FACILITY PLANNING

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Introduccin
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Contextualizacin

Hello, dear apprentices!

Welcome to this section!

This material will be very useful because it is going to teach you about
facility planning. This topic is essential for organizing the physical pro-
duction plan and offers you some key items needed to achieve the best
results.

The contents you will examine are:

Facility planning objectives

Characteristics
Advantages of planning a facility

Facility planning process

Planning process
Strategies for planning a facility
Product design
Process design
Communication design
Facility design
Structuring a facility
Trends in office layout
Plot planning

The efficient and effective movement of goods from production plants,

distribution centers, retailers and customers requires a well-planned de-
cision from selecting, designing, constructing and developing a facility
to satisfy all the drivers in the supply chain.

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Contenido

Well, Mr. Builder, as you know Im inte-

rested in expanding the factory facilities
in order to satisfy the customers require-
ments.

Indeed, nowadays, it is necessary to plan,

design, and structure the factory facilities
in order to get the best results into the
competitive market.

Exactly. As you know, I need to plan the

plant design according to:

Facility planning objectives Process design

Facility planning process Communication design
Product design Facility design

Facility planning objectives

Ok. Lets see every item in detail in order

to clarify the process sequentially.

To continue normally activities.

To integrate different activities into the company processes.
To combine common processes into the organization.
To have workers understand the processes of the company.
To integrate collaboration among the different sections of the company.
To satisfy the customers necessities.
To implement technology upgrades.
To do continual improvement.
To do activities in a short time.

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 Additionally, companies have to make a facilities plan
that meets the needs of the supply chain drivers. It ensu-
res product manufacturing and timely delivery. Therefo-
re, planning a facility has the following characteristics:

Modularity
Modular facilities have interrelated systems to operate.
Flexibility
Flexible facilities can handle different requirements without alterations.
Adaptability
Facilities can be adapted according to organizational needs.
Easy to update
Updated facilities can be adapted to new technologies, technological sys-
tems and machines.
Operational capacity
It allows us to understand how all the areas in the facility work to be able to
prepare emergency plans.

Facility planning process

Facility planning is a competitive advantage
strategy to satisfy the supply chain drivers.

Customers and providers can locate the organization easily

Organizational layout permits one to see the flow of materials, processes
and communication
To increase productivity
To reduce costs
To eliminate unnecessary activities

Ok, Mr. Prez. Now, we are going to analyze the different possibilities you have
for adjusting the facilities plan. It is important to bear in mind that a facility life
cycle is frequently changed or reconsidered with the company objectives.

Thats right. We will become a successful company and we will

design the facilities according tothis new condition.

Exactly. Right now, we are going to define and analyze the problem, consider the
spacial needs, evaluate the alternatives, and select and implement the design.

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 Well, lets continue explaining the
steps above.

Define the problem

What is the objective of the facility?
Define the use of the facility with products made or services provided, quantity, volume and
levels of activity.

What primary and support activities are going to be performed?

Specify the primary and support activities to be performed with equipment, personnel and
material flow. Also, specify the support activities to carry out the primary activities.

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Analyze the problem
How activities are going to be interacted?
Establish the relationship of activities and actions to be taken.

How is available space to be distributed?

Distribute the space according to equipment, material, and personnel in each activity.

Evaluate operational alternatives

What factors can affect a facilitys alternatives operation?
Evaluate alternative facility plans to develop the operation in case of an operational problem.

Select design
What design is suitable for the organization?
Select a facility design to satisfy the goals and objectives of the organization.

Implement design
What is the final design for the organization?
Update the facility plan to keep or restructure the place if it is necessary.

What organizational areas are going to be adapted or modified?

Implement the final design of the facility to construct or layout an area.

Mr. Perez, we can see that this book has

excellent information and will help us to
determine the best way.

