Professional Documents
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ENGINEERING
DIPLOMA IN
INDUSTRIAL & OPERATIONS
MANAGEMENT
All rights reserved. No part of this document may be reproduced, stored in a retrieval
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
E212 Facilities Planning and Design
School of Engineering
Facilities Planning and Design
Facilities planning is a complex and broad subject that cuts
across several engineering disciplines - civil, electrical,
industrial, mechanical, etc.
School of Engineering 2
Objectives of Facilities Planning
Effectively utilizing people, equipment, space, energy
School of Engineering 3
Motivations for Facility Planning
3. Energy conservation
School of Engineering 4
Facilities Planning Hierarchy
Facilities planning covers both facilities location and facilities
design.
Facilities
Location
Facility
System
Design
Facilities
Planning
Facilities Layout
Design Design
Handling
Systems
Design
School of Engineering 5
Facilities Location
Facilities location refers to the place with respect to
customer, suppliers and other facilities with which it
interfaces.
School of Engineering 6
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 7
Facilities Planning Process
Applying the engineering design approach:
Steps
1. Define the problem
Define (or redefine) the objective of the facility
Specify the primary and support activities to be performed
in accomplishing the objective
2. Analyze the problem
Determine the inter-relationships among all activities
3. Determine the space requirements for all activities
Generate alternative facilities plans
School of Engineering 8
Facilities Planning Process
School of Engineering 9
Facilities Design
School of Engineering 10
P01 Sample Solution
School of Engineering
Sample Solution
School of Engineering 12
Sample Solution
Visual Art Gallery
Purpose: Showcase art pieces for visitors
School of Engineering 13
Sample Solution
Facilitation/Conference rooms
School of Engineering 14
Sample Solution
A video library
Purpose: Place for video storage and retrieval of art and culture material and
discussion
School of Engineering 15
Sample Solution
An open-air cafeteria
School of Engineering 16
Learning Objective
DIPLOMA IN
INDUSTRIAL & OPERATIONS
MANAGEMENT
All rights reserved. No part of this document may be reproduced, stored in a retrieval
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
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
E212 Facilities Planning and Design
P02 Location! Location!
Location!
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.
2
Type of Analysis
Macro analysis
Micro analysis
To evaluate specific sites in the selected community
3
Factors Affecting Location Selection
Regional factors
International Company = country
National Company = section of country or state
Local Company = country or city
Market location
Important for service firms / manufacturers of fragile or perishable goods
Cost of shipping to customers
Firms that are suppliers for JIT process
Customer identification with firm due to proximity
Location of competitors
Raw material and supplier proximity
For example, manufacturers that use perishable raw materials locate near
source
4
Factors Affecting Location Selection
Transportation facilities (less important now than before 1950s)
Airports, Seaports, Highways.
Labour climate
Labour force is crucial to operation of the firm
Availability: large pool
Skills must match needs of firm
Cost: wage rate in that area; level of unionization
Quality of life
- Customer profile
Government
Taxes & Incentives
5
Factors affecting Site Selection
Typical engineering considerations
Sufficient land to build and expand
Availability of utilities / infrastructure
Waste disposal
Transportation access
Legal and other impediments
Proximity to supporting industries
Land Zoning
6
Factor Analysis Technique
7
FAT Example
Weight Factor Perth Kuala Bangkok Jakarta
Lumpur
0.30 Lease Cost 80 70 60 65
0.10 Competition in 75 65 70 65
area
0.25 Suitability of 85 80 75 90
location
0.10 Customer profile 70 75 70 85
W=1
8
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
9
Example of a Hierarchy Structure
10
An Example of Pairwise Comparison
of Factors
Assuming that there are 3 factors: Cost, Availability and
Human Traffic
11
An Example of Pairwise Comparison of
Alternatives
Assuming that there are 3 alternatives: RP, CP and WM
12
Problem Objectives
13
Factors for F&B Outlet
(Theme Resturant)
More emphasis placed on the customers and location:
1) Customers Volume drive sales
2) Strategic Location (where the place is located)
3) Operation/ Lease Cost
4) Business Sustainability (Long-term survival)
5) Availability of location (Tenure)
6) Accessibility to complementary business / supplies
7) Surrounding Business (Compete vs Complementary)
8) Customers profile
14
Choose Jakarta
Using FAT
Weight Factor Perth Bangkok Kuala Jakarta
Lumpur
4) Select pairwise to
enter numeric pairwise
comparison of factors
16
Expert Choice Solution
17
Conclusion
Angie can use Factor Analysis Technique (FAT) or
Analytical Hierarchy Process (AHP) to help her select
suitable location for her restaurant.
18
Learning Objective
DIPLOMA IN
INDUSTRIAL & OPERATIONS
MANAGEMENT
All rights reserved. No part of this document may be reproduced, stored in a retrieval
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
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.
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:
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
E212 Facilities Planning and Design
School of Engineering
Layout Decisions
The need for layout decisions:
2
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
3
Layout Types
1. Fixed-Position Layout
4
Layout Types
An example of Fixed-position layout: Ship building
5
Layout Types
2. Product Layout
6
Layout Types
An example of Product layout: Product Assembly Line
7
Layout Types
3. Process Layout
8
Layout Types
An example of Process layout: Components machining
9
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
Different Approaches to Layout
Planning
Systematic Layout Planning (SLP Procedure)
Apples Plant Layout Procedure
Reeds Plant Layout Procedure
13
Systematic Layout Planning (Muthers)
Input Data and Activities
Analysis
1. Flow of Materials 2. Activity Relationships
3. Relationship Diagram
Search
7. Modifying Considerations 8. Practical Limitations
Selection
10. Evaluation
14
P03 Sample Solution
Problem Objectives
Analyze a product and determine the process flow in
manufacturing of the product
16
Sample Solution
Some essential questions for Jason
17
Sample Solution
Assumptions when recommending layout type to use
18
Sample Solution
A suitable kitchen layout for Jason
19
Developing the layout
In process layout, it is important to reduce the flow of materials in the facility
2 departments with high flow between them should be situated close
together
It is therefore necessary to know the material flow and activity relationship
between departments
The space required for each department have to be ascertained based on:
Equipment (Number of equipment required has to be worked out)
Aisle space
Maintenance/ servicing space
A space relationship diagram can then be developed and detailed layout of
equipment done upon considering practical limitations and other modifying
considerations
Various alternatives can be generated before the best one is chosen
20
Sample Solution
Process layout for the Kitchen Food
Collection
Drink
Washing Counter
& Cleaning Cutting and Preparation Toasting
Kitchen Kitchen Kitchen Kitchen Toaster
Sink Top Top Top
Assembly
Assembly bench
Mixing Grilling
Assembly bench
Small mixer Griller Griller
21
22
23
Learning Objective
All rights reserved. No part of this document may be reproduced, stored in a retrieval
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
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.
