Professional Documents
Culture Documents
ENGINEERING
DIPLOMA IN
INDUSTRIAL & OPERATIONS
MANAGEMENT
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system, or transmitted, in any form or by any means, electronic, mechanical,
photocopying, recording or otherwise, without the prior permission of the School of
Engineering, Republic Polytechnic, Singapore.
SCHOOL OF
ENGINEERING
Utilizing Space
There is presently a theatre building in the city centre, commissioned by the Arts Council, to host
premier arts and cultural events.
After running the facility for two years, there has been feedback from the management of the
theatre building that the facility has not been fully utilized. The management committee has
commissioned your company to propose improvements to the theatres upper level layout. The
main objective is to add vibrancy to the theatre while fully utilizing space.
After some research, your company proposed introducing these features. These are
1) A small video library for visitors to browse and borrow classic and art videos
2) 1 Facilitation room and 1 Conference room for meeting and discussion
3) A visual art gallery to showcase art exhibits.
4) An open-air cafeteria for food and drinks.
Below is the floor layout for the upper level of the theatre. Your team will need to study how the
above features can be incorporated into the layout to achieve the objective that the theatre
management has mentioned.
Utilizing Space.vsd
Your team shall present your proposed layout for the theatre building to the Arts Council for
consideration.
Page 2 of 2
School of Engineering
School of Engineering
School of Engineering
School of Engineering
Facility
System
Design
Facilities
Planning
Facilities
Design
Layout
Design
Handling
Systems
Design
School of Engineering
Facilities Location
Facilities location refers to the place with respect to
customer, suppliers and other facilities with which it
interfaces.
Some factors influencing location:
Proximity to raw material source
Customer markets
Transportation system
Economic development (financial) incentives
School of Engineering
Facilities Design
Facilities design consists of the facility systems, layout and
handling system:
o Facility systems structural, atmospheric, enclosure,
lighting, electrical, communications, safety and sanitation
systems
o Layout equipment, machinery, furnishings and fittings
within the facility envelope
o Handling system the mechanisms needed to satisfy the
required movements within the facility
Material handling is important to the facility design activity. The
choice of material handling equipment will greatly influence the
suitability of the facility design.
School of Engineering
School of Engineering
School of Engineering
Facilities Design
Dimensions for Improvement:
o Physical factors fittings, equipment, layout, furnishings,
human factor interactions
o Time factor traffic flows, ingress, egress
School of Engineering
10
School of Engineering
Sample Solution
There is no unique, best solution to this problem,
School of Engineering
12
Sample Solution
Visual Art Gallery
Purpose: Showcase art pieces for visitors
Effectiveness- Location: Good- visible
Effectiveness- Systems Design: Good- adequate humidity control
Alternative 1 (Visual emphasis)
Physical: Ample lighting on the art pieces for viewing
Time: Use colors to identify different zones of different type of art pieces.
Safety: Art pieces may need to be secure. There should be a mark out zone.
Alternative 2 (Functional emphasis)
Physical: Need to cater space in front of the art pieces for viewing.
Time: Clear direction flow to highlight important art piece.
Safety: Differentiate emergency signs from the surroundings
School of Engineering
13
Sample Solution
Facilitation/Conference rooms
Purpose: Area for discussion and meeting sessions
Effectiveness- Location: Good - accessible
Effectiveness- Systems Design: Well equipped with facilitation equipment
Alternative 1 (Visual emphasis)
Physical: Long table to be at centre of the room. Good lighting for room.
Time: Use colors to identify exit and entrance to room
Safety: All exposed ceilings should be covered. Ample ventilation in the room.
Alternative 2 (Functional emphasis)
Physical: Layout the tables for discussions. Accessible to white board.
Time: Change table design to allow easier movements and discussion
Safety: Increase to two doors for each class to provide emergency exits
Ensure free access for facilitation/conference room at all times
School of Engineering
14
Sample Solution
A video library
Purpose: Place for video storage and retrieval of art and culture material and
discussion
Effectiveness- Location: Good- Spacious, visible, accessible
Effectiveness- Systems Design: Opportunity to explore other alternatives
Alternative (Functional emphasis)
Physical: Discussion tables at the video library section
Newspaper racks should to be located at Level 1 instead
Time:
Use colors to differentiate different section (eg. Reference, Video)
Indicates the direction to other parts of the facilities clearly
Safety: Mark out emergency exit doors clearly
Indicates locations of safety equipment clearly
School of Engineering
15
Sample Solution
An open-air cafeteria
Purpose: Area for food and drink consumption.
Effectiveness- Location: Good Accessible, ventilated.
Effectiveness- Systems Design: Opportunity to explore other alternatives
Alternative (Functional emphasis)
Physical: Install ventilators
Ensure good lighting and space at each tables
Change door swing orientation for toilets
Time:
Ensure all toilets are available at any time
More prominent directions/ signage to the toilets
Safety: Remove swinging doors at the toilets
School of Engineering
16
Learning Objective
Identify different design components of a
facility (location, types of physical
systems)
Recognize different physical systems in a
facility and how they functions
Know the objectives of planning and laying
out a facility
SCHOOL OF
ENGINEERING
DIPLOMA IN
INDUSTRIAL & OPERATIONS
MANAGEMENT
SCHOOL OF
ENGINEERING
Location! Location! Location!
Angie has been operating her theme restaurant, Iron Rock Cafe for a number of years and
it has attracted a large number of faithful patrons. She has decided that it is time to expand
her business and she is keen to expand to a neighboring country. This will not only
increase her customer base but it will also serve to increase awareness to her theme
restaurant. After much consideration, she narrows down to 3 possible locations in the
region to expand her restaurant: Perth (Australia), Bangkok (Thailand) and Jakarta
(Indonesia).
Angie wants her new restaurant to start well and be sustainable. She attributes the
success of an F&B business to successful selection of a strategic location for the theme
restaurant.
Instinctively, she considered factors such as human traffic flow, cost and vibrancy of the
sites when she assessed the different locations for her restaurant.
She is still not confident that she has considered all the factors in selecting the most
strategic location. And since some sites are better when she considered one factor, but
not as well when she considered another, she is having difficulty in deciding on the best
site.
What can she do to decide on the best site for her theme restaurant?
Page 2 of 2
School of Engineering
Location Selection
Recall from P01
Facilities location refers to the place with respect to customer,
suppliers and other facilities with which it interfaces.
