, and/or point of ultimate and eliminating intermediate
people. A flow process can be described in terms steps
of (a) the subject flow (b) the resources that
 • Minimizing multiple flows by planning for the • Define the criteria for assigning closeness
flow between two consecutive points of use to relationships and itemize and record the criteria
take place in as few movements as possible, as the reasons for relationship values on the
preferably one relationship chart
• Combining flows and operations wherever
possible by planning for the movement of
materials, information, or people to be
combined with a processing step

Minimizing the Cost of Flow

• Eliminate unnecessary movements of material

by reducing the number of manufacturing steps.
• Minimize manual handling by minimizing travel Facility Layout Program
distances
- It is an adaptation of an earlier program
• Eliminate manual handling by mechanizing or
developed by Khator and Moodie.
automating flow
- The procedure has been significantly modified
• Minimizing material handling by reducing the
and computerized to include algorithmic steps
flow density through containerization
that can be used for placing departments on a
Activity Relationship layout.

- These are defined by material/personnel flow, Procedures

environmental considerations, organizational
• The program accepts relationship matrix.
structure, continuous improvement
• Using the closeness codes A, E, I, O, U, and X, it
methodology, control issues, and process
determines a closeness rank and a selection
requirements
order of departments.
- It is used to evaluate alternative arrangements
• A numerical value is given to each closeness
and may be specified as:
code, the departments are placed on the layout
(a) Quantitative measure may include pieces
according to the predetermined selection order,
per hour, moves per day, or pounds per week
in such a way that the score of the layout will be
(b) Qualitative measures may range from an
as high as possible.
absolute necessity that two departments be
close to each other to a preference that two Develop a layout using FLAP by doing the following
departments not be close to each other. requirements: (a) Closeness ranking (b) Selection Order
(c) Optimal layout with maximum score.
Qualitative Flow Measurement

- Flows may be measured qualitatively using

closeness relationship values developed by M2.2: LOCATION MODELS IN FACILITIES PLANNING
Muther. The values may be recorded in
conjunction with the reasons for the closeness Three classes of location models
value using relationship chart 1. Single-Facility - desired to determine the number
Constructing a relationship chart and location of a new facility (number of trips)
with a group of existing facilities.
• List all departments on the relationship chart. 2. Location-Allocation - desired to determine the
• Conduct interviews or surveys with persons from number and location of new facilities and the
each department listed on the relationship chart allocation of the existing facilities among new
and with the management responsible for all ones, given the number of trips between each
departments existing facility and one of the new facilities.
 3. Quadratic Assignment - based on the interaction - The weight acts as a force pulling the new facility
among them and the distance between the coordinate of the location of existing facility i.
potential sites, subject to two types of
Contours for Minisum Model - provides meaningful
constraints that each facility must be located
information on the shape of the surface of the objective
exactly once, and that each site must
function. Allow the selection of attractive feasible
accommodate exactly one facility.
locations when optimal location is not possible.
Single-Facility Model
Resultant force diagram - it is defined as the sum of
- Several types of distance measures of weights to the left of a point minus the sum of weights at
effectiveness are used in a diversity of facility the point or to its right.
location models.
Minimax Location Model for Single Facility
- Typically, the objective of the mathematical
models is to minimize a total value of this - This model involves locating new facility given m
measure of effectiveness subject to a set of existing facilities achieving the objective of
constraints that differentiate among several minimizing the distance from the new facility to
cases to be considered. the farthest existing one.
- Three best-known types of distance measures: - It can be further classified according to the type
(a) Rectilinear or rectangular (b) Euclidean of distance between the facilities as follows: (a)
(straight line) method (c) Actual distance Euclidean distance (b) Rectilinear distance
- The unweighted minimax single-facility location
Euclidean and Squared Euclidean Method
problem for rectilinear distances is to find the
- Euclidean distance is the “ordinary” distance location for a new facility that will minimize the
between two points that one would measure function.
with a ruler, and is given by the Pythagorean
Location-Allocation Problem
formula.
- Squared Euclidean distance uses the same - The primary objective in this problem is
equation but does not take the square root. determining the number and location of the new
facilities, as well as the allocation of item
Center of Gravity
movement between new and existing facilities.
- This method is applicable when the distance is - A common example is the location of distribution
not linear but nonlinear. centers that receive products from production
facilities and distribute them to retail or
Minisum Location Problem with Rectilinear distances
wholesale outlets.
- Minimization of the sum of weighted distances
traveled from the new facility to each existing
facility
- If rectilinear distances are used, the distance
between two points is equal to the sum of the
absolute values of the difference between their
coordinates: location of new facility & location of
existing facility