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 Equipment Footprint Time/Cycle
number description (m2) Output/Cycle (sec) Description
1 Bread Toaster 1.0 x 1.0 2 60 Machine station, single operator
2 Grilling station 2.0 x 1.0 4 200 Machine station, single operator
Condiments Cabinet/
3
Storage Shelf 3.0 x 1.0 - - Non-workstation, for materials
Sink and Assembly
4
Work desk 2.0 x 1.0 1 20 Manual station, single operator
5 Wrapping Work desk 1.0 x 1.0 1 12 Manual station, single operator
6 Mixing Station 1.0 x 1.0 8 220 Manual station, single operator
Sandwich Picking
7
Station 1.0 x 1.0 - - Non-workstation, for picking
8 Storage Area 1.0 x 1.0 - - Non-workstation, for materials
9 Drink Dispenser 1.0 x .1.0 2 15 Manual station, single operator
10 Cashier 3.0 x 1.0 - - Manual station, 1 to 3 persons
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?
7000.00
2000.00
2000.00
2000.00 2000.00
2000.00
2000.00
Kitchen Layout
3000.00
Kitchen Layout (dimension in mm)
Page 3 of 3
E212 Facilities Planning and Design
2
Flow within a facility considering the
locations of entrance and exit
At the same location
On adjacent sides
3
Flow within a facility considering the
locations of entrance and exit (contd)
On the same side but
at opposite ends
On opposite sides
4
Vertical Flow Pattern
Flow between buildings exists and the Ground level ingress (entry) Ground level ingress (entry) and egress
connection between buildings is elevated and egress (exit) are required (exit) occur on the same side of the building
Travel between floors occurs on the Some bucket and belt conveyors and Backtracking occurs due to the
same side of the building escalators result in inclined flow return to the top floor
5
Flow Patterns (between departments)
6
Flow Patterns (within department)
The flow pattern within departments depends on the
type of department.
In a product and/or product family department, the
flow follows the product flow.
1 machine/operator 2 machines/operator
1 machine/operator
More than 2
machines /operator
1 machine/operator
Flow Pattern (within department) (contd)
8
Flow Patterns: Flow within Workstation
10
Uninterrupted Flow Path
11
Flow Analysis Information
A. Product Structured Parts List
- Provides a listing of all component/parts of a product, includes part
name, part number, drawing references, quantity of parts
- Product structure is a hierarchy referring to the level of product
assembly: such as final product, sub-assemblies.
- Product Structure information and Structured Parts List will make
up the Bill of Materials
B. Operation Process Chart
- Presents information on production method and assembly flow of
the product
- Differentiates between in-house produced part and purchased part
- Can also include information on raw material used, operation
times, inspection stations
12
Flow analysis information
C. 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
Flow Dominance Measure (FDM)
Notation:
M: number of activities.
Nij: number of different types of items moved between activities i and j.
fijk: flow volume between i and j for item k (in moves/time period).
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
Flow Dominance Measure (contd)
fU f '
Flow dominance measure = f=
where
fU fL
1
M M 2 2 2 2
w
i 1 j1 ij M w
M 2
1
M M
w ij
i 1 j 1
f' , w=
w M2
1 1
M2 M 1 2 1 2
fU M , fL M
(M 1)(M 1)
2 2
(M 1)(M 1)
15
Flow Dominance Measure (contd)
Three cases:
f 0 (a few dominant flows exist) product layout
can use operations process chart as starting point for developing
layout and material handling system design
quantitative measures principal source of activity relationship.
f 1 (many nearly equal flows exist)
any layout equally good with respect to flows .
qualitative measures principal source of activity relationship.
0 << f << 1 (no dominant flows exist) difficult to develop layout
process or product family layout .
both quantitative and qualitative measures important source of
activity relationship.