Type of Analysis
Macro analysis
To evaluate alternative countries, regions, communities
Micro analysis
To evaluate specific sites in the selected community
For example, manufacturers that use perishable raw materials locate near
source
4
FAT Example
Weight
Factor
Perth
0.30
Lease Cost
80
70
60
65
0.25
Customer volume
60
75
70
80
0.10
Competition in
area
75
65
70
65
0.25
Suitability of
location
85
80
75
90
0.10
Customer profile
70
75
70
85
Kuala
Lumpur
Bangkok
Jakarta
W=1
Pairwise Comparison
(Analytic Hierarchy Process - AHP)
Involves prioritization of potential alternate solutions through
evaluation of a set of criteria element
Elements can be sub divided into sub-elements and so on, forming a
hierarchy tree
Once Hierarchy definition is established, criteria are weighted
individually at each level with each other
Prioritization of the alternate solutions are then evaluated based on
these weights
Software which makes use of AHP Expert Choice
10
11
12
Problem Objectives
Identify possible objectives of a facility
Determine factors for selecting a site based on
the objectives of the facility
Select an appropriate site for a facility after
considering the importance of each factors and
how well each alternative site fare for each
factor
13
Using FAT
Perth
Choose Jakarta
Weight
Factor
Bangkok
0.30
Lease Cost
80 x
0.30
=24
18
21
19.5
0.25
Customer volume
15
17.5
18.75
20
0.10
Competition in area
7.5
6.5
6.5
0.25
Suitability of
location
21.25
18.75
20
22.5
0.10
Customer profile
7.5
8.5
W=1
Sum of Weighted
Score
74.75
68.75
73.25
77
Kuala
Lumpur
Jakarta
15
Insert description
of project
16
Conclusion
Angie can use Factor Analysis Technique (FAT) or
Analytical Hierarchy Process (AHP) to help her select
suitable location for her restaurant.
Though FAT is relatively easier to use, AHP can capture
both subjective and objective evaluation measures.
In order to do her location analysis, she needs to
decides on her factors and alternatives. Data and
information are also needed to help her in her analysis.
For her problem, she found that Jakarta is the most
suitable location for her next theme restaurant.
18
Learning Objective
Analyze different locations and select a
suitable location for a facility based a set of
selection criteria
Assign weights to different decision criteria
based on their importance (according to
management guidelines and decision)
Select a suitable location for a facility based a
set of selection criteria
SCHOOL OF
ENGINEERING
DIPLOMA IN
INDUSTRIAL & OPERATIONS
MANAGEMENT
SCHOOL OF
ENGINEERING
Setting the layout
It has always been Jasons dream to open a shop selling sandwich to the
masses. Recently, he managed to secure a shop space in an international school
to realize his dream.
He intends to sell sandwiches which allow customer to customize their
combination of meats upfront. Snacks and drinks will also be available at the
payout counter. They will then proceed to pay at the counter before bringing their
food back to the sitting area for consumption.
With the location confirmed, Jason has to decide on the appropriate equipment to
buy for his shop kitchen. As he intends to make the bread for his sandwiches, he
will need to arrange the oven and bread making equipment in a way most
suitable for his business. Salad and salad dressing will need to be prepared in
the kitchen as well.
Jason has never tried doing his own layout before so he thought that a good way
to start is to study how others do their layouts. He recalled two instances:
1. When he was studying in Republic Polytechnic, he always frequent
Subway fast food outlet. He noticed that it offers a lot of varieties of
sandwhich which the customer can choose from. Payment for the food
is at the respective stall counter. There are also seats around the store
where customers can sit down for their meal.
Page 2 of 3
SCHOOL OF
ENGINEERING
He is not sure which layout is most suitable for his business and he is concerned
that there are other issues which he needs to consider when doing his layout.
Can you help him?
Page 3 of 3
School of Engineering
Layout Decisions
The need for layout decisions:
Layout Decisions
Inputs to the layout decision:
Specifications of system objectives ~ in terms of output and
flexibility
Estimation of product or service demand on the system
Processing requirements ~ in terms of number of operations and
amount of flow between departments and work centers
Space requirements for the elements in the layout
Space availability within the facility itself
Basic layout types: 1. Fixed-position
2. Product
3. Process
4. Cellular
5. Mixed
3
Layout Types
1. Fixed-Position Layout
Layout in which the product remains stationary and workers, materials
and equipment are moved as and when needed
Equipment and tooling costs are low compared to other layout types
Not geared for high-production quantities
Used when the product is bulky, heavy or fragile
High degree of product customization can be achieved
Minimizes the amount of product movement
Examples:Ship building
Aircraft assembly
Layout Types
An example of Fixed-position layout: Ship building
Layout Types
2. Product Layout
Layout that uses standardized processing operations to achieve
smooth, rapid, high-volume flow
Equipment and tooling costs are generally higher
High levels of labor and equipment utilization can be achieved
Requires balance of time between operations: i.e. line balancing
Provides opportunities for process automation
Can achieve low production cost per unit
Examples:Domestic appliance manufacture
Chemical plating
Layout Types
An example of Product layout: Product Assembly Line
Layout Types
3. Process Layout
For producing a fairly large number of similar products (in batches)
Consists of several well-defined operations
Layout Types
An example of Process layout: Components machining
Layout Types
4. Cellular Layout
Layout in which machines are grouped into a cell that can handle
items with similar processing requirements
Grouping into part families of items with similar design or
manufacturing characteristics is called group technology
Group technology helps in achieving process standardization when
processing large quantities of different components
Examples:Domestic appliance manufacture
Machine component manufacture
5. Mixed Layout
A combination of product, process and/or cellular layouts across the
entire product manufacturing flow
10
Layout Types
An example of Cellular layout: Machine components manufacture
11
Layout Types
12
13
1. Flow of Materials
2. Activity Relationships
Analysis
3. Relationship Diagram
5. Space Available
4. Space Requirements
7. Modifying Considerations
8. Practical Limitations
Search
10. Evaluation
Selection
14
Problem Objectives
Analyze a product and determine the process flow in
manufacturing of the product
Identify different types of layout and explain what is the
advantages and disadvantages of each layout
Select a suitable type of layout for the process
Know the process of layout design
16
Sample Solution
Some essential questions for Jason
1.
2.
3.
4.
5.
17
Sample Solution
Assumptions when recommending layout type to use
1.
2.
3.
4.
5.
6.
18
Sample Solution
A suitable kitchen layout for Jason
19
20
Sample Solution
Food
Collection
Materials Picking
Storage
Shelf
Fridge
Washing
& Cleaning
Kitchen
Sink
Food
Counter
Baking
Oven
Miller
Oven
Snack
Counter
Drink
Counter
Kitchen
Top
Kitchen
Top
Toasting
Toaster
Assembly
Assembly bench
Mixing
Small mixer
Grilling
Griller
Griller
Assembly bench
21
22
23
Learning Objective
Identify different types of layout and explain
the advantages and disadvantages of each
layout
Select a suitable type of layout based on the
type of process required in the facility
The process of layout design
SCHOOL OF
ENGINEERING
SCHOOL OF
ENGINEERING
KEEP THE SANDWICHES COMING
Jason has been looking into setting up his own sandwich joint at an international
school. In additional to selling soft drinks and salad boxes, he wants to offer set meals
consisting of: one sandwich, one soft drink and a salad box. There will be 3 types of
sandwiches to choose from: grilled turkey, ham and tuna; all marinated and prepared in
his kitchen.
After conducting some market research, he has finalized the ingredient list for his
different sales items. He formulated a product part list for these ingredients for
inventory tracking purpose. A rough demand forecast was also produced from his
market research.
Demand
Forecast.xlsx
After obtaining the forecast and process details, Jason proceeded to work out what
equipments to buy for his sandwiches joint. Requirement for his equipment were
obtained from expected output and cycle time as shown below.