Great! This topic reminds me of the Eisen-

howers maxim The plan is nothing, but
planning is everything

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Planning a facility must be considered in the development of business strategies to reach
a common goal. Each organization will have strategies in marketing and manufacturing as
well as distribution sections to contribute to the business objectives. The company must
include manufacturing and distribution strategies for warehousing, movement, protection
and control of raw materials to deal with the process and its results.

All of these processes are interrelated and there must be a fluent, quick communication
between them. Thus, useful communication systems today must be updated every five to
ten years.

Strategies

These are some strategic aspects to consider for planning a facility:

Number, location and size of warehouses and distribution centers.

Centralize or decentralize warehousing for storing raw materials, work processes
or final products.
Modern and adaptable facilities to design factories and distribution centers.
Flexibility for new markets and technologies.
Interfacing between warehousing and manufacturing.
Vertical integration with outsourcing or manufacturing own products.
Control systems of material, machines and level of distribution processes.
Internal and external movement of materials inside building, facilities and be-
tween them.
Changes among customers, technology providers, manufactured technology,
material movement, protection, storage, and company control technology.
Designing the cost of the facility.

I see there are many things to take into

account for planning a facility.

Yes, of course! This topic is very broad.

Now, Lets continue with the product de-
sign. So far, we have talked about facili-
ties design, but we also need to consider
how the product process is developed in
order to structure the plant according to
the product design.

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 We have a staff comprised by people from diverse departments such
as manufacturing, finance and marketing to production management
and design of products.

Each company has to determine its product, the process and the program ne-
cessary to design it. How does the company implement the product design?

ROUTE SHEET
Company: Blue Cookies Product name: Nice Cookie Prepared by A. L. B. P. Date 2012
Materials /
Task Operation description Process Machine type Department Time (h) Quantity
description
50 bulks Flour
20 bulks Sugar
1 Get products Buy ingredients Purchasing 78
1000 bulks Eggs
5 gallons Flavors
Flour
Sugar
2 Mixing Mix products Mixer Production 15 1000 units Eggs
Flavors
Water

Product design
In our company, the process follows some steps that Im going to describe:

Definition

Define the product to be made, manufactured or assembled.

Determine the process and activities to make, manufacture or assemble the product.

Requirements

Establish the space for the process.

Establish different plans to develop in the plant.

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Evaluation and employment

Evaluate the different plans to develop in the plant.

Implement different plans to develop in the plant.
Update and adapt the different plans in the plant.
Update the products to be manufactured.

What if there is a new product?

Well, according to a series of questions such as:

What is the company going to produce?

How are the products going to be produced?
When are the products going to be produced?
How much of each product is going to be produced?
How long each product is going to be produced?
Where are the products going to be produced?

The company evaluates its necessities.

Who participates in the process?

All the companys members. For example, product designers decide

final product specifications such as: dimensions, materials compositions,
and packaging.
Product planners define production quantities and product manufacture and
plant planners control the complete information flow in the plant in order to
improve the process velocity and attain the companys goals.

Absolutely. A company is required to have a committed team working together

on the processes to achieve its objectives. These processes must be clear for
organizing the facility. Otherwise, the product process will have interruptions or
take longer to accomplish.
I need to recognize how the process works in the company so that, I can con-
sider how the machines and facilities can be structured in the company accor-
ding to the process of the product production.

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 Process design

This is Mr. Fernandez. He is the produc-

tion designer.

Hi! Welcome to our section.

Hi, It is nice to meet you.

In this company, a process designer or

process planner is responsible for de-
termining how a product is going to be
produced.

I am in charge of selecting who is going

to do the process or if it is necessary
to make or buy a part of the product or
supplies.

He also determines what machine is re-

quired and how much time it will take
to get it.

I get all the information to identify the steps during the process. Then, Ill
decide the production or manufacturing steps. The factory needs to establish
the machines that are necessary to manufacture a product. We called it an
identification of the process where everybody is working toward the final
product. Here, we require an organizational division that allows us to know
where to process or acquire the raw materials or products to be used. It is an
internal division that carries out these tasks.