16
Equipment Requirements Planning
Equipment Capacity Table
17
P04 Sample Solution
18
Flow Analysis Information
Part Number Part Description Part Type
Structured Parts List RA00001
RA00002
Bread Loaf
Turkey slice
Raw material
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 Thousand Island Dressing
Raw material
RC00001 Lemon Tea in barrel Raw material
RC00002 Ice Raw material
PA00001 Sandwich wrapper Packing
PA00002 Salad box Packing
PA00003 Cups Packing
SA00001 Sandwich without wrapper
Sub assembly
FA00001 Wrapped sandwich Finished goods
FA00002 Salad Finished goods
FA00003 Cups of Lemon Tea Finished goods
19
Flow Analysis Information
Operations Process Chart
Turkey Slice Bread Loaf
Honey Mustard Mayonnaise Lettuce Tomato Olive Pickles
RA00002 RA00001
RA00010 RA00009 RA00008 RA00007 RA00006 RA00005
O-13 Chill O-12 Chill O-10 Wash O-08 Wash O-06 Peel O-03 Preserve O-02 Grill O-01 Toast
O-04 Bottle
O-05 Store
SA-01
Sandwich Wrapper
PA00001
SA-02
O-14 Mix
Salad Box
PA00002
Ice
RC00002 Lemon Tea in a Barrel
RC00001
SA-05
Cup
PA00003
20
Flow Analysis Information
Part Number Part Description Machine Routing
21
From-To Chart (Shows the flow volume)
From 1 2 3 4 5 6 7 8 9 10
To Sample calculation
From storage (Bread) to toaster:
1 =164/3 133 set of meals and 31 sandwiches per
= 54.7 hour (3 bread loaves toast per batch)
2 7.6
3
4 54.7 7.6 94.9 9.8
5 41 6.6
6 24 7.6
7 82
8
9 4.5
10 95 82 78
22
From-To Chart (Shows the equivalent flow
volume) Taking into account of difficulty
of move
From 1 2 3 4 5 6 7 8 9 10
To
1 54.7
2 7.6
3
4 54.7 7.6 94.9 9.8
5 42 6.6
6 24 7.6
7 82
8
9 =2x3.87
Sample calculation 5 + 0.62
Assuming moving lemon tea barrel is
=8.4
twice as difficult, 1 trip with barrel = 2
trips of other items = 3.875 x 2
10 95 82 78
Moving cups is as per normal
23
Flow Dominance Measure (f)
1
M M 2 2 2
2
w
i 1 j1 ij M w
M 2
1 = 3.14658 w ij
M M
i 1 j 1
= 6.539
f
'
, w= 2
w M
1 1
M M1
2 2 1 2
fU M , fL M
(M 1)(M 1)
2 2
(M 1)(M 1)
= 3.1958 = 0.335
24
Flow Dominance Measure (f)
fU f '
= 0.01721
fU fL
25
Minimum Equipment Requirement
Time/Cycle Gross Material Equipment Net Equipment
Equipment (sec) Output/Cycle Output/hr Scrap Efficiency Output/hr Required
Burger Picking - - - - - - 1
Storage Area - - - - - - 1
Cashier - - - - - - 1
26
Between Stations Flow
From 1 2 3 4 5 6 7 8 9 10
To
1 54.7 54.7
2 7.6 7.6
3 94.9 24
4 41 9.8
5 82 6.6
6 7.6 95
7 82
8 8.4
9 78
10
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
All rights reserved. No part of this document may be reproduced, stored in a retrieval
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
Page 1 of 3
SCHOOL OF
ENGINEERING
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.
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.
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.
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
E212 Facilities Planning and Design
A = absolutely necessary 5 %
E = especially important 10 %
I = important 15 %
O = ordinary closeness 20 %
U = unimportant 50 %
X = undesirable 5 %
2
Relationship (REL) Chart
A number of factors other than material handling flow (cost) might be of
primary concern in layout.
A Relationship (REL) Chart represents M(M-1)/2 symmetric qualitative
relationships, i.e.
3
Example of REL Chart for a Hospital
4
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
5
Total Closeness Rating
For each department, the Total Closeness Rating
(TCR) is the sum of the values of the relationships
with other departments
Department Summary
Department 1 2 3 4 5 6 7 8 9 A E I O U X TCR Order
1. Reception U E O U U U A O 1 1 0 2 4 0 152 2
2. Emergency Unit U I U A I U U U 1 0 2 0 5 0 135 3
3. Outpatients Clinic E I U U O U U E 0 2 1 1 4 0 56 6
4. Wards O U U U I O U O 0 0 1 3 4 0 8 9
5. Intensive Care U A U U E I U O 1 1 1 1 4 0 156 1
6. Surgery U I O I E U U I 0 1 3 1 3 0 41 7
7. Laboratory U U U O I U U E 0 1 1 1 5 0 31 8
8. Administration A U U U U U U O 1 0 0 1 6 0 126 4
9. Pharmacy O U E O O I E O 0 2 1 4 1 0 59 5
6
Manual CORELAP Algorithm
The manual CORELAP algorithm is an initial
process layout method which makes use of the
REL chart
The departments to be placed are selected based
on a set of criteria
The departments are then placed one by one
based on the procedures to place departments
The departments are assumed to be squares of
uniform sizes, i.e. actual shape and size are not
taken into consideration when following the manual
CORELAP algorithm
7
Selection of Departments to Place
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.
8
Procedure to Place Departments
Consider the figure on the right.
Assume that a department is placed in the middle
(position 0).
Position 1, 3, 5 or 7 is fully adjacent with
that department
Position 2, 4, 6 or 8 is partially adjacent
with that department
9
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.
10
P05 Sample Solution
11
Relationship Chart for the New
Logistics Office
12
TCR Value Computation
CV Values
V (A) 125 Choose the department
V (E) 25 with highest TCR
V (I) 5
V (O) 1
(Department 9) to
V (U) 0 start the layout
V (X) -125
Partial Adjacency (a): 0.5
Department Summary
Department 1 2 3 4 5 6 7
8 9 A E I O U X TCR Order
1. Accounts U O E I O O
U A 1 1 1 3 2 0 158 2
2. Legal U U U E U U
O U 0 1 0 1 6 0 26 6
3. Human Resource U U U U I O
O O 0 0 1 3 4 0 8 8
4. Information Technology E U U O I O
U A 1 1 1 2 3 0 157 3
5. Sales and Marketing I E U O U I
U E 0 2 2 1 3 0 61 5
6. Reception O U I I U U
U O 0 0 2 2 4 0 12 7
7. Quality Assurance O U O O I U U A 1 0 1 3 3 0 133 4
8. Facility U O O U U U U U 0 0 0 2 6 0 2 9
9. Operations A U O A E O A U 3 1 0 2 2 0 402 1
13
Department 9 with the highest TCR value is placed first.