Cumulative Weight Diagram

- It is a graphical approach to the minisum location

model and is helpful to gain more understanding
about the location problem.
- The number of trips for an existing facility is
considered as its weight.
MODULE 3.1: MATERIAL HANDLING • Generate alternative designs for meeting
material handling system requirements
Material Handling
• Evaluate material handling system designs
- the art and science associated with the • Select the preferred design for moving, storing,
movement, storage, control, and protection of protecting, and controlling material
goods and materials throughout the process of • Implement the preferred design, including the
their manufacture, distribution, consumption, selection of suppliers, training or personnel,
and disposal. installation, debugging, and startup of
- providing the right amount of the right material, equipment; and periodic audits of system
in the right condition, at the right place, in the performance
right position, in the right sequence, and for the
Developing alternative material handling system design
right cost, by the right methods.
“Ideal Systems Approach” proposed by Nadler
10 principles recognized by the College Industry Council
on Material Handling Education • Aim for the theoretical ideal system
• Conceptualize the ultimate ideal system
1. Planning – a plan defines the material and the • Design the technologically workable ideal system
moves; together defines the method (how and • Install the recommended system
who)
2. Standardization – less variety and customization
involved Unit Load Design refers to a number of items, or bulk
3. Work – Measured by material flow material, so arranged or restrained that the mass can be
4. Ergonomic – Seeks to adapt work or working picked up and moved as a single object too large for
conditions to suit abilities of worker manual handling, and which upon being released will
5. Unit load – A unit load is one that can be moved retain its arrangement for subsequent movement
or stores as a single entity one at a time such as
pallet, container, tote Stackability means that a full container can be stacked on
6. Space utilization – Is three dimensional- cubic top of another full container in the same spatial
space orientation.
7. System – A collection of interacting and or
Nestability means that the shape of the containers
interdependent entities that form a unified
permits an empty container to be inserted into another
whole
empty container.
8. Automation – A technology concerned with the
application of electromechanical devices,
electronics, and computer-based systems to
Efficiency of Returnable Containers
operate and control production and service
activities • Container space utilization is obtained by
9. Environmental – Has a desire not to waste dividing the usable cube by the exterior envelop
natural resources and eliminate the possible of the container
negative effects to the environment • Storage space efficiency is the ratio of the usable
10. Life-Cycle Cost – Includes all cash flows that will cube divided by the storage cube.
occur from the time the first dollar is spent • Container nesting ratio is determined by dividing
Designing Material Handling the overall container height by the nested height

