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Introduction to Facility Design

Introduction to Facility Design. Chapter 1 S.S. Heragu, Facilities Design , 4 th Edition, CRC Press. Case Study – Ann, Inc. Founded in 1954 1,000 Ann Taylor and Loft stores DC in Louisville, KY – Why? 60% of the items cross-docked – Why? Many part-time workers – Why?. Ann, Inc.

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Introduction to Facility Design

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  1. Introduction to Facility Design Chapter 1 S.S. Heragu, Facilities Design, 4th Edition, CRC Press

  2. Case Study – Ann, Inc • Founded in 1954 • 1,000 Ann Taylor and Loft stores • DC in Louisville, KY – Why? • 60% of the items cross-docked – Why? • Many part-time workers – Why?

  3. Ann, Inc.

  4. Ann, Inc.

  5. Ann, Inc.

  6. Chronological list of facilities planning and design activities

  7. Typical Design and Planning Problems

  8. Levels of decisions • Strategic or Design or Long-term • Planning or Intermediate • Operational or short-term

  9. Why is facilities layout important? • 30-75% of product cost attributed to materials handling (Sule, 1991 and Tompkins et al. 2003) • Layout of facilities affects materials handling costs • Facilities includes machines, departments, workstations, locker rooms, service areas, etc.

  10. Why is facilities layout important? • Good layout increases productivity efficiency • Reducing congestion permits smooth flow of people and material • Space utilization is effective and efficient • Facilitates communication and supervision • Safe and pleasant working environment

  11. Constraints in developing facilities layout • Some pairs of departments must be adjacent • Some pairs of departments must not be adjacent • Some departments only in specific locations • Existing building constraints • OSHA regulations, fire codes, etc.

  12. Types of layout problems – Some examples • JIT manufacturer • Relayout of an existing facility • Relayout due to increased traffic (resulting from a merger) • Consolidation of manufacturing operations from two or more sites to one • Leasing of office space in a multi-story building • Find a better layout in existing space • Introduction of new product lines

  13. Types of layout problems • Layout of a service system • Layout of a manufacturing facility • Warehouse layout • Nontraditional layout

  14. Applications • Manufacturing • Healthcare • Service • Restaurants • Banks • Airports • Entertainment • Logistics and Distribution • Ports/Terminals • Distribution Centers

  15. Types of Projects • New Facility • General Re-layout (retrofit) • Expansion due to new product(s) • Expansion due to sales growth in existing products • Re-organization of work areas (evolutionary design) • Outsourcing of logistics capability • Addition of automation technology • Problem elimination • Cost reduction • Product discontinuation

  16. Service system layout – Dentist’s office

  17. Service system layout – Grocery store

  18. Operations review for office layouts (Suskind, 1989) • Is the company outgrowing its space? • Is available space too expensive? • Is building in the proper location? • How will a new layout affect the organization and service? • Are office operations too centralized or decentralized? • Does the office structure support the strategic plan? • Is the new layout in tune with the company’s image • Does customer physically participate in service delivery?

  19. Office structures • Closed structure • Semiclosed structure • Open structure • Semiopen structure

  20. Closed structure

  21. Semiclosed structure

  22. Open structure

  23. Semiopen structure

  24. Manufacturing layout • Minimize transportation cost of raw materials, sub-assemblies, work-in-process inventory, tools, parts, finished products, etc. • Facilitate traffic flow • Improve employee morale • Minimize or eliminate risk of injury and property damage • Ease of supervision and face-to-face communication

  25. Factory Floor Layout

  26. Warehouse layout

  27. Driveway layout

  28. Nontraditional layout • Keyboard layout • IC board layout • Computer disk storage layout • Airport gate layout

  29. Engineering design approach

  30. VIP-PLANOPT Layout

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