Department 1, 4 and 7 have A relationship with
department 9. Since department 1 has the highest TCR
value among the 3, the next department to be placed is
Department 1.
Since department 1has an A relationship
62.5 125 62.5 with department 9, the box which is directly
adjacent to department 9 has WP of 125.
125 9 125
Assuming a partial adjacency factor = 0.5
62.5 125 62.5 The WP of the boxes partially adjacent to
department 9 is 0.5 x 125 = 62.5
14
Department 4 has A & E relationship with Department 1
and 9. Department 7 have O & A relationship with
Department 1 and 9. Thus, the next department to be
placed is Department 4
15
3) Placing Department 2
1) Placing Department 7 2) Placing Department 5
2.5 5 2.5 0 0 0
0.5 63.5 125.5 62.5
2.5 22.5 7 17.5 0 0 7 25 12.5
1 1 9 125.5
5 1 9 28 0 1 9 5 25
0.5 64.5 4 63.5
2.5 18.5 4 13.5 0 0 4 25 12.5
0.5 1 0.5
0.5 1 0.5 0 0 0
1 1 9 5 0 3.5 1 9 5 0 1 3 1 9 5 0.5
2.5 5 2.5 0 0 0 0 0
2.5 5 2.5
16
Initial Layout
7. Quality 2. Legal
Assurance
17
Practical Considerations
18
Ask yourself this:
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
Construction of REL chart
Manual CORELAP algorithm
20
SCHOOL OF
ENGINEERING
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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
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
E212 Facilities Planning and Design
School of Engineering 1
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 2
Parkinsons Law
School of Engineering 4
Workstation Specification - Equipment
Obtain the following information from machinery data sheets or physical
inventory check:
Equipment actual dimensions
Machine travel
Maximum travel to left and right
School of Engineering 7
Department Specification
Sum of total workstation requirements
Departmental equipment storage
Aisles space allowance between workstations
Aisle Allowance Estimates
a Expressed as a percentage of the net area required for equipment, material and personnel
School of Engineering 8
Aisle Arrangement
Departmental aisle and main aisle
Aisle Width
Types of Flow (feet)
Tractors 12
3-ton Forklift 11
2-ton Forklift 10
1-ton Forklift 9
Narrow aisle truck 6
Manual platform truck 5
Personnel 3
Personnel with doors opening in the 6
aisle from one side
Personnel with doors opening in the 8
aisle from two sides
School of Engineering 9
P06 Sample Solution
School of Engineering 10
Workstation Specification
Equipment:
4 x Sputtering machine footprint: 2410 mm X 1520 mm
footprint area
Machine maintenance area: Area at the back of machine required
maintenance
School of Engineering 11
Workstation Specification
Material:
Incoming, outgoing and storage materials:
School of Engineering 12
Workstation Specification
Personnel:
Operator: area of 1500 mm x 1000 mm
Material handling: assume on magazine holder, no extra
space
Aisle space:
Minimal 762 mm (30) aisle to travel pass through 2 stationary
objects
Minimal 914 mm (36) to travel pass stationary and moving
objects
Minimal 1067 mm (42) aisle to travel pass through 2 moving
objects
Operator ingress and egress: nil
School of Engineering 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 Aisle Allowance % a
a Expressed 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)
Aisle Width
Types of Flow (feet)
Tractors 12
3-ton Forklift 11
2-ton Forklift 10
1-ton Forklift 9
Narrow aisle truck 6
Manual platform truck 5
Personnel 3
Personnel with doors opening 6
in the aisle from one side
Personnel with doors opening 8
in the aisle from two sides
School of Engineering 15
Initial Layout
School of Engineering 16
Proposed Layout
School of Engineering 17
Learning Objective
18
SCHOOL OF
ENGINEERING
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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
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.
Director
- James
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.
E212 Facilities Planning and Design
Size / Capacity
Adequate work space
Noise / Sound level
Kept to minimum
Proximity to amenities such as lift, door, printer, etc
Productivity
Minimize walking long distances, performing useless work etc
Nature of work activities
Ergonomics
Security / Privacy
Budgets Constraint
Scalability
support business expansion / restructuring
2
Office Facility Planning
Closed office space
Presence of floor-to-ceiling partition walls (permanent/ temporary) that
segment the office space into smaller rooms
Advantages
Contains noise level well
Conducive for work tasks requiring
concentration/ confidentiality
Assures privacy for staff
Visible status recognition for staff
Disadvantages
Higher maintenance cost due to more built-in structures
and fixtures
Less flexible
3
Office Facility Planning
Open office space
No floor-to-ceiling partition walls exist
Advantages
Promotes staff interaction and communication
Facilitates supervision of staff
Lower maintenance cost
Cooling, ventilation costs are reduced
Less space is required
Layout changes are quicker and less costly
Disadvantages
May present difficulty in controlling noise
Lesser visual and aural privacy
Lacks status recognition for staff
Confidentiality
4
Recent Office Layout Trends
Trends affecting Office Layout
Hot Desking
Employees do not have their own desks
Sharing of workstation
5
Office Facility Planning
Steps
6
Office Facility Planning
Typical Area Requirements
Designation Square feet (ft2) Square meter (m2)
Director/Presidents Office 250 to 400 23.2 to 47.2
7
Office Facility Planning
Example of office space plan (2-D): Open & closed structure
8
Office Facility Planning
Example
3-D Plan
9
Office Facility Planning
Security System
10
Office Facility Planning
Examples of security measures / devices
Outer Circle: Gates / Doors
Locks
Alarms
Warning signs
Ample lighting
Motion detectors
Integrated: Closed-Circuit TV
11
Office Facility Planning
Solutions
12
Office Plan (Proposed)
Facility objective: Secured, low capacity office
13
Office Plan (Proposed)
Staffing capacity:
14
Office Plan (Proposed)
Security System: Concentric approach with integration
a) Outer circle: Doors fitted with lock and alarm
b) Inner circle: Card Reader
c) Integration: Closed-Circuit TV (round-the-clock)
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
3.00
2.50
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
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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
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
P8 : Automation House
Systematic Layout Planning : Macro Map
Data Gathered on Work & Information Flows, Volume of work flows,
Sequencing of work, and Critical Timing Issues of work
Relationship
Diagram
Space Relationship
Diagram
Selected Layout
Adapted from: Muther, Richard. Systematic Layout Planning, second edition
Relationship (REL) Chart
Any effective layout needs to start with an in-depth discussion of
work relationships.
