IE 101 Facilities Location and Design By Assist.Prof.Dr. Nureddin KIRKAVAK Department of Industrial Engineering

My Personal Vita High School: Bursa Anadolu Lisesi, 1983, University Education: – BS in IE, Middle East Technical University, 1987, – MS in IE, Bilkent University, 1990, – FMS Loading Problem & – Alternative Control Policies: Push, Pull, Conwip Systems – PhD in IE, Bilkent University, 1995, – Pull Production Systems: Workload & Buffer Allocation Problems Professional Work as an Academician: – Instructor, Bilkent University, , Courses on Linear Algebra, Probability & Statistics, – Assistant Professor, Eastern Mediterranean University, , – Associative Professor, Eastern Mediterranean University, 1999-, Introduction to IE, Computer Programming, Engineering Economy, Financial Decision Making, Simulation Modelling, Facilities Planning, Production Planning, Systems Design Project – Department Chairman, EMU, Department of Industrial Engineering, , – Assistant Professor, ÇANKAYA University, 2010-, Facilities Design and Location, System Simulation, Material Handling Systems, Computer Applications in IE, Systems Design Project – Department Chairman, ÇANKAYA University, Department of IE, ,

Overview Introduction Facilities Planning – Facility Location (Where?) – Facility Design (What? How? When? How much?) Market Analysis Product, Process, Schedule Design – (What? How? When?) Space and Flow Planning : Departmentalization Personal Requirements Material Handling Systems Design and Warehousing Distribution Systems Facility Layout

Introduction to Facilities Planning WHAT should we produce? Market Analysis & Product Design HOW should we produce? Process Design HOW MUCH should we produce? Lot-sizing WHEN should we produce? Production Planning & Scheduling WHERE should we produce? Facility Location

Introduction to Facilities Planning Facilities can be broadly defined as buildings where people, material, and machines come together for a stated purpose – typically to make a tangible product or provide a service. Due to various internal and external forces, the facility must be properly managed to achieve its stated purpose while satisfying several objectives. Such objectives include producing a product or providing a service at lower cost, at higher quality, or using the least amount of natural resources.

Introduction to Facilities Planning To manage facilities so that the objectives are attained, one must understand the underlying decision problems faced: – Facility Location, – Type and Volume of Products (Services) to Be Manufactured (provided), – Manufacturing (Service) Processes Required, – Design of Components (Services), – Type and Quantity of Equipment Required, – Process Planning, – Tooling and Fixture Design, – Determination of Machine (Service) Cells, – Layout of Equipment within each Cell, – Layout of Machine Cells, – Determine Material Handling Methods, – Type and Quantity of Material Handling Devices, – Determining Flow of Products & People, – Scheduling and Planning Jobs (Service Steps), – Overall System Design, – Inventory Control, – Distribution of Goods, – Quality Control and Customer Service,

Introduction to Facilities Planning

Facilities Planning determines how an activity’s tangible fixed assets best support achieving the activity’s objectives. It is important to recognize that facilities planning ≠ facilities location, facilities design, facilities layout, plant layout – Facilities Location ( macro aspect ) : Location of the facility refers to its placement with respect to customer, suppliers, and other facilities with which it interfaces. It consists of selecting a site for a new facility that will minimize the production and distribution cost of product and/or services to potential customers. – Facilities Design ( micro aspect ) : Design components of a facility consists of the – Facility Systems (i.e. the structural systems, the atmospheric systems, the lighting/ electrical/communication systems, the life safety systems, the sanitation system...), – Layout (all equipment, machinery and furnishings within the building), and – Handling System (the mechanisms needed to satisfy the required interactions).

Introduction to Facilities Planning

The objective FP & D is defined as planning a facility that achieves both facilities location and facilities design objectives. Although a facility is planned only once, it is frequently re-planned to synchronize the facility and its constantly changing objectives. Planning and re-planning are linked by the continuous improvement facilities planning cycle. Facilities Planning is not and exact science, but it can be approached using an organized and systematic approach.

Introduction to Facilities Planning Engineering Design Process (similar to problem solving approach): – Define the problem, – Analyze the problem, – Generate alternative designs, – Evaluate the alternatives, – Select the preferred design, – Implement the design.

Introduction to Facilities Planning Some Reasons the Facility Location Decision Arises – Changes in the market Expansion Contraction Geographic shift – Changes in inputs Labor skills and/or costs Materials costs and/or availability Utility costs – Changes in technology – Changes in the environment Regulations and laws Attitude of the community

Introduction to Facilities Planning Facilities Location Problems DiscreteContinuous – Solution Space: Discrete v.s. Continuous MinisumMinimax – Objectives: Minisum v.s. Minimax RectilinearEuqlidean – Distance Measures: Rectilinear v.s. Euqlidean Discrete Solution Techniques – Qualitative Methods: Sum of Weighted Scores – Quantitative Methods:Transportation Model – Hybrid Methods: Brown & Gibson, Buffa & Sarin Continuous Solution Techniques – Minisum Rectilinear: Median Method – Minisum Sq.Euqlidean: Gravity Method – Minisum Euqlidean:Wiesfeld Method – Minimax Rectilinear:Parametric Method

Introduction to Facilities Planning Site Selection:

Introduction to Facilities Planning Non-economic – Labor attitudes and traditions – Training and employment services – Community’s attitude – Schools and churches – Recreation and cultural attractions – Amount and type of housing available … Economic – All types of costs – Revenue …

Introduction to Facilities Planning Site Planning:

Introduction to Facilities Planning Material Handling – Moving, – Storing, – Protecting, – Controlling, To provide material: Right method, Right amount, Right place, Right time, Right sequence, Right position, Right condition, Right cost …

Introduction to Facilities Planning Material Handling & Block Layout Planning:

Introduction to Facilities Planning

Flow Diagram for Harley and Davidson:

Introduction to Facilities Planning

Detailed Layout Planning: