Facilities and Layout Planning SPACE REQUIREMENT Facilities and Layout Planning

The Facilities Planning Process 1. Define or redefine objective of the facilites 2. Specify primary and support activities 3. Determine the interrelationship 4. Determine space requirements 5. Generate alternatives facilites plan 6. Evaluate alternatives facilities plan 7. Select a facilities plan 8. Implement the plan 9. Maintain and adapt the facilities plan 10. Redefine the objective of the facility

SPACE REQUIREMENT WORKSTATION DEPARTMENT AISLE ARRANGEMENT

WORKSTATION SPECIFICATION

Workstation Specification equipment space Material area Personnel area

Workstation Specification The equipment space for a workstation consists of space for The equipment Machine travel Machine maintenance Plant service

Workstation Specification The material areas for a workstation consist of space of Receiving and storing inbound material In-process material Storing outbond material Storing and shipping waste and scrap Tools, jigs, dies, and maintenance material

Workstation Specification The personnel area for a workstation consists of space for The operator Material handling Operator ingress and egress

Workstation Specification Guidelines Workstation should be designed so the operator can pick up and discharge material without walking or making long or awkward reaches Workstation should be designed for efficient anf effective utilization of the operator Workstation should be designed to maximize operator safety, comfort, and productivity Workstation should be designed to minimize hazards, fatigue, and eye strain

DEPARTMENT SPECIFICATION

Department Specification Once the space requirement for individual workstation have been determined, the space requirement for each department can be established.

Department Specification Possible tools Possible dies Equipment maintenance Plant service Housekeeping item Storage area Operator Spare part Problem board etc

AISLE ARRANGEMENT

Aisle should be located in facility to promote effective flow Aisle Arrangement Aisle should be located in facility to promote effective flow

Aisle Arrangement Planning too narrow aisle May result in high level of damage Planning too narrow aisle May have safety problem

Planning too wide aisle Aisle Arrangement Planning too wide aisle Wasted space Poor housekeeping practice

Aisle Arrangement The width of aisle should be determined by considering: the type of flow volume of flow to be handled by the aisle

Aisle Arrangement Aisle Allowance Estimates If the largest load is 5-10% 10-20% 20-30% 30-40% Less than 6 ft2 6-12 ft2 12-18 ft2 Greater than 18 ft2 Tompkins et al. (2003)

Aisle Arrangement Tompkins et al. (2003) Recommended Aisle Width for Various Types of Flow Type of Flow Aisle Width (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 door opening into aisle from one side Personnel with door opening into aisle from two side 8 Tompkins et al. (2003)

Aisle Arrangement Two-way flow The aisle width should equal to the sum of the aisle widths required for the types of flow in each direction

Calculate Estimation Space Requirement Area Station Width Length Requirement Manufacturing WS Fabrication Strip Shear Chop Shear Punch Press Roll Former 2 4 3 6 1 9.5 7 8 12 13 11 228 364 264 528 108 Fabrication Total Space Required 1492 WS Spot Weld 26 30 780 WS Paint 28 100 2800 WS Assembly 16 38 608 Total 5680 Allowance 50% 2840 Manufacturing total 8520

Calculate Estimation Space Requirement Area Station Width Length Requirement Production Service Receiving steel 13 25 325 Receiving Cartons 17 19 323 Stores 18 450 Warehouse 64 68 4352 Shipping 20 400 Maintenance tool&room 800 Utilities 100 Production Service Total 6750

Calculate Estimation Space Requirement Area Station Width Length Requirement Employee Service Employee entrance 10 20 200 Locker rooms 50 employee 3.5 ft2 each 175 Toilets Cafetaria 50 empoyee 10 ft2 per employee 500 Drinking fountain 6 15 ft2 each 90 Medical Service 100 Employee Service Total 1265 Office 11 employee 200 ft2 each 2200

Calculate Estimation Space Requirement Area Station Width Length Requirement Manufacturing Total 8520 Production Service Total 6750 Employee Service Total 1265 Office Total 2200 TOTAL BUILDING SPACE REQUIRED 18735

Building Size Determination Standard building has many type of dimension and ratio (100’ x 100’, 50’ x 50’, 40’ x 40’, dll.) 25’ x 50’  refers to ratio of length and width 2:1. Ratio 2:1 is ideal dimension which consider to povide smoother and more comfortable material flow and facility usage

Building Size Determination If the required building space is 18.735 square feet, below is the step to obtain building dimension: Divided total space required with 2. Based on the previous case, 18.735/2 = 9.367 Calculate the square root. √9.367 = 97  100. Using the calculation of square root, we already obtain the width and length that is 100’ x 200’  Ratio 2:1

Building Size Determination If the required building space is 18.735 square feet, below is the step to obtain building dimension: Divided total space required with 2. Based on the previous case, 18.735/2 = 9.367 Calculate the square root. √9.367 = 97  100. Using the calculation of square root, we already obtain the width and length that is 100’ x 200’  Ratio 2:1 400 sq2

Other Considerations Most of our layout design has concentrated on floor space, but no everything needs to be place on the floor. Other levels within the plant may be suitable: Under the floor Overhead Clear Space Roof Always review for cube utilization

Space Requirements Under the Floor Clear Space: the space from 8’ above the floor to the ceiling Truss Level: Many plants run utilities in the trusses. Heaters, blowers, ovens, and the like can be placed in the trusses (Meyers) www.inspectionlibrary.com

Study Case An entrepreneur is considering to buy land to be built into foodcourt. The foodcourt will has 15 food stand with the size of width and length for each stand is 3 x 3.5 meters, 2 cashier post with width and length is 1 x 2 meters each, two wastafel post where each post has 3 wastafel with the “footprint” size is 0.5 x 0.5 meter for each wastafel, and two toilets for female and two for male with dimension for each toilet is 2 x 2 meters. There are three types of table set that will be placed in the foodcourt which are dining table for 6 people (1 x 2 meters), for 4 people (1 x 1.5 meters) and for 2 people(1x1 meter). Based on the consideration that the foodcourt visitor may come in large or small group. The foodcourt visitor capacity is 250 people. Help the entrepreneur to determine the width and the length of the land that he will buy. If the land price is Rp. 250.000/meters, calculate the money to be spent by the entrepreneur to buy land! Make simple power point based on the problem above! (Note: the number of 6 people table, 4 people table, and 2 person table is up to you, there’s no wrong number)

THANK YOU 