Each of the major office tasks can be listed on the left side of the
relationship chart and related to every other task in the office.
In the relationship chart, these closeness values are placed
based on the following scale:
A = Absolutely Necessary
E = Especially Important
I = Important
O = Ordinary Relationship
U = Unimportant
X = Undesirable
Relationship Chart
Systematic Layout Planning : Macro Map
Data Gathered on Work & Information Flows, Volume of work flows,
Sequencing of work, and Critical Timing Issues of work
Relationship
Diagram
Space Relationship
Diagram
Selected Layout
Adaptedfrom:
Adapted from:Muther,
Muther,Richard.
Richard.Systematic
SystematicLayout
LayoutPlanning,
Planning,second
secondedition
edition
Activity Relationship Diagram
7 8 5 6
1 2
9 10
3
4
13 14 12
Jasper/Carol 11
Fatimah
Lewis/Fiona
Mr Tan
Initial Relationship Diagram with Tasks
Samuel
(Electrical) Dominic (Mechanical) Belinda
7 8 5 6 1 2
9 10
3
4
Jasper/Carol 13 14 12
11
Fatimah
Lewis/Fiona
Mr Tan
Systematic Layout Planning : Macro Map
Data Gathered on Work & Information Flows, Volume of work flows,
Sequencing of work, and Critical Timing Issues of work
Relationship
Diagram
Space Relationship
Diagram
Selected Layout
Adaptedfrom:
Adapted from:Muther,
Muther,Richard.
Richard.Systematic
SystematicLayout
LayoutPlanning,
Planning,second
secondedition
edition
Space Requirements for People and Tasks
Space needs for people and task are examined and discussed
during planning
A final output in terms of square feet (or meter) of space desired
for maximum productivity for each person/ task is generated
Physical Space Requirements
Personnel Area Equipment Area
(Sq meter) (Sq meter)
Administrative :Pay 4 Drawing Racks 2
ment
Procurement 4 Filing Cabinets 1
R&D engineers (2 2X4=8 Photocopy 0.5
person) Machine
R&D Project 5
Manager
Draftsman/ 2X3=6 Room Area
Draftswoman (Sq meter)
Integration 2X4=8 Meeting Room 13.5
Engineers (2 person)
Systematic Layout Planning : Macro Map
Data Gathered on Work & Information Flows, Volume of work flows,
Sequencing of work, and Critical Timing Issues of work
Relationship
Diagram
Space Relationship
Diagram
Selected Layout
Adaptedfrom:
Adapted from:Muther,
Muther,Richard.
Richard.Systematic
SystematicLayout
LayoutPlanning,
Planning,second
secondedition
edition
Draw Space Relationship Diagram
5 6 7 8 1 2
13 3 4
11
14 12
9 10
Systematic Layout Planning : Macro Map
Data Gathered on Work & Information Flows, Volume of work flows,
Sequencing of work, and Critical Timing Issues of work
Relationship
Diagram
Space Relationship
Diagram
Selected Layout
Adapted from: Muther, Richard. Systematic Layout Planning, second edition
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
Final Layout (with Equipment)
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
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ENGINEERING
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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
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.
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?
E212 Facilities Planning and Design
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
Examples of provisions: first aid, food services, locker
rooms
Extent of provisions depends on government regulations
and managements policy
In Singapore, provisions pertaining to safety and health are
controlled by legislations
Workplace Safety and Health Act
2
Facilities Planning for Personnel
Requirements
Key aspects to consider when doing facilities planning:
Locker rooms proximity to staff entrances, allocation by
gender, ventilation, traffic flow
Restrooms near work area, minimum number required,
privacy, allocation by gender
Food services number of staff, kitchen and dining area
layout, ease of cleaning, aesthetic factors,
location, ventilation
Drinking fountains quantity, location, distribution
Health services first aid room and first aid kits, location,
evacuation routes
Car parks number of staff, space utilization, traffic flow
3
The Workplace Safety and Health Act
(Singapore)
Came in effect 1st March 2006 as an essential part of the
new framework to cultivate good safety habits in all
individuals so as to engender a strong safety culture in our
workplace.