Page 2 of 3
SCHOOL OF
ENGINEERING
Equipment List
Equipment
number
1
2
3
4
5
6
7
8
9
10
Equipment
description
Bread Toaster
Grilling station
Condiments Cabinet/
Storage Shelf
Sink and Assembly
Work desk
Wrapping Work desk
Mixing Station
Sandwich Picking
Station
Storage Area
Drink Dispenser
Cashier
Footprint
(m2)
1.0 x 1.0
2.0 x 1.0
Output/Cycle
2
4
Time/Cycle
(sec)
60
200
3.0 x 1.0
2.0 x 1.0
1.0 x 1.0
1.0 x 1.0
1
1
8
20
12
220
1.0 x 1.0
1.0 x 1.0
1.0 x .1.0
3.0 x 1.0
2
-
15
-
Description
Machine station, single operator
Machine station, single operator
With these data, Jason decided that he has sufficient information to plan the most
appropriate layout type for his shops kitchen. Below is the floor layout of the shops
kitchen. Can you help Jason determine the appropriate layout and equipments
arrangement for his shops kitchen?
2000.00
2000.00
7000.00
2000.00
2000.00
2000.00
2000.00
Kitchen Layout
3000.00
Page 3 of 3
Flow Planning
Process of arranging activities in combinations of
basic flow patterns (based on flow analysis), both
quantitative (from-to chart) and qualitative (activity
relationship diagram).
Types of flow
Materials
People
Equipment
Documents
Flow can be within workstation, within a department
(intra-cell) or between departments (inter-cell)
On adjacent sides
On opposite sides
Travel between floors occurs on the Some bucket and belt conveyors and
escalators result in inclined flow
same side of the building
2 machines/operator
1 machine/operator
More than 2
machines /operator
1 machine/operator
Aisle
Aisle
Aisle
One way
Aisle
One way
10
11
12
From-To Chart
A matrix that contains numbers representing a measure
(unts, unit loads, etc) of the material flow between machines,
departments, buildings, etc.
D.
Others
Assembly chart
Flow process chart
Multi product process chart
Flow diagram
13
Notation:
M:
number of activities.
Nij:
fijk:
hijk: equivalence factor for moving item k with respect to other items moved between i
and j (dimensionless)
[all hijk = 1 since assume equal ease of movement]
wij: equivalent flow volume specified in from-to chart (in moves/time period),
N ij
w ij = f ijk h ijk .
k 1
14
fU f '
fU fL
f=
where
1
2
M M 2
2 2
w
M
w
i 1 j1 ij
2
M
f'
,
w
1
2
M2 M 1
fU M
,
2
(M 1)(M 1)
M M
w ij
w=
i 1 j 1
M2
fL M
2
(M
1)(M
1)
1
2
15
17
18
Part Number
Part Description
Part Type
RA00001
Bread Loaf
Raw material
RA00002
Turkey slice
Raw material
RA00003
Ham slice
Raw material
RA00004
Tuna chuck
Raw material
RA00005
Pickles
Raw material
RA00006
Olive
Raw material
RA00007
Tomato
Raw material
RA00008
Lettuce
Raw material
RA00009
Mayonnaise
Raw material
RA00010
Honey Mustard
Raw material
RB00001
Fruits
Raw material
RB00002
RC00001
RC00002
Ice
Raw material
Raw material
PA00001
Sandwich wrapper
Packing
PA00002
Salad box
Packing
PA00003
Packing
SA00001
Cups
Sandwich without wrapper
FA00001
Wrapped sandwich
Finished goods
FA00002
Salad
Finished goods
FA00003
Finished goods
Raw material
Sub assembly
19
Mayonnaise
RA00009
O-13
Chill
Lettuce
RA00008
O-12
Chill
Tomato
RA00007
Olive
RA00006
Turkey Slice
RA00002
Pickles
RA00005
O-10
Wash
O-08
Wash
O-06
O-11
Cut
O-09
Cut
O-07
Peel
O-03
Preserve
O-04
Bottle
O-05
Store
Bread Loaf
RA00001
O-02
Grill
O-01
Toast
Cut
SA-01
Thousand Island Dressing
RB00002
Fruit
RB00001
Sandwich Wrapper
PA00001
O-14
Mix
Salad Box
PA00002
SA-03
Ice
RC00002
SA-02
SA-04
A-01
O-15
O-16
Scoop
Dispense
SA-05
Cup
PA00003
20
Part Number
Part Description
Machine Routing
RA00001
Bread Loaf
3-1-4
RA00002
Turkey slice
3-2-4
RA00003
Ham slice
34
RA00004
Tuna chuck
36-4
RA00005
Pickles
34
RA00006
Olive
34
RA00007
Tomato
34
RA00008
Lettuce
34
RA00009
Mayonnaise
34
RA00010
Honey Mustard
34
RB00001
Fruits
36
RB00002
36
RC00001
Thousand Island
Dressing
Lemon Tea in barrel
8-9
RC00002
Ice
PA00001
Sandwich wrapper
85
PA00002
Salad box
86
PA00003
89
FA00001
Cups
Sandwich without
wrapper
Wrapped Sandwich
FA00002
Salad
6 - 10
FA00003
9 - 10
SA00001
45
5 - 7 - 10
21
=164/3
= 54.7
7.6
Sample calculation
10
3
4
54.7
7.6
94.9
5
6
7
9.8
41
6.6
24
7.6
82
9
10
4.5
95
82
78
22
10
54.7
7.6
54.7
7.6
94.9
9.8
42
6.6
7.6
24
82
=2x3.87
5 + 0.62
=8.4
Sample calculation
95
82
78
23
M M 2
2 2
w
M
w
i 1 j1 ij
2
M M
M
= 3.14658 w ij
i 1 j 1
'
= 6.539
f
,
w=
2
w
M
1
2
M M1
fU M
,
2
(M 1)(M 1)
2
= 3.1958
fL M
2
(M
1)(M
1)
1
2
= 0.335
24
= 0.01721
25
Time/Cycle
Gross Material Equipment
Net
Equipment
(sec)
Output/Cycle Output/hr Scrap Efficiency Output/hr Required
Bread Toaster
60
120
3%
92%
107
Grilling Station
Sink and Assembly
Workdesk
200
72
3%
92%
64
20
180
0%
92%
165
Wrapping Workdesk
12
300
0%
92%
276
Mixing Station
220
131
3%
92%
116
Drink Dispenser
Condiments Cabinet /
Storage Shelf
15
480
1%
92%
437
Burger Picking
Storage Area
Cashier
1
26
54.7
7.6
54.7
7.6
94.9
41
24
9.8
82
6.6
7.6
10
To
1
2
3
4
5
6
7
8
9
10
95
82
8.4
78
27
Proposed Layout
A simple layout can be done
based on the from-to chart
Process with high flow are
placed together to minimize
the transportation work
Further modification can be
made to the layout on the left
to reduce the distance
between areas of high flow
Note that the layout will be
affected by actual floor plan
28
Learning Objective
Analyze and determine the process flow of a product from a
flow diagram
Calculate the total flow volume for a particular layout
Identify different areas of inefficiency in a facility and identify
areas of changes in order to reduce the flow volume
Layout different departments within a facility to ensure a
good flow of materials and finished goods
SCHOOL OF
ENGINEERING
Page 1 of 3
SCHOOL OF
ENGINEERING
Who will be my neighbour?