What are the steps for identifying process?

Right now, Im going to describe the process we have developed in

this company.

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 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6

NICE
COOKIE
Mixing buy Mixer by 30
Ingredients
to
Cooking make Oven by 60

Purchasing to
Production Packing to
Packing by 3 hrs
Department Section machine

Storage make Warehouse by 30 days

Transport make Truck by 5 hrs

Step 1
To define elemental manufacturing operations such as the selection of raw ma-
terials and elemental manufacturing operations.

Step 2
To identify, for each operation, alternate processes such as machines and se-
lection of alternate mechanic and automotive manuals.

Step 3
To analyze alternate processes.
It analyzes the time of unitary production and the use of equipment to make
elemental alternate operations and different alternate machines.

Step 4
To standardize processes. The data gathered is transformed into the company
procedures.

Step 5
To evaluate alternate processes. Operation prices and machines used are eva-
luated during the process.

Step 6
To select processes. The process evaluation takes into account such diverse
factors as: the economic results, intangible factors, versatility, reliability, ease
conservation of the machines used and security, among other factors.

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 Right! It is a complex process.

Well, I would say this is an organized process where every worker knows his or
her own role into the organization.

What about transportation and warehousing?

As you notice in the diagram, those items are included in the process. Additio-
nally, we include delays, distance and time between production and manufac-
turing. Everything is carefully designed to carry it out from start to finish.

Ok. Mr. Fernandez. Thank you so much. This information will be very useful
and I will bear in mind all these design processes in order to design your
organization facility.

Communication design

It is important to note that our company has an internal relationship about the process and
product design to achieve the company purposes.

Hi,Yes, you are right. However, I need to know how the different sections of the
process keep in touch. In other words, how the communication works.

Communication is one of the most important tools for transmitting information in the different
sections of the company and plant offices. It transmits management objectives and provides
means for understanding those objectives at various key company levels.
The main goal of this companys communication design is to transmit data, to persuade, to
give directions and to gather information or receive input.
The most common ways to transmit messages are writing messages like e-mails. It is sent
and received quickly and confirms messages received by others. An added practice is that
each section director transmits oral messages immediately to their collaborators and these
directors receive a ppositive answer as to acceptance or denial.

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 What about the communication between company levels?

Well, we have a Diagram Flow which shows how communication, material, and
cash flow into the company.

I think I will check it.

I have received enough information about places and activities of this company.
Now, I need to evaluate the location, design, administration, warehousing, and
unit load to plan the process of the plant and layout it.
It is important to consider some aspects such as:

Organizational relationship
It will permit to have control and communication among the different places in the plant.

Information flow
There must be accurate information about raw materials, machines, cash flow and people

Control relationships
The materials have been controlled in each step of the process. Some of the specific areas
are: central point, inventory, real time batch, control on the floor, workstations and automation

Environmental relationships
Each organization is required to have norms of biosecurity, proper temperature, noise, toxic
emanations, humidity and dust.

Process relationship
Each plant process has to include the load on the floors, water treatment requirements, che-
mical processes and special services.

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Building
The company is required to use industrial building structures for offices and plant layouts.
There are heavy structures as needed for gantries, cranes or other equipment.
These industrial buildings are constructed with steel frames.
The spacing of the columns and bays define major aisles and walled partition divide various
departments. The size of bay between columns ranges from 20x20 to 35x160 feet. It is esti-
mated that each column effectively uses up between 9 and 16 square feet of floor space.
Long spans also require deeper steel frame construction, and this permits the overhead spa-
ce within the frame to be used for compressed-air piping, air-conditioning ducts, and electri-
cal conduits.
A square building is preferred over a rectangular one because it can be flexible for expansion.
The clear height of the building depends on the products, generally from 11 to 38 feet, with 18
20 feet being the most common.