4
Guidelines To First Aid Provisions
a) Provide first aid boxes, number required according to
number of staff (1 First Aid Box A for 25 employees)
b) Provide a trained first-aider if staff number exceeds 25
c) Provide a first aid room if staff number exceeds 500,
d) Provide flushing point for chemical/toxic substances
5
Guidelines To First Aid Provisions
MOM Workplace Safety and Health Act 2006 (Second Schedule)
6
Guidelines To Provision Of First
Aid Room
Design to include: A couch for waiting patients
Moving space for people and equipment
Emergency lighting
Signboard to identify room
First Aid equipment
Total floor space
7
Guidelines To Provision Of First
Aid Room
Items required: Sink with running potable water
Paper towels
Smooth-topped working surface
Supply of sterile dressings
Stretchers
Splints
Thermometer
Couch with pillow and blanket
Wheelchairs
Personal disinfectants
Garments for first-aider
Refuse bin
Chairs
Any other special requirements
8
P09 Sample Solution
9
Location Of First Aid Facilities
1) Location for
First Aid Room
(assuming
workforce at 500)
- near toilet
- near entrance
to factory floor
2) Provide
additional four
more First Aid
Kit. Change First
Aid Kit to Type C
10
Layout Of First Aid Room
1) Design factors
- adequate moving space
- quick access for wheelchair,
stretcher and medical supplies
- bedside screen for privacy
- area for medical equipment
11
Other Welfare Provisions That Could
Be Considered
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
Know where to find the Workplace Safety and Health Act
and how to interpret them
Evaluate a facility according to its functionality, human
friendliness and accordance to government regulation
13
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ENGINEERING
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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
Page 1 of 2
Handling Systems
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
School of Engineering
Materials Handling Principles
Unit Load A unit load is one that can be stored or moved as a single
entity at one time (pallet, container or tote) regardless of
Principle the number of individual items that make up the load
School of Engineering 3
Materials Handling Principles
Life Cycle Cost Consider all cash flows from first dollar spent on
planning, procurement, installation, training to
Principle implementation until operation
School of Engineering 4
Material Handling Equipment
Pallets, Skid & Skid
Containers Boxes, Tote Pans
Containers and
Unitizing Equipment
Unitizers Stretchwrap, Palletizers
Operator-to-Stock
Storage
Stock-to-Operator
Storage and System
Retrieval Equipment
Pallet / Unit
Retrieval
Pallet / Unit
System
School of Engineering 5
Material Transport Equipment
Automated Guided
Conveyors
Vehicles (AGVs)
Quantity
Distance
School of Engineering 6
Material Transport Equipment
- Conveyors
A conveyor is a form of material transport equipment in the same
category as industrial vehicles, hoists and cranes
Conveyors are used when material is to be moved frequently between
specific points over a fixed path
Bases to classify conveyors:
The type of product being handled (bulk or unit) and
the location of the conveyor (overhead or floor)
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 7
Main Conveyor Types
1. Flat-belt conveyor
A wide belt pulled over a flat framework or rollers by a driving pulley, with the slack taken up
by a driven pulley
The belt can be made from rubber or fabric, or composed of slats or wire mesh, depending
on application requirements
2. Roller conveyor
Commonly used for packaged materials or materials on pallets
The minimum package size is 2 roller width
Gravity rollers (non-powered) can be applied for slight inclines
Conveyor can be powered by running a belt below the rollers
3. Trolley conveyor
Built on I-beam, acting as the track, like a monorail
The lower flange supports wheeled trolleys spaced at regular intervals via a chain
The chain is pulled at constant speed by a drive mechanism located along the conveyor route
Material is moved by placement on hooks, racks, hangers, etc attached to wheeled trolleys
Can act as in-process storage due to conveyor variable height characteristic
The conveyor forms a (variable height) loop within the plant, eventually returning to its
starting point
School of Engineering 8
Material Transport Equipment
- Main Conveyor Types
Flat-belt Roller Trolley
School of Engineering 9
Storage and Retrieval Equipment
Small Load Unit Load
Operator-to-Stock Stock-to-Operator Pallet/Unit Storage Pallet/Unit Retrieval
Storage Systems Storage Systems Systems Systems
School of Engineering 10
Operator-to-Stock Storage System
- Example: Space Saving System (Mezzanine)
School of Engineering
Operator-to-Stock Storage System
- Example: Space Saving System (Mezzanine)
School of Engineering
Stock-to-Operator Storage System
- Example: Automated Storage/Retrieval System
Computer algorithms in the AS/RS control computer determine
storage locations such that total distance traveled is minimized.
When storing materials/parts, the system delivers the items to an
open random location appropriate for the characteristics (i.e.
size, weight, etc.) of the items and records the location for future
reference so that the items may be retrieved.
The items retrieved are accumulated at a staging area, where
they are transferred to various materials handling devices for
delivery to other work areas.
Use AS/RS to
Increase storage capacity
Improve productivity
Improve safety
Improve security
Better inventory control
Increase throughput
School of Engineering 13
Stock-to-Operator Storage System
- Example: Automated Storage/Retrieval System
Miniload AS/RS
Front
View of
AS/RS
School of Engineering 14
Stock-to-Operator Storage System
- Example: Automated Storage/Retrieval System
(Miniload)
School of Engineering 15
Pallet Storage System
- Example: Flow Rack
School of Engineering
Pallet Storage System
- Example: Flow Rack
Based on a First-In-First-Out
(FIFO) concept
As the load is removed from the
front of a storage lane, the next
load advances to the pick face.
High-throughput unit storage and
retrieval and good space
utilization
Used for items with high
inventory turnover and with
several units on hand
School of Engineering
Pallet Retrieval System
- Example: Walkie Stacker
Operator steers from a walking
position behind the vehicle
Can stack loads 3 loads high
Offers both pallet retrieval/putaway
and truck loading/unloading
Advantage: Low cost
Disadvantage: Short distances
Used when low throughput, short
travel distances and low vertical
storage height and low cost
requirements
School of Engineering
Suggested Solution
P10: Handling Systems
19
Todays Problem (Handling Method)
1. Peter had applied the Planning Principle when selecting a material
handling method.
2. He planned in a conveyor as the material transport equipment for
small load product.
- The conveyor (floor) can be designed with an angle of elevation
by increasing the friction factor.
3. He had also planned in the following storage and retrieval systems:
Small Load Unit Load
Operator-to-Stock Stock-to- Pallet/Unit Pallet/Unit
Storage System Operator Storage Storage System Retrieval System
System
Shelf/ Rack Miniload Flow rack (FIFO Walkie stacker
Automated concept)
storage and
retrieval (AS/RS)
School of Engineering 20
Proposed Layout
Storage
Area
Manual
Pallet Pallet Jack
Operator A
Conveyor
Operator Operator Unitization
B D
Flow Rack Operator F
Packing
Area Walkie Stacker
Operator
C Operator
E
Operator G
Shelf / rack
Shipping
Fire extinguisher,
First aid box, Area
Safety boots &
helmets
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
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ENGINEERING
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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
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.