E & L Pte Ltd is a third party logistic firm that services multinational companies.
They are expanding rapidly and are shifting all their office operations to a vacant
facility in six months time.
You have been tasked to plan the layout of the new office. You conducted
interviews with the following key personnel of the various departments of E & L.
Based on what they have told you, how would you layout the various departments?
Interview Details
Sam, IT Specialist: We are the nerve centre, managing most of the software
systems in E & L. We are currently using SAP software to manage most of our
transactions in E & L. Accounts and Operations Department will often work with
me to resolve system issues. At times, I will also need to help resolve IT problems
from other departments.
Bee Leng, Account Executive: I work very closely with the planners in the
Operations Department. I will need to ensure that all shipments are billed correctly
to our customers. All incoming invoices will also be directed to our department for
processing. At the end of each month, I will need to balance the accounts and
report the balance sheet to management.
Daisy, Quality Assurance Officer: I work closely with customers on quality
requirements and issues. When there is a complaint received from Sales
Department, I will work with Operations to investigate the case log. We will then
follow up with a corrective action plan to close the complaint.
Janet, Human Resource Officer: I spend most of my time in office. Usually, I
look into payroll matters and coordinate interviews for departments that need
additional manpower.
Emily, Sales and Marketing Executive: When I receive new customers order, I
usually send it over to the planners in Operations Department for processing. At
Page 2 of 3
SCHOOL OF
ENGINEERING
times, I may need to walk over to discuss customers delivery status with our
planners.
Betty, Receptionist: I know most of the people working in E & L as it is my job to
direct visitors to them. However, I work closely with Human Resources
Department to help arrange candidates for interview.
Yi Ling, Legal Advisor: I manage all legal and contractual matters in E & L. I
spend a lot time working with Sales and Marketing Department to review all new
contracts.
Jackson, Facility Manager: I am in charge of the security and cleanliness within
the company. One of the areas that I am particularly concerned about is the
server room in the IT department, where all our important data is stored and
backed up. For contractual matters, I usually consult Yi Ling when drafting up
new contracts for cleaning companies or security contractors.
Robert Ng, Operations Manager: I have a few groups of people working for me.
When a new customer order is received from our Sales and Marketing
Department, my planner will check with our warehouse for the availability of the
goods. The order will be keyed into our SAP system and Accounts Department
will be notified. Our planners also monitor incoming shipment. If we have orders
for storing finish goods in our warehouse, our SAP system will capture it and notify
our warehouse and Accounts Department. I will need to attend weekly
management meeting with the other department managers. At times, I would also
need to go down to our warehouse to observe what is happening over there.
Page 3 of 3
Assignment of Importance
A = absolutely necessary 5 %
E = especially important 10 %
I = important 15 %
O = ordinary closeness 20 %
U = unimportant 50 %
X = undesirable 5 %
Assign the relationship with the ratings shown.
The percentage is a guideline to how much of each
rating should be assigned with respect to the total
number of relationships.
2
Closeness Value
V(rij) = arbitrary cardinal value assigned to rij,
for example,
V(A) = 125
V(E) = 25
V(I) = 5
V(O) = 1
V(U) = 0
V(X) = -125
1
U
E
O
U
U
U
A
O
2
U
I
U
A
I
U
U
U
3
E
I
U
U
O
U
U
E
4
O
U
U
U
I
O
U
O
5
U
A
U
U
E
I
U
O
6
U
I
O
I
E
U
U
I
Summary
7
U
U
U
O
I
U
U
E
8
A
U
U
U
U
U
U
O
9
O
U
E
O
O
I
E
O
A
1
1
0
0
1
0
0
1
0
E
1
0
2
0
1
1
1
0
2
I
0
2
1
1
1
3
1
0
1
O
2
0
1
3
1
1
1
1
4
U
4
5
4
4
4
3
5
6
1
X
0
0
0
0
0
0
0
0
0
TCR
152
135
56
8
156
41
31
126
59
Order
2
3
6
9
1
7
8
4
5
First department to be placed is the one with the greatest TCR value.
If a tie exists, choose the department with more As
If a department has an X relationship with the first one, it is placed
last in the layout
If a tie exists, choose the one with the smallest TCR value
Second department is the one with an A relationship with the first one
If a tie exists, choose the one with the greatest TCR value
If a department has an X relationship with the second one, it is placed
next-to-the-last or last in the layout
If a tie exists, choose the one with the smallest TCR value
The third department is the one with an A relationship with one of the
placed departments.
If a tie exists, choose the one with the greatest TCR value
The procedure continues until all departments have been placed.
Important Notes
Once the department is placed, it is called a permanent facility while the
department yet to be located is called a temporary facility.
In choosing an entering department, it is based on
A, E, I, O, U
If ties exist, the largest TCR value
If ties persist, the largest area (space requirement)
WP is also called PR (Placement Rating) and is defined by the sum of
the numerical values assigned to the closeness ratings between the
entering facility and adjacent permanent ones.
We try to maximize WP. If ties exist, consider
largest boundary length
arbitrary assignment
10
11
12
1
U
U
E
I
O
O
U
A
2 3
U O
U
U
U U
E U
U I
U O
O O
U O
4 5
E I
U E
U U
O
O
I U
O I
U U
A E
6
O
U
I
I
U
Summary
7
O
U
O
O
I
U
8 9
U A
O U
O O
U A
U E
U O
U
U A
U U
U
O A U
A
1
0
0
1
0
0
1
0
3
E
1
1
0
1
2
0
0
0
1
I
1
0
1
1
2
2
1
0
0
O
3
1
3
2
1
2
3
2
2
U
2
6
4
3
3
4
3
6
2
X
0
0
0
0
0
0
0
0
0
TCR Order
158
2
26
6
8
8
157
3
61
5
12
7
133
4
2
9
402
1
13
125
14
125
3) Placing Department 2
2.5
2.5
2.5 22.5
17.5
2.5 18.5
0.5
125.5
0.5
64.5
63.5
0.5
0.5
4) Placing Department 6
0
0.5
1.5
0.5
6.5
5.5
2.5
2.5
25 12.5
28
13.5
25 12.5
0.5
5) Placing Department 3
25
6) Placing Department 8
0
0.5
0.5
0.5
0.5
0.5
0.5
2.5
0.5
0.5
1.5
3.5
5.5
0.5
2.5
2.5
16
Initial Layout
7. Quality
Assurance
2. Legal
5. Sale and
Marketing
3. Human
Resource
1. Accounts
9. Operations
8.Facility
6. Reception
4.IT
17
Practical Considerations
Location of building core (Structural columns,
Staircase, AHU(Air Handling Unit))
Size of department
Shape of building
Location of loading/unloading bay (same place,
location of road leading to the office)
18
19
Learning Objective
Qualitative analysis
Layout different departments within a facility based on
importance of relationships between departments
Construction of initial (process) layout base on relationships
between departments
20
SCHOOL OF
ENGINEERING
Page 1 of 3
Space Limitation
E212-P06- Space
Limitation-SOP.docx
The Research Manager also requested Jason to speak to Alex, the research
assistant, as Alex has had several concerns with current placement of the
sputtering machines. The attached document lists Alexs feedback.