Walls
Outside walls provide protection and security to the plant. Most of the walls are made out of
masonry or concrete that provides good fire protection and presents a neat appearance.
Walls made out of corrugated aluminum or sheet metals with fiberglass insulation are normally
used when expansion is predicted.
Interior walls can be prefabricated or built in different materials. In a food plant, walls might be
tiled for a smooth and sanitary interior.

Floors
The plant floor is almost always a concrete slab, strong to support heavy equipment loads. It
can be leveled from +- 4 mm in 2 m (normal) to +-1 mm in 2m (super flat). The flatness faci-
litates vehicle dynamics and sound deflection of a material handling device such as a forklift
truck.
Floors should be durable, impact and vibration resistant, sound absorbent, nonskid, non-spar-
king and easy to clean. They shouldnt be affected by temperature, humidity, accidental spills
of chemicals, oils, or other industrial substances.Environmental relationships
Each organization is required to have norms of biosecurity, proper temperature, noise, toxic
emanations, humidity and dust.

Roof
Roof shapes are constructed according to building characteristics. The materials can be alu-
minum or steel with a combination of fire resistant and cement sheeting.
Flat concrete roof is covered outside with an insulating material similar to cork to reduce tem-
perature variations in the plant.
A sawtooh roof with translucent glass on one side of the teeth that permits natural light to
penetrate into the plant without causing glare.
It also allows fresh air and ventilation.

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Interior
A comfortable working environment can increase workers productivity. Air temperature in the
plant is suggested to be from 68F to 72F and relative humidity should be kept at 50%. Air
conditioning and heating units can help maintain an adequate ambient temperature.
Flow of air is required to avoid feelings of stuffiness, dust, odor, vapors and fumes generated
by machines.
Vacuum ducts and tubing can transport air and particles to a centralized location away from
the work spaces.
Sound absorbing tiles reduce noise with proper maintenance. Hearing protection (earplugs or
muffs) can be used in unsafe and high decibel areas.
Lighting in plants requires a proper illumination to avoid illnesses.
Light interior colors allow more light in the plant. Cream, peach, and light shades of green and
blue are favorite colors for walls.
White color is common for ceilings, whereas yellow is used to indicate caution.
Black and white stripes generally define traffic areas, and aisles are marked with white bor-
ders. Additionally, red is associated with danger and is also used to indicate fire protection
apparatus, stop signs, traffic lights, and dangerous or restricted areas.

Prefabricated buildings
Prefabricated buildings are modern and have a great variety of shapes. Prefabricated is a
cost-effective and time-saving method of construction. Corrugated or flat-channel steel are
commonly used materials to construct buildings. Modular approaches allows for future expan-
sion or alterations. Interior walls or offices can be easily moved from one location to another
to modify the layout of an existing plant.

Support facilities
A facility must contribute to the improvement of an employees satisfaction and productivity.
Therefore, we have to include:
Shop offices: A manufacturing facility is normally divided into several shops or departments.
Each one functions according to its needs.

Inspection
It is a central office to inspect activities of products and transportation.

Maintenance
A production plant requires a building maintenance division, as well as equipment and mate-
rial handling systems to fix any equipment failures and take preventive actions.

Tool room
A tool room is a place to store and repair tools that are used in the plant such as mold dies,
punch press tools, milling cutters, drills, and cutting tools for lathes, jigs and fixtures.

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Tool crib
A tool crib is a storage center for all tools and accessories. It consists of cabinets and racks for
holding such items as emery cloth, steel wool, sander belts, socket sets, drill bits, milling tools ,
cam followers, grinding wheels, special clamps, and general purpose dowel pins. Map 1

Lockers / changing area

A locker stores employees belongings such as uniforms or protective clothing. Map 2

Map 1

Lockers Lockers

Lockers

Bench

Bench
Mirrors Mirrors

Sinks Sinks

Toilets Showers Toilets Showers

Urinals

Male lockers room Female lockers room

Lavatories
ThereIn most plants, locker rooms and lavatories are combined into one area.