Warehouse Layout
A.dwg
a. Space utilization
b. Equipment utilization
c. Labor utilization
d. Material accessibility
e. Material protection
Warehousing Storage
Example of a Storage Analysis Chart used in calculating space requirements
Warehousing Storage
There are 2 major material storage philosophies:
Tractors 12
3-ton Forklift 11
2-ton Forklift 10
1-ton Forklift 9
Narrow aisle truck 6
Manual platform truck 5
Personnel 3
Personnel with doors opening in the aisle 6
from one side
Personnel with doors opening in the aisle 8
from two sides
Aisle Types (Lift Truck Classification)
Wide Aisle and Narrow Aisle trucks are designed to turn in the aisle
while Very Narrow Aisle trucks do not turn within the aisle
Wide Aisle
Standard forklifts fall into this category of trucks designed to work
in aisles greater than 11' wide.
Narrow Aisle (NA)
Narrow aisle trucks operate in aisles of 8' to 10' and are
generally stand up vehicles such as Reach Trucks.
Very Narrow Aisle (VNA)
Very narrow aisle trucks operate in aisles less than 6' and often
use guidance systems (wire, rail, or optical) to travel within the
aisles
Other Considerations (Material Handling
Selection)
Assumptions:
1.The office, toilet, receiving pallets area, outgoing pallet areas are
non-usable space
2.Forklift can be parked at any aisle in the warehouse.
3.Storage assignment is not location-specific
4.Total horizontal clearance allowance between stacks is 2 feet for
whole length of rack (12 feet)
Present Warehouse Layout
Total storage space (based on 17 feet stack height)
= Individual rack volume x Number of racks
= 12 x 4 x 17 x 24
= 19584 cubic ft
10 additional racks
can be added.
Proposed Warehouse Layout
Storage quantity per 17 stack = 5 unit loads
Number of stacks per 12 rack = (12 / 4) - 1 = 2
Total number of racks = 34
Assumptions:
1.The office, toilet, receiving pallets area, outgoing pallet areas are
non-usable space
2.The narrow aisle truck is within the specifications
3. Storage assignment is not location-specific
4. Total horizontal clearance allowance between stacks is 2 feet for
whole length of rack (12 feet)
Proposed Warehouse Layout
Total storage space (based on 17 stack height)
= Individual rack volume x Number of racks
= 12 x 4 x 17 x 34
= 27744 cubic ft
The space standard from the proposed layout will meet the
corporate requirements of < 300 cubic ft / unit load
19
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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
Page 1 of 3
Docking Arrangement
Security Office
OFFICE
81'-6 9/16"
46'-0"
10'-9"
STORES AREA
Incoming and
12'-0"
shipment
Storage Container
Storage Container
Staging Area
Control Station
WAREHOUSE
Storage Container
A
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.
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.
Page 3 of 3
E212 Facilities Planning and Design
90o Dock
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.
Present Warehouse Layout
The Distribution Centre is a small-sized warehouse with storage
area taking up close to half the total land area. There is a small
back-end office at the back of the facility.
One-side access
R: Receiving
S: Shipping
30 1.875 3 0.1211
30 1.875 4 0.0421
With four docks, the probability of a container truck having to wait its turn at the
Distribution centre is 4.21%.
(11)
Warehouse Dock Layout
Dock need to be change to point-of-use, to avoid mixing of goods for
shipment. The present area should be able to support a maximum of
4 point-of-use docks (2 receiving, 2 shipping) with sufficient internal
maneuvering space for trucks.
Finger dock, using the 45o angle will be more appropriate. Dock
width of 12 feet should suffice as dock activity is unlikely to be
highly busy. An important assumption will be that external
maneuvering space for trucks (just outside the facility perimeter) is
available, e.g. using part of access road.
14
SCHOOL OF
ENGINEERING
All rights reserved. No part of this document may be reproduced, stored in a retrieval
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
Page 1 of 2
Maintaining Sound Quality
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 $10,000 per annum. The new AV system is
expected to incur 15% less running cost per year. You have also managed to
find a bank loan for the capital cost at 6% per annum over 5 years period for the
new AV system.
What will be the most viable option for the theatres AV system based on
maintenance strategies? Justify your selection.
E212 Facilities Planning and Design
a) in-house maintenance
b) service contract
c) centralized or de-centralized management
d) scheduling of equipment service or inspection
e) preventive maintenance
f) individual or group replacement
2
Facilities Maintenance
- Key terms used in facilities maintenance:
a) Reliability (R)
- probability that an item will function for a given time
b) Mean Time Between Failures (MTBF)
- average time between failures of a repairable item
c) Failure Rate (FR)
- reciprocal of MTBF
3
Facilities Maintenance
Breakdown Maintenance versus Preventive Maintenance
- Remedial, responsive - Pre-emptive, averts failure
- Non-routine servicing - Regular inspection and servicing
- Trigger: equipment failure - Basis: schedule, control charts
4
P13 Proposed Solution
5
Proposed Solution
Assumption for this calculation
Maintenance Cost, Service Cost and Running Cost remain constant
Tax Benefits and Depreciation is not taken into accord for this
calculation.
6
Proposed Solution
Capital Cost per annum over 5 year for new AV system
7
Proposed Solution
Cost Analysis
Calculate cost per annum for each option.
Lease AV New AV Variance ($)
System ($) System ($)
Capital cost at 6% Nil 47,479 47,479
over 5 years p.a.
Servicing and Nil 10,000 10,000
Maintenance
Running Costs 10,000 8,500 -1,500
Leasing 50,000 0 -50,000
Agreement with
AV vendor
Total Costs 60,000 65,979 5,979
8
Proposed Solution
Conclusion
Base on cost analysis, it is cheaper to lease the AV system from the
vendor.
