1. Facilities and Layout Planning
SPACE REQUIREMENT
Facilities and Layout Planning

2. 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

3. SPACE REQUIREMENT
WORKSTATION
DEPARTMENT
AISLE ARRANGEMENT

4. WORKSTATION SPECIFICATION

5. Workstation Specification
equipment space
Material area
Personnel area

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

7. 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

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

9. 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

10. DEPARTMENT SPECIFICATION

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

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

13. AISLE ARRANGEMENT

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

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

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

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

18. 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)

19. 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)

20. 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

21. 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

22. 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

23. 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

24. 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

25. 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

26. Building Size Determination
If the required building space is square feet, below is the step to obtain building dimension:
Divided total space required with 2. Based on the previous case, /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

27. Building Size Determination
If the required building space is square feet, below is the step to obtain building dimension:
Divided total space required with 2. Based on the previous case, /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

28. 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

29. 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)

30. 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 /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)

31. THANK YOU 