Janitorial and custodial services

Upkeep and facility cleaning of the facility are the responsibilities of the janitorial group. A
storage area must be provided for custodians to maintain brooms, mops, cleaning powders,
fluids, and other necessary elements.

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Map 2

Showers Toilets Urinals

Sinks

Bench

Bench
Mirrors Lockers

Handicapped
Lockers Sinks shower
Toilets
Showers
Mirrors

Male lockers room Female lockers room

Dining area
This is a special place to relax and eat during breaks. It provides tables and benches, vending
machines, and microwave ovens. Also, there is a furnished kitchen with refrigerator, coffee
maker, stove, drink dispenser, and counter with a cash register.

Security force
The need for a security force depends on the field of the company. Chemical production fa-
cilities are required to have a special supervisor all the time. Other plants only require a night
watchperson or an alarm system.
Other plants use passes with the employees picture and personal data. In some others, there
are automatic doors and gates to be opened with the magnetic strip on the pass.

Parking lot
A parking area needs to have specific spaces for big and small cars. It must be built with a
weather resistant surface such as asphalt or concrete and adequate lightening in the area to
protect it. Each space must be clearly marked on the surface. Also, the entrance, exit, and
speed limit signs should be marked.

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Medical facilities
Medical facilities are often provided with basic first aid kits to an infirmary capable of handling
medical emergencies, sicknesses and accidents.

Trends in office layout

A modern office layout combines private and general office areas as space is available. Todays
general offices areas are located in open spaces according to the employee and their duties.
In contrast, private office layouts are often based on the hierarchal structure of the organization.
An office design must consider the information flow and processes established along with the
technology implemented in the organization. Thus, the modular and cluster, and landscape
workstation approaches to work areas are composed of panels and furniture components. The
panels are available in many colors, as well as in wood, metal, plastic, glass, carpet and fabric.

Modular workstation approach

It consists of individual work areas witha desk or a table to store required office elements.
These workstations are designed according to the specific job duties and their occupants.
This layout can be easily made or modified.

Cluster workstation approach

This is a group of work areas clustered in a common place. These are not as elaborate as
modular workstations but can be used in different moments of the day when employees are
away. Clusters advantages include reduced costs of purchase and maintenance a well as
ease of modification.

Plot planning
Plot planning involves location of the warehouse, driveways, entrances and loading docks
and their relations to roads, parking, and entrances. It is important, also, to locate sidewalks,
steps, utilities and traffic control installations with signage.
Plot planning facilitates the planning of the facilities, the plant, and any auxiliary buildings to
be used in the organization. The functions of plot planning are:

Planning the best use of the space available

Planning the flow of materials throughout the facilities
Planning for future needs

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Referencias

Tompkins, J. (2010). Facilities planning. John Wiley & Sons. Recuperado de http://
goo.gl/y6jhUS

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Crditos

Asesora temtica
Clara Patricia Sanabria
Economista de la Universidad Autnoma de Colombia
Especialista en Gerencia Logstica Integral de la Universidad Mili-
tar Nueva Granada
Asesora didctica
Magda Zulena Trujillo R.
Licenciada en lengua castellana de la Universidad del Tolima
Candidata a Magster en literatura de la Pontifica Universidad
Javeriana
Asesora didctica, SENA Virtualizacin - RDC
Centro de Gestin de mercados, Logstica y TICS
Diseo grfico
Giovanni Guerrero Lozano
Publicista
Universidad Central de Colombia
Centro de Gestin de Mercados, Logstica y Tecnologas de la
Informacin, Regional D.C.
Programacin
Andrs Felipe Salcedo Osorio
Productor multimedia
Servicio Nacional de Aprendizaje
Programacin, SENA Virtualizacin - RDC
Centro de Gestin de mercados, Logstica y TICS

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