E212-P06- Space
Limitation-User's Feedback.docx
The dimensions of the new clean room, which Alex will work in, are (L) 12000
mm x (W) 9000mm. It will house 4 sputtering machines, 4 workbenches [(L) 800
mm x (W) 500 mm each], 1 Surface Profiler [(L) 1200 mm x (W) 1200 mm], 1
Atomic Force Meter [(L) 1200 mm x (W) 1200 mm] and 3 metal storage racks [(L)
1500 mm x (W) 800 mm each] for equipment maintenance tools. There will also
be need for 18 magazine storage holders measuring 500 mm each to be
placed in the clean room. Each sputtering machine will need a workbench and 3
magazine storage holders. The remaining magazine storage holders are used as
SCHOOL OF
ENGINEERING
departmental storage bins. The new clean room floor plan and machine
orthogonal projection are provided below.
Your task today is to help Jason draft a layout for the new clean room. You will
need to take into consideration all necessary space requirements.
Page 3 of 3
School of Engineering
Space Requirement
Determining the amount of space required in a facility
is perhaps the most difficult determination in facilities
planning
Design lifespan for a facility: typically 5 10 years
Uncertainties:
Technologies
Product mix
Demand level
Organizational designs
School of Engineering
Parkinsons Law
Things will expand to fill all available capacity
sooner than you plan!
School of Engineering
School of Engineering
School of Engineering
Operator
Material handling
Requires knowledge of method of performing operation
Based on motion study and ergonomic study taking into account:
Pick up and discharge with walking or making long/awkward
reaches
Efficient and effective utilization of operator
Minimize time spent on material handling
Maximize operator safety comfort and productivity
Minimize hazards, fatigue and eye strain
Minimal 30-inch aisle to travel pass through 2 stationary objects
Minimal 36-inch aisle to travel pass stationary and moving objects
Minimal 42-inch aisle to travel pass through 2 moving objects
Operator ingress and egress
School of Engineering
Department Specification
Sum of total workstation requirements
Departmental equipment storage
Aisles space allowance between workstations
Aisle Allowance Estimates
Largest Load
Aisle Allowance %a
5 - 10
10- 20
20- 30
30- 40
as a percentage of the net area required for equipment, material and personnel
School of Engineering
Aisle Arrangement
Departmental aisle and main aisle
Recommended Aisle Widths for Various Types of Flow
Types of Flow
Tractors
3-ton Forklift
2-ton Forklift
1-ton Forklift
Narrow aisle truck
Manual platform truck
Personnel
Personnel with doors opening in the
aisle from one side
Personnel with doors opening in the
aisle from two sides
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Aisle Width
(feet)
12
11
10
9
6
5
3
6
8
School of Engineering
10
Workstation Specification
Equipment:
4 x Sputtering machine footprint: 2410 mm X 1520 mm
4 x Workbench for material preparation : 800 mm X 500 mm
1 Surface Profiler (assume at department level) :
1 Atomic Force Meter (assume at department level)
Machine travel: assume opening of covers and doors within
footprint area
Machine maintenance area: Area at the back of machine required
for maintenance, allow perimeter of 800 mm at the back and side
of the machine for maintenance, allow 1200 mm if next to wall
Plant service area: Clearance area near to power source for
maintenance
School of Engineering
11
Workstation Specification
Material:
Incoming, outgoing and storage materials:
Department storage area
Individual workstation storage area (3 holder)
Assume raw substrate to be held inside wafer magazine
holder
Assume completed item to be placed in a 500 mm
magazine holder
In-process materials: nil
Waste from scrap
Assume dump into 500 mm magazine storage holder
Housekeeping / maintenance materials
Assume at department level only
School of Engineering
12
Workstation Specification
Personnel:
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13
Department Specification
Workstation area: 4 x Work areas (3400 mm x 2530 mm)
Department storage area: 6 x Magazine Storage holder ( 500
mm)
Common department test equipment: Surface Profiler (1200 mm
x 1200 mm), Atomic Force Meter (1200mm X 1200mm)
Maintenance Equipment Racks: 3 x Cabinets(1500 mm x 800
mm)
Aisle allowance estimates: 30-40% of total area
Largest Load
a Expressed
Aisle Allowance % a
5 - 10
10- 20
20- 30
30- 40
as a percentage of the net area required for equipment, material and personnel
School of Engineering
14
Aisle Arrangement
Departmental aisle : By personnel = 914 mm (3 feet)
Main aisle: By Narrow Aisle Truck = 1829 mm (6 feet)
Types of Flow
Tractors
3-ton Forklift
2-ton Forklift
1-ton Forklift
Narrow aisle truck
Manual platform truck
Personnel
Personnel with doors opening
in the aisle from one side
Personnel with doors opening
in the aisle from two sides
School of Engineering
Aisle Width
(feet)
12
11
10
9
6
5
3
6
8
15
Initial Layout
School of Engineering
16
Proposed Layout
School of Engineering
17
Learning Objective
Plan for sufficient aisle space for the materials handling
and human flow in a facility.
Determine the minimal space requirement of a
department based on the number of machine required,
machine footprint, minimal aisle space and maintenance
requirement
Define minimal space requirement for the facility based
on the department requirement and common aisle
requirement.
18
SCHOOL OF
ENGINEERING
Page 1 of 2
Designing an office
James is the boss of Adilas, a web design company. Apart from web design, his
company also hosts clients website and handles many confidential information.
Recently, Adilas leased a new office space. James was looking at his companys
(Adilas) organization chart and the floor plan of the new leased office. He
recalled complaints by Annie few days ago that her office seat was very
distracting. This is because her desk was near the door where every few minutes
there will be people walking past her. In addition, she mentioned that the office is
not secured without CCTV.
James is also keen to look at open office concept for the new office as he heard
it is commonly practiced in design companies.
Adilass Organization Chart
Director
- James
Web Designers
- May
- John
Office Space
IT
Henry
- Ben
- Jane
HR/ Finance
- Annie
Receptionist
- Kat
15.00
9.60
11.00
2.50
Initial_Office_Layout
.dwg
James will need to submit his office layout plan this week to the estate management
office. Prepare a layout plan for James.