• Define the objectives and scope for the material

handling system
• Analyze the requirements for moving, storing,
protecting, and controlling material
ERIKA CERVANTES
Material Handling Equipment ▪ Automated Industrial Vehicles
c. Monorails, Hoists, and Cranes
A. Containers and Unitizing Equipment
▪ Monorails
a. Containers - These are frequently used
▪ Hoists
to facilitate the movement and storage
▪ Cranes
of loose items.
▪ Pallets - It is the most common Conveyors: These are used when materials is to be
form of unitizing device moved frequently between specific points; They are used
▪ Skids and Skid Boxes - to move material over a fixed path.
Frequently used in
1. Chute Conveyor
manufacturing plants; Often
- One of the most inexpensive methods of
made of metal, rigid and are well
conveying material.
suited for unitizing a wide
- It is often used to link two powered
variety of items
conveyor lines and also used to convey
▪ Tote pans - Used to unitize and
items between floors with a minimum
protect loose items.
amount of space required.
2. Belt Conveyors
b. Unitizers - These are used to unitize load
- Flat Belt Conveyor: It is normally used for
▪ Stretchwrap/Shrinkwrap - A
transporting light and medium weight
strapping/banding equipment
loads between operations, departments,
used to unitize load; It can be
levels, and buildings.
made of fiber, and plastic
- Telescoping Belt Conveyor: It operates
materials
on telescoping slider beds; These are
▪ Palletizers/De-palletizers - These
popular at receiving and shipping docks
are used for case goods handling
where the conveyor is extended into
as well as bottle handling.;
inbound/outbound trailers for
Receives products and place
unloading/loading
them on a pallet according to a
- Magnetic Belt Conveyor: Consists of a
specified pattern
steel belt and either a magnetic slider
c. Pallet Containers – Cargo trucks for
bed or a magnetic pulley; It is used to
transportation where pallets are placed.
transport ferrous materials vertically,
upside down, and around corners, as
B. Material-Transport Equipment
well as for the separation of ferrous and
a. Conveyors
nonferrous materials
▪ Chute Conveyor
3. Roller Conveyor
▪ Belt conveyor
- May be powered or nonpowered
▪ Roller conveyor
- The nonpowered roller is termed as
▪ Wheel conveyor
“gravity” conveyor, as motion is achieved
▪ Slat conveyor
by inclining the roller section
▪ Chain conveyor
4. Wheel Conveyor
▪ Towline Conveyor
- Similar to the roller conveyor in design
▪ Trolley Conveyo
and function
▪ Power-and-Free Conveyor
5. Slat Conveyor
▪ Cart-on-Track Conveyor
- Consists of discretely spaced slats
▪ Conveyor Sortation Devices
connected to a chain.
b. Industrial Vehicles
- Functions much like a belt conveyor in
▪ Walking Industrial Vehicles
that the unit being transported retains
▪ Riding Industrial Vehicles
ERIKA CERVANTES
 its position relative to the conveying - Walkie stackers: Allows pallet to be
surface lifted, stacked, and transported short
6. Chain conveyor distances.
- In transporting bulk materials, a chain is 2. Riding Industrial Vehicles - Allow the vehicle
located in the bottom of a trough and operator to ride to, from, and between locations.
pulls the material through the trough. - Pallet Trucks: Extends the transporting
- These are often used to transport tote capability of the pallet jack by allowing
boxes and pallets, as only two or three the operator either to ride or walk.
chains typically are required to provide - Tractor Trailer: Extends the transporting
sufficient contact with the rigid support capability of the hand truck by providing
or container to effect movement a powered, rider-type vehicle to pull a
7. Trolley Conveyor train of connected trailers.
- Consists of a series of trolleys supported 3. Automated Industrial Vehicles
from within an overhead track. - These vehicles are automatically guided
- They are generally equally spaced in a by electrified wires buried in the floor,
closed loop path and are suspended magnetic tape lined along the floor, rails
from a chain mounted in the ceiling, cameras
8. Power-and-Free Conveyor mounted on the vehicle, or intertial
- Similar to the conveyor in that discretely and/or GPS guidance systems.
spaced carriers are transported by an (Automated Guided Vehicles,
overhead chain Automated Electrified Monorails,
9. Towline Conveyor Sorting Transfer Vehicles)
- It used to provide power to wheeled cars
such as trucks, dollies, or carts that move
along the floor. Monorails, Hoists, and Cranes
10. Cart-on-Track Conveyor
- Used to transport a cart along a track Monorails and cranes are generally used to transfer
11. Conveyor Sortation Devices material from one point to another in the same general
- It used to assemble material with a area.
similar characteristic by correctly Hoists are used to facilitate the positioning, lifting, and
identifying the similar merchandise and transferring of material within a small area.
transporting it to the same location.
These generally provide more flexibility in the movement
path than do conveyors, however, they do not have the
Industrial Vehicles degree of flexibility provided by variablepath
equipment, such as industrial trucks.
1. Walking industrial vehicles
- Hand trucks and hand carts: Used for 1. Monorails: Consists of an overhead track on
small loads and short distances, the which a carrying device rides; The carrier can be
hand truck is a versatile method of top running, underhung powered, or
moving material manually. nonpowered
- Pallet jacks: Used to life, maneuver, and 2. Hoists: A lifting device that is frequently attached
transport a pallet load of material short to a monorail or crane
distances. 3. Cranes
- Platform trucks: A version of the - Jib crane: Has an appearance of an arm
industrial truck; Provides a platform for that extends over a work area, A hoist is
supporting the load attached to the arm to provide lifting
capability

