FACILITY LAYOUT & LOCATION PROF. DR. ORHAN TORKUL M. RAŞİT CESUR

Auxiliary Services Requirement Space Objectives; Understand the need for support activities in a manufacturing enterprise Be able to identify support activity departments such as receiving, storage, maintenance, and so on Be able to calculate the space requirements for such support functions

Plant Space Requirements There are many service functions to consider in a manufacturing plant, but the activity centers that require a lion’s share of space are; Receiving and shipping Storage Warehousing Maintenance and tool room Utilities, heating, and air conditioning

Receiving and Shipping The functions of a receiving department include; Assisting in locating a trailer at the receiving dock door Assisting in the unloading of material Recording the receipt of the number of containers Opening, separating, inspecting, and counting the material being received Preparing overage, shortage, or damage reports as needed Developing a receiving report Sending material to raw material stores or straight to production if needed

Facilities Required for a Receiving Department Dock Doors Dock Plates, Dock Levelers, and Dock Boards Aisles Outside Areas Offices

Facilities Required for a Receiving Department

Functions of a Shipping Department Packaging finished goods for shipping Addressing cartons or containers Weighing each container Collecting orders for shipping (stage) Spotting trailers Loading trailers Creating bills of lading

Shipment Area

Stores Stores is a term used to denote an area set aside to hold raw materials, parts, and supplies. There are many different types: Raw material stores Finished parts stores Office supplies stores Maintenance supplies stores Janitorial supply stores

Inventory Policy The space requirements for stores is dependent on the stated inventory policy of the company. The policy could be as straightforward as providing space to store a one-month supply of raw material, or a more creative policy might be to provide an area to store a one-week supply of A items, 2 weeks of B items, and a one-month supply of C items. Inventory Classification Percentage of Parts Percentage of $Inventory Policy A2080One-week supply B2015Two-weeks supply C605One-month supply

Just-in-Time Inventories Primary manufacturers depend on their suppliers to deliver parts as often as every 4 hours, thereby eliminating the need for raw material inventory storage area. JIT depends on unfailing vendor performance. JIT will affect the plant layout in many ways. You will be able to Adjust or eliminate receiving, receiving reports, and so on Eliminate incoming quality control checks Eliminate or greatly reduce stores area requirements

Just-in-Time Inventories The goals of any stores department should be; 1. To maximize the use of the cubic space 2. To provide immediate access to everything (selectivity) 3. To provide for the safekeeping of the inventory including damage and count control

Inventory Amounth d =DL σ = √L σ ss=F (SL) σ ROP=d +ss SL=F(ROP,d, σ ); L L D L S L L L d : Average demand σ : Standart deviation of demand during order period σ : Standart deviation of order SL: Service Level ss: Safety Stock ROP: Re – order point F: Normal distribution function L L D

Warehousing Warehousing is the storage of finished products. As in the storeroom, the area requirement will depend on management policy. Seasonality could require stockpiling finished products for months in order to meet market demands. A warehouse can be a department or an entire building. Many manufacturing plants sending their product to warehouses in order to service the company’s customers is a function called distribution.

Warehousing The distribution system of a company tries to minimize the cost of moving its product to customers while maintaining superior customer service. A warehouse building will have a receiving department, a stores department, a warehouse department, a shipping department, and an office. The warehouse department in a warehouse building will have the same purpose as the warehouse department in a manufacturing plant. The warehouse department (called just warehouse from now on) has the primary purpose of safekeeping the company’s finished product.

Maintenance and Tool Room The maintenance and tool room function is to provide and maintain production tooling. These functions vary widely from one company to another. Sizing the maintenance and tool room is dependent on management’s desire to do it in-house or to contract out all or part of these jobs. A tool room is made up of machines and an assembly area similar to production. Once management determines what the plant will do, a machinery list is determined and each machine needs a workstation design. The tool room size is the sum total of all the equipment space requirements times 200 percent. The extra space is for everything except raw material and finished tool storage areas. These areas are calculated just like every other storage area. Maintenance is service to the company’s equipment.

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