A new AV system will improve the efficiency of the sound quality.
Base on the facility objective, there should be minimum breakdown
as it will cause disruption to performance in the theatre.
Despite the higher annual cost, a new AV system will be the best
option based on the facility objective.
9
Life Cycle Costing
Life Cycle costing is all about preplanning to anticipate replacement,
applying it at the point that is most beneficial to the organization and
ensuring that there are no consequential risk.
As the facilities manager you will not get this correct all the time, but
with experience of your building activities, plus an increase base point
where it can be contained within a small contingency budget of, say
five to ten per cent.
10
Life Cycle Costing
11
Lesson Objectives
Know the importance of break down maintenance and preventive
maintenance in facility planning
12
SCHOOL OF
ENGINEERING
All rights reserved. No part of this document may be reproduced, stored in a retrieval
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
Page 1 of 2
Car Park
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
.
E212 Facilities Planning and Design
School of Engineering 2
Vehicle Parking Design in Singapore
The Land Transport Authority (LTA) provides the rules
and guidelines on the requirements for provision of
parking places and spaces
The Parking Places (Provision of Parking Places and
Parking Spaces) Rules stipulate the minimum number
of parking spaces to be provided for the various land
and building uses, the minimum dimensions of such
parking spaces, circulation aisle, access ramps and
other details on the arrangement of the parking place
and spaces. (From Handbook on vehicle parking provision
development proposals, LTA)
School of Engineering 3
Car Park Design considerations
Parking Provision Standards
Factory
- Handicapped Parking
4
Parking Stall Dimensions
Standard Car
All dimensions in mm
School of Engineering 5
Parking Stall Dimensions
Handicapped Parking Lot
All dimensions in mm
6
Parking Stall Dimensions
Motor-cycle Parking Lot
All dimensions in mm
7
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
School of Engineering 8
Parking Configurations
School of Engineering 9
Typical Parking Aisle Dimensions
All dimensions in mm
10
Typical Parking Aisle Dimensions
11
Other Considerations
12
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
14
Learning Objectives
15
SCHOOL OF
ENGINEERING
All rights reserved. No part of this document may be reproduced, stored in a retrieval
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
Page 1 of 2
Reviewing the Facility Plan
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
E212 Facilities Planning and Design
School of Engineering
Recall: Facilities Planning Hierarchy
Facility
System
Design
Facilities
Planning
Facilities Layout
Design Design
Handling
Systems
Design
School of Engineering 2
Recall: Factors Affecting Location Selection
Regional factors
Market location
Raw material and supplier proximity
Transportation facilities
Labour climate
Quality of life
Government
School of Engineering 3
Recall: 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
School of Engineering 4
Recall: Facilities Planning for Personnel
Requirements
Key aspects to consider when doing facilities planning:
Locker rooms proximity to staff entrances, allocation by
gender, ventilation, traffic flow
Restrooms near work area, minimum number required,
privacy, allocation by gender
Food services number of staff, kitchen and dining area
layout, ease of cleaning, aesthetic factors,
location, ventilation
Drinking fountains quantity, location, distribution
Health services first aid room and first aid kits, location,
evacuation routes
Car parks number of staff, space utilization, traffic flow
School of Engineering 5
5
Recall: Layout Types
Basic layout types: 1. Fixed-position
2. Product
3. Process
4. Cellular
5. Mixed
School of Engineering 6
6
Recall: REL Chart and CORELAP
A relationship (REL) chart shows the relationship
between all the department
7
Recall: Space Requirement
Determining the amount of space required in a facility
is perhaps the most difficult determination in facilities
planning
Determine the space requirement based on
workstation specifications for equipment, materials,
and personnel and departmental specifications.
Aisles has to be taken into account when doing space
planning. Typical aisle space for personnel: 3 feet
School of Engineering 8
8
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
School of Engineering 9
9
Recall: Office Facility Planning
Examples of security measures / devices
Outer Circle: Gates / Doors
Locks
Alarms
Warning signs
Ample lighting
Motion detectors
Integrated: Closed-Circuit TV
School of Engineering 10
10
Recall: Facilities Maintenance
- Refers to all the work activities that need to be carried out to keep a
facilitys systems functioning well
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
School of Engineering 11
11
Recall: Materials Handling Equipment
Types of Material Handling Equipment
Industrial Trucks
Automated Guided Vehicles
Monorail
Conveyors
Cranes & Hoists
Fork Lifts
Automated Storage/Retrieval Systems (AS/RS)
Hand Trucks
School of Engineering 12
Recall: Vehicle Parking Design
Procedures:
1) Determine the number of vehicles to be parked
2) Determine the space requirement for each vehicle
3) Determine the available space
4) Determine alternative parking layouts for different
parking configurations
5) Modifying alternatives based on any other
requirements
6) Select the most suitable layout
School of Engineering 13
Some Guidelines and Regulations for
Facility Plan
School of Engineering 14
14
Example of an Evaluation Report
School of Engineering 15
Problem Statement: Evaluating the
Existing Facility Plan
When evaluating a facility layout plan, there are some
questions you may want to consider:
1) What is the facility objective(s)?
2) Is the facility suitably located?
3) What is the layout type used?
4) Is the layout type suitable?
5) What are the material handling equipment used?
6) How does the traffic flows within the facility?
7) Does the layout suits the facility objective(s)?
8) Are the sport amenities placed appropriately?
9) Are there sufficient facility system (Example: life safety equipment)
and are they suitably located?
10)Does the facility adhere to various guidelines and requirements?
(Example: aisle space, amenities space and etc.)
11) How will the facility systems be maintained?
12) How could the facility layout and plan be improved?
School of Engineering 16
Facility Plan of the Sport Complex
Strengths:
- There is a large variety of sport amenities in the sport complex.
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.
School of Engineering 17
Lesson Objectives
Identify the strengths and weakness of an existing layout
18