ERIKA CERVANTES
- Bridge Crane: Resembles a bridge that MODULE 3.2 LAYOUT PLANNING MODELS
spans a work area, The bridge is
The generation and evaluation of a number of layout
mounted on tracks so that a wide area
alternatives is a critical step in the facilities planning
can be covered.
process since the layout selected will serve to establish
- Gantry Crane:It spans a work area in a
the material flow patterns and physical relationships
manner similar to the bridge crane, It is
between activities.
generally floor separated rather than
overhead supported on one or both Facility layouts can be viewed in two levels:
ends of the spanning section.
- Tower Crane: Consists of a single upright • Block Layout - It shows the location, shape, and
that may be fixed or on a track having a size of each planning department; It is concerned
cantilever boom. primarily with the “macro” flows in the facility
- Stacker Crane: It is often used for storing • Detailed Layout - Shows the exact location of all
and retrieving unit loads in storage racks, equipment, work benches, and storage areas
It can be controlled either remotely or within each department; It is concerned with the
with an operator on board in a cab “micro” flows in the facility
attached to the mast, The mast is Basic Layout Types
equipped with forks or a platform, which
are used to lift unit loads. - Fixed Material Layout Types
- Production Line Departments
- Product Family Departments
- Process Departments

Layout Procedures

- Construction layout methods – involves

developing a new layout from “scratch”
- Improvement procedures – generate layout
alternatives by seeking improvements in an
existing layout

- Apple’s Plant Layout Procedures

- Reed’s Plant Layout Procedure

Muther’s Systematic Layout Planning (SLP) Procedure

- Systematic Layout Planning was developed by

Richard Muther in 1961
- It is arguably the best-known, widely-used, and
best coordinated methodology for layout
planning.
- It is an approach to develop a feasible layout
through a multistep procedure that uses the
following types of information:
o List of products to be manufactured,
production quantities, routing sheets for
all products, list of supporting services,
standard times for operations, and all
manufacturing activities grouped into
planning departments.
ERIKA CERVANTES
 o Relationships between the various o Considers all possible two-way
departments exchanges (pairwise) or three-way
department exchanges and identifies
• Discrete Layout - Allows the computer to store the best exchange. The process
and manipulate the layout as matrix; selecting continues until no further reduction in
appropriate grid size is an important decision layout cost can be obtained
• Continuous Layout - More flexible than the • Micro-CRAFT
discrete layout but hard to be implemented using o A personal computer implementation of
a computer; has no underlying grid structure Craft developed by Hosni, Whitehouse,
and Atkins and was distributed by
Different Layout Methods
Institute of Industrial Engineers (IIE)
• Pairwise Exchange Method o It is similar to CRAFT except that it can
o An improvement type algorithm that exchange any two departments whether
can be used with both adjacency and they are adjacent or not
distance-based objective o Improvements are obtained by using a
o It states that, for each iteration, all layout formation technique (Automated
feasible exchanges in the locations of Layout Design Program or ALDEP) that
department pairs are evaluated one at a automatically shifts other departments
time, and the pair that results in the when two unequal area, non-adjacent
largest reduction in the total cost is departments are exchanged.
selected o Instead of assigning grids to
• Graph-Based Method departments, MCRAFT divides the
o It is a construction-type algorithm that is facility into “bands” and the grids in each
often used with an adjacency-based band are then assigned to one or more
objective departments.
o The recognition of the usefulness of • BLOCPLAN
graph theory as a mathematical tool in o Developed by Donaghey and Pire and is
the solution of facilities planning similar to MCRAFT since departments
problems dates back to the late 1960s are arranged in bands
and early 1970s o It uses a relationship chart as well as a
• CRAFT from-to chart as input data for the
o Introduced in 1963 by Armour, Buffa, “flow”
and Vollman. One of the earliest layout o Layout cost can be measured either by
algorithms. Uses from-to chart as input the distance-based objective or the
data for the flow adjacency-based objective
o The algorithm begins by determining the o It can be used both as an improvement
centroids of the departments in the algorithm or a construction algorithm
initial layout then calculates the • LOGIC
rectilinear distance between pairs of o Layout Optimization with Guillotine
department centroids and stores the Induced Cuts. Developed by Tam
values in a distance matrix. o It is based on dividing the building into
o The initial layout cost is determined by smaller and smaller portions by
multiplying each entry in the from-to executing successive “guillotine cuts”-
chart with the corresponding entries in straight lines that run from one end of
the unit cost matrix and the distance the building to the other
matrix • MIP, MULTIPLE (others)

ERIKA CERVANTES