Hot Desking
Sharing of workstation
Director/Presidents Office
250 to 400
23.2 to 47.2
150 to 250
13.9 to 23.2
Executive Office
100 to 150
9.3 to 13.9
80 to 110
7.4 to 10.2
Secretary/Administrator
(open space)
60 to 110
5.6 to 10.2
Reception area
11.6 to 27.9
125 to 300
10
Gates / Doors
Locks
Alarms
Warning signs
Ample lighting
Motion detectors
Inner Circle:
Smart Cards
Biometrics
Integrated:
Closed-Circuit TV
11
Solutions
12
Office structure:
Closed or Mixed
Fully open structure is not recommended
due to confidential nature of work activities
Amenities:
Meeting Room
Reception
13
14
15
Proposed Layout
2-D Plan
15.00
4.00
2.70
2.75
2.70
2.7000
IT
IT
IT
6.00
Director Office
Web Designer
11.00
HR/Finance
5.00
Reception Area
2.50
3.00
Meeting
Room
16
Learning Objectives
Define the minimal space requirement for an office facility
based on the individual work requirement and departmental
requirement
Draft a office layout plan
17
SCHOOL OF
ENGINEERING
Page 1 of 2
Automation House
Spark Industry Pte Ltd has recently secured a contract to design and
manufacture automation equipment for their customers. They will need to design,
develop and manufacture a series of automation equipment for their customers
new manufacturing processes which is scheduled to be operational in one years
time. Spark Industry plans to transfer their Research & Development (R&D)
department to a bigger premise of 14.22m x 8.23m in a new building. The R&D
engineers, designers, project manager, procurement and administrative staff
involved in the project would be stationed there. A meeting room for up to 8
people is required for the engineers to hold daily meetings.
You are tasked to develop the layout. You know that every office staff performs a
variety of tasks and it is essential to minimize unnecessary movement flows
when they work. List all your considerations in your layout design.
Initial R&D
Layout.vsd
Staff Information
Name
Belinda
Fatimah
Job title
Procurement Executive
Administrative Executive
Work tasks
Sourcing and Purchasing
Billing/Payment; Administrative matter
Dominic
Samuel
Jasper and
Carol
Mr Tan
Lewis and
Fiona
Draftsman/Draftswomen
P8 : Automation House
Relationship
Diagram
Space Requirements
Space Available
Space Relationship
Diagram
Modifying Considerations
A = Absolutely Necessary
E = Especially Important
I = Important
O = Ordinary Relationship
U = Unimportant
X = Undesirable
Relationship Chart
Relationship
Diagram
Space Requirements
Space Available
Space Relationship
Diagram
Modifying Considerations
Dominic (Mechanical)
Belinda
5
6
1
10
3
Jasper/Carol
13
14
12
11
Lewis/Fiona
Mr Tan
Fatimah
Dominic (Mechanical)
5
Belinda
1
10
3
Jasper/Carol
13
14
12
11
Lewis/Fiona
Mr Tan
Fatimah
Relationship
Diagram
Space Requirements
Space Available
Space Relationship
Diagram
Modifying Considerations
Area
(Sq meter)
Equipment
Area
(Sq meter)
Administrative :Pay
ment
Drawing Racks
Procurement
Filing Cabinets
R&D engineers (2
person)
2X4=8
Photocopy
Machine
0.5
R&D Project
Manager
Draftsman/
Draftswoman
2X3=6
Room
Area
(Sq meter)
Meeting Room
13.5
Integration
2X4=8
Engineers (2 person)
Relationship
Diagram
Space Requirements
Space Available
Space Relationship
Diagram
Modifying Considerations
13
4
11
14
12
9
10
Relationship
Diagram
Space Requirements
Space Available
Space Relationship
Diagram
Modifying Considerations
Detailed Layout
Layout within work station exact list of
equipment required for individuals to be
efficient and effective in their various roles
and responsibilities
E.g. By Job Position, By Job Function
Practical Limitations
Security
Privacy
Confidentiality
Aesthetics
Emergency evacuation
Staff welfare
Learning Objective
Know the process of layout design using systematic
layout planning
Define the minimal space requirement of a department
based on the number of equipment and personnel
Layout different departments within a facility based on
importance of relationships between departments
Draft a layout plan
20
SCHOOL OF
ENGINEERING
Page 1 of 2
Safety First
Albert has been recently appointed as a safety consultant for Pretech Pte Ltd, a
precision engineering company. Pretech employs 400 workers per shift for the
manufacturing of precision components, with the expansion plan of adding another 100
workers within the next year.
The existing factory layout is as shown below.
Initial Factory
Layout.dwg
The company has no plans for expansion of floor space however the office and the store
are not fully utilized.
Albert is tasked to assess the adequacy of the companys first aid and welfare provisions
in view of the increase in workers hired. How can Albert ensure that adequate provisions
are provided?
School of Engineering
Personnel Requirements
Objectives:
Provide an interface between work and private time
Improve safety and health at workplace
Improve personnel productivity by improving personnel
morale
Location factors:
Near toilets
Near lifts and main passageways
Accessibility to work area
Accessibility to car park
- near toilet
- near entrance
to factory floor
2) Provide
additional four
more First Aid
Kit. Change First
Aid Kit to Type C
10
12
Lesson Objectives
Plan for safety and welfare provision for workers
Recognize the benefits of maintaining safety and health in workplace
Identify personnel provisions in workplace that can help achieve
safety, health in workplace, as well as improve workers productivity
Know the key areas of personnel provision that are governed by
government guidelines and regulations, and the authorities
controlling them
13
SCHOOL OF
ENGINEERING
Page 1 of 2
Handling Systems
Peter works as a warehouse assistant manager for a pharmaceutical company.
Due to expansion, he has been tasked to implement an automated material
handling system, including the safety aspects, at another new distribution
warehouse.
He was provided with the following requirements by his manager:
a. The warehouse should be designed to handle high volume of
pharmaceutical products in small load and unit load such as packed
capsules and drugs with high inventory turnover to maximize the scarce
space of the new warehouse
b. The items should be sorted out properly according to customers during
storage and to be later retrieved easily at the pick deposit station via a
conveyor for packing before pushing them to the unitizing areas.
c. Footprint Area of Warehouse (L x W): 20 m x 20 m
d. Footprint Area of miniload AS/RS (L x W) = 6 m x 2.15 m
e. Footprint Area of Walkie Stacker (L x W) = 2.20 m x 1.18 m
Help Peter plan a layout for an appropriate automated material handling system
for storage and materials handling warehouse facility based on the above
requirements and the below material handling planning chart he has come up
with.
E212-P10-Handling E212-P10-Warehous
Procedures.xls
e.vsd
Material Handling
Is the art and science of moving, storing, protecting
and controlling material.
Means providing the:
Standardization
Principle
Work Principle
Ergonomic
Principle
Unit Load
Principle
System Principle
Automation
Principle
Environmental
Principle
Unitizers
Stretchwrap, Palletizers
Containers and
Unitizing Equipment
Material
Handling
Equipment
Material Transport
Equipment
Operator-to-Stock
Storage
Storage and
Retrieval Equipment
System
Stock-to-Operator
Pallet / Unit
Retrieval
System
School of Engineering
Pallet / Unit
Quantity
Automated Guided
Vehicles (AGVs)
Hand Trucks
Power Trucks
Distance
School of Engineering
Such classification systems are not mutually exclusive, that is, the
same conveyor can convey both bulk and unit materials, and can be
located overhead or on the floor
Bulk materials such as grain, dry chemicals, etc. might be conveyed
using flat-belt, chute or vibrating conveyors
Unit materials such as machined parts, materials in carton boxes, etc
might be conveyed using roller, trolley or flat-belt conveyors
Conveyors characterize the product line layout in a continuous
manufacturing environment
School of Engineering
School of Engineering
Unit Load
Operator-to-Stock
Storage Systems
Stock-to-Operator
Storage Systems
Pallet/Unit Storage
Systems
Pallet/Unit Retrieval
Systems
Bin shelving
systems
Modular storage
drawers/cabinets
Gravity flow rack
Space saving
systems
Mezzanines
Mobile storage
systems
Carousels
1. Horizontal
2. Vertical
Miniload
Automated storage
and retrieval
(AS/RS)
Block stacking
Pallet stacking
frames
Single-deep pallet
rack
Double-deep pallet
rack
Drive-in rack
Drive-thru rack
Flow rack
Push-back rack
Mobile pallet rack
Cantilever rack
Walkie stackers
Counterbalanced
lift trucks
Straddle trucks
Straddle reach
trucks
Sideloader trucks
Turret trucks
Hybrid trucks
Automated storage
and retrieval (AS/RS)
machines
School of Engineering
10
School of Engineering
School of Engineering
13
Miniload AS/RS
Front
View of
AS/RS
Miniload AS/RS
School of Engineering
14
School of Engineering
15
School of Engineering
Suggested Solution
P10: Handling Systems
19
Unit Load
Operator-to-Stock
Storage System
Stock-toOperator Storage
System
Pallet/Unit
Storage System
Pallet/Unit
Retrieval System
Shelf/ Rack
Miniload
Automated
storage and
retrieval (AS/RS)
Walkie stacker
School of Engineering
20
Proposed Layout
Storage
Area
AS/RS
AS/RS
AS/RS
Manual
Pallet Jack
Pallet
Operator A
Operator
B
Packing
Area
Conveyor
Operator
D
Operator
C
Flow Rack
Operator F
Walkie Stacker
Operator
E
Shelf / rack
Fire extinguisher,
First aid box,
Safety boots &
helmets
Unitization
Operator G
Shipping
Area
21
Learning Objective
Know the objectives of selecting material
handling equipment
Know the different types of material handling
equipment and evaluate their suitability for
the function required
Incorporate the considerations on material
handling equipment for layout planning
22
SCHOOL OF
ENGINEERING
Page 1 of 2
Optimizing Space
Bookworld Pte Ltd is a book distributor that distributes different types of books for
local publishing houses in Singapore. Recently they secured business deals with
overseas publishers to distribute their books in the country.
Bookworld Pte Ltd has a small warehouse in an industrial estate which has just
enough storage capacity to support its existing customers. Currently, the space
standard for determining the effective use of space in the warehouse exceeds
300 cubic feet per unit load.
Bookworlds management has decided not to expand the existing warehouse
floor space. The Operations Manager is tasked to increase the existing
warehouse storage by achieving a space standard of 300 cubic feet per unit load.
The warehouse presently employs 1-ton forklifts for material handling.
Below is the existing layout:
Warehouse Layout
A.dwg
Rack type:
Rack size:
Max stack height:
Unit load dimensions:
Storage quantity (Max):
Pallet Rack
12 feet (length) by 4 feet (width)
17 feet
4 feet (width) by 4 feet (depth) by 3.3 feet
(height)
5 unit loads per stack
Warehousing Storage
Storage and warehousing resources are space,
equipment and personnel.
In designing storage and warehousing systems, it is
desirable to maximize:
a.
b.
c.
d.
e.
Space utilization
Equipment utilization
Labor utilization
Material accessibility
Material protection
Warehousing Storage
Example of a Storage Analysis Chart used in calculating space requirements
Warehousing Storage
There are 2 major material storage philosophies:
1.
2.
Warehousing Storage
A space standard is the volume requirement per unit load stored
to include allocated space for aisles and non-usable space.
Total warehouse volume = Storage space + Aisleway space +
Non-usable space
Space standard = Total warehouse volume /Total unit load quantity
10 additional racks
can be added.
3.
Lesson Objectives
Determine the storage area profiling based on storage
capacity required and types of unit load
Achieve additional warehouse storage capacity through
facilities re-layout.
19
SCHOOL OF
ENGINEERING
Page 1 of 3
Docking Arrangement
Autosmax Pte Ltd is a Distribution Centre (DC) for automotive engineering
products. Due to business expansion, there has been an increase in the volume
of shipment in recent months. The existing receiving and shipping department is
facing difficulty in managing the incoming and outgoing goods of the Distribution
Centre. Recently, there have been incidents where goods are mixed up and
wrong parts are shipped to the customers. Below is the layout of the storage and
warehouse department in the Distribution Centre.
Security Office
OFFICE
81'-6 9/16"
12'-0"
10'-9"
46'-0"
Incoming and
shipment
STORES AREA
Storage Container
Storage Container
Staging Area
Control Station
WAREHOUSE
Storage Container
Storage Container
WAREHOUSE
Existing FacilityA.vsd
There is a central docking bay in the company that supports up to two 40 ft trucks
at any point of time. Currently, all the incoming and outgoing shipment will need
to go through this central docking bay.
At the present moment, your distribution centre is able to handle 10 container
trucks with arrival time following a Poisson distribution which arrived in a Poisson
fashion. The distribution centre operates on an 8 hours day. The loading and
unloading time for each truck is exponentially distributed with a mean of 30
minutes. The chance of a truck having to wait for it turns to berth is less than 5%.
SCHOOL OF
ENGINEERING
Your company management wants to re-layout the existing receiving and
shipping areas to triple the handling capacity of trucks while maintaining the
service level.
The storage containers as well as the car park lots can be reduced to cater for
additional space. However, for security reasons, transportation access located on
one side of the facility will remain unchanged.
You are tasked to a work team for this re-layout project. A meeting with
management has been scheduled in a weeks time, to look into dock location and
the type of dock configurations to use.
Prepare the discussion materials for this meeting.
Page 3 of 3
Warehouse Functions
Analysis Chart
Example of an Analysis Chart
For finger dock, if tractors will be disconnected when the container is parked,
decrease the required apron space shown in the table by 7.3, 6.7, 5.6 and 4.2
meters for 15, 30, 45 and 60 degrees respectively.
Dock location
Space between
R and S
Point-of-use
Not Used
Point-of-use
Centralized
Not used
Used
Mean Number of
Trucks per Calls per
30mins interval
Total
Number of
Docks
Probability of
waiting
30
1.875
0.2895
30
1.875
0.1211
30
1.875
0.0421
With four docks, the probability of a container truck having to wait its turn at the
Distribution centre is 4.21%.
(11)
Lesson Objectives
Identify different types of dock layout
Identify the physical constraints posed by a particular
building design/ layout
14
SCHOOL OF
ENGINEERING
Page 1 of 2
You are the newly appointed Facilities Maintenance Manager for a theatre in the
city centre. Your duties include identifying and establishing strategies for
equipment replacement, outsourcing of services and budgeting.
One of the main equipment in the theatre is its Audio and Visual (AV) system.
The current AV system is reaching the end of it 10 years service life. There have
been several incidents of the AV system breakdown in the past year and the AV
vendor has to be activated for urgent repair as in-house technicians are unable to
resolve. The servicing and maintenance cost over the past year obtained from
records is $25,000 while running costs every year is $10,000.
You have been quoted $200,000 by the vendor for a replacement AV system of
equal capability. The estimated servicing and maintenance costs for the
replacement AV system will be at $10,000 per annum. The new AV system is
expected to incur 15% less running cost per year. You have also managed to
find a bank loan for the capital cost at 6% per annum over 5 years period for the
new AV system.
Alternatively, the AV vendor has proposed to lease an AV system to the theatre
at $50,000 per annum. The vendor will take care of all breakdown repairs and
maintenance cost.
What will be the most viable option for the theatres AV system based on
maintenance strategies? Justify your selection.
Facilities Maintenance
- Refers to all the work activities that need to be carried out to keep a
facilitys systems functioning well
- Objective is to ensure system capability at minimal cost
- Examples of maintenance works:
a) in-house maintenance
b) service contract
c) centralized or de-centralized management
d) scheduling of equipment service or inspection
e) preventive maintenance
f) individual or group replacement
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Facilities Maintenance
- Key terms used in facilities maintenance:
a) Reliability (R)
- probability that an item will function for a given time
b) Mean Time Between Failures (MTBF)
- average time between failures of a repairable item
c) Failure Rate (FR)
- reciprocal of MTBF
- Some tactics for good facilities maintenance:
a) constantly improve repair capabilities
b) implement preventive maintenance where feasible
c) improve equipment reliability
d) always cater redundancy for critical equipment
Facilities Maintenance
Breakdown Maintenance
- Remedial, responsive
- Non-routine servicing
- Trigger: equipment failure
versus
Preventive Maintenance
- Pre-emptive, averts failure
- Regular inspection and servicing
- Basis: schedule, control charts
Proposed Solution
Assumption for this calculation
Maintenance Cost, Service Cost and Running Cost remain constant
Tax Benefits and Depreciation is not taken into accord for this
calculation.
Proposed Solution
Capital Cost per annum over 5 year for new AV system
Given that the new AV system costs $200,000 at 6% interest.
The cost per annum over a period of 5 year will be
Method 1: Use relation A=P(i(1+i)n/[(1+i)n -1])
A = $200,000((0.06) *(1+0.06)5/[(1+0.06)5 -1]) = $47,479
Method 2: Use table
A = P[A/P , 6%, 5]=$200,000(0.2374) = $47,480
Method 3: Excel Financial Function
A = PMT (6/100, 5, 200000, 0, 0) = ~$47,479
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Proposed Solution
Cost Analysis
Calculate cost per annum for each option.
Lease AV
System ($)
New AV
System ($)
Variance ($)
Capital cost at 6%
over 5 years p.a.
Nil
47,479
47,479
Servicing and
Maintenance
Nil
10,000
10,000
Running Costs
10,000
8,500
-1,500
Leasing
Agreement with
AV vendor
50,000
-50,000
Total Costs
60,000
65,979
5,979
Proposed Solution
Conclusion
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Lesson Objectives
Know the importance of break down maintenance and preventive
maintenance in facility planning
Selecting suitable Maintenance Approach
Calculate the facility maintenance cost and select an appropriate
maintenance plan based on facility objective(s)
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SCHOOL OF
ENGINEERING
Page 1 of 2
Car Park
Geo medical, a pharmaceutical company based in Australia has decided to build a
flatted factory in Singapore to support their Asian market. The factory building occupied
350m x 50m. A team from the company is tasked to work on this new project.
Kenneth being part of the team was tasked to design the car park 50m x 35m layout for
the new factory. However he is not familiar with the Singapore car park guidelines and
the only information he knows was the factory was conveniently accessible by public
transport.
What advice and car park layout would you recommend him based on the given layout
plan.
Initial_Drawing.vsd
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Factory
(a) Factory includes office, up to
25% of total floor area, canteen
and ancillary storage
(i) Flatted Type
All dimensions in mm
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All dimensions in mm
Parking Aisle
A parking aisle refers to an access lane or driveway with
adjacent parking stalls.
Parking angle is the angle measured between the longer
side of the parking stall and the line of traffic flow of the
aisle.
Traffic Flow refers to the direction of vehicle movement.
Parking Angle
Traffic Flow
Parking Aisle
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Parking Configurations
90o Parking
Angled Parking
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Parallel Parking
All dimensions in mm
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All dimensions in mm
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Other Considerations
Increasing the area provided for parking decreases
the amount of time required to park
Angular configurations allow quicker turnover
Perpendicular parking often yields greater space
utilization, although it also requires wider aisles
As the angle of a parking space increases, so does
the required space allocated to aisles
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Proposed Solution
Based on parking provision standards,
Minimum car lots = (350 x 50)/350
= 50
Minimum Handicapped stalls
=2
Recommended
Parking stalls allocation is as follows:
Motorcycles stalls 26
Standard car stalls 60
Handicapped stalls 2
Reserved stalls 2
Proposed
Solution
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Learning Objectives
- Know the dimensions requirements for different
vehicles in a parking facility
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SCHOOL OF
ENGINEERING
Page 1 of 2
The new Asia-Pacific Youth Games will be held in two years time and your
Polytechnic has been selected as one of the venues for the sports event.
You are tasked to review the existing facility plan of the Sport Complex in your
Polytechnic with regards to its location, layout type, sport facilities and
maintenance.
How will you present your evaluation report? What other considerations do you
need to look into?
How could the existing facility layout be improved to cater for the upcoming
games?
sports_complex_map
.pdf
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Facility
System
Design
Facilities
Planning
Facilities
Design
Layout
Design
Handling
Systems
Design
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Transportation facilities
Labour climate
Quality of life
Government
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1. Fixed-position
2. Product
3. Process
4. Cellular
5. Mixed
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Facility Systems
1) Structural System: Refers to the steel skeleton frame or reinforced concrete
skeleton frame used in most industrial facilities
2) Enclosure System: Refers to the floor, walls and room within a facility
3) Atmospheric System: Refers to systems for heating, ventilation and airconditioning that control the temperature, humidity and cleanliness of a facility
4) Electrical and Lighting System: Refers to electrical mains, switchgear,
transformers, feeders, panel boards and circuits
5) Life Safety System : Refers to systems that are designed to control
emergency situations created by fire, seismic events and power failure
6) Sanitation System : Refers to refuse handling system and plumbing
system
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Gates / Doors
Locks
Alarms
Warning signs
Ample lighting
Motion detectors
Inner Circle:
Smart Cards
Biometrics
Integrated:
Closed-Circuit TV
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Weakness:
- Small Parking lots for coach buses and cars.
- Not able to support Track and Field events due to lack of tracks.
- Need to relook into the flow of human traffic during big events.
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Lesson Objectives
Identify the strengths and weakness of an existing layout
Prepare an evaluation report for an existing layout plan
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