1. Facilities Planning and Design Course code: 1704031511
Spring
Required Text: Tompkins et al., (2003). Facilities Planning, 3rd or later Edition, John Wiley and Sons Inc.
Students are encouraged to refer to the text book, and to take notes during the lectures.

2. Chapter 2: Product, Process and Schedule Design
Chapter Topics:
PART I
Facilities Planning Process for Manufacturing and Assembly Facilities.
Relationship between PP&S design and Facilities Planning.
Product Design
PART II, III, IV
Process Design
Schedule Design
Facilities Design

3. Facilities Planning Process for Manufacturing and Assembly Facilities.
1. Define the products to be manufactured and /or assembled.
2. Specify the required manufacturing process and/or assembly processes and related activities.
3. determine the interrelationships among the activities.
4. Determine the space requirements for all the activities.
5.Generate alternative facilities plans.
6. Evaluate the alternative facilities plans.
7. Select the preferred facilities plan.
8. Implement the facilities plan.
9. Maintain and adapt the facilities plan.
10. Update the products to be manufactured and/or to be assembled and redefine the objective of the facility.

4. Relationship between PP&S design and Facilities Planning.
Before we start developing alternative facility plans, we should have answers for the following questions:
What is to be produced?
How are the products to be produced?
When are the products to be produced?
How much of each product will be produced?
For how long will the product be produced?
Where will the products be produced?

5. Product Design Specify products to be made in the facility
Detailed design of each product.
Impact of Product design on Process, Schedule and Facilities planning.
Tools used in Product Design:
Quality Function Deployment (QFD)
Benchmarking
Concurrent Engineering (CE)
CAD systems

6. Specify products to be made in the facility
Product Design – Product Determination
Marketing
Manufacturing
Finance
Most of the time final decisions are made by the top management
Uncertainty regarding the mission of the facility:
The occupants of the facility may change frequently or may never change at all
If changes are likely – a high degree of flexibility and a very general space
If a high degree of confidence about the products – the facility design should optimize the production of those products
Product specifications (dimensions, material, packaging, etc.)

7. Product Design – Detailed Design
The detailed design of the product is influenced by aesthetics, function, materials and manufacturing considerations
Quality Function Deployment - translation of the customers’ desires into product design, and subsequently into parts characteristics, process plans and production requirements.
Benchmarking – used to identify the
approach of the competition

8. Product Design – Detailed Design
Finally, detailed designs take place (CAD designs, prototypes, assembly designs, 2D drawings and dimension determinations)
Concurrent Engineering is a systematic way of enabling communication between all the related units during the product development
The aim is to minimize the changes in design parameters once the design is finalized
70% of the manufacturing cost is set during the design phase
Changing the design later in the process costs significantly more

9. Sequential development method Concurrent development method

10. Cost of Product Design Changes during its life cycle
100
Life-cycle cost committed
Total Cost (%) 60
Cost incurred 40 20
Ease of change
Conceptual Design
Detailed Design Prototype
Manufacturing
Distribution, service, and disposal
Design phase determines the most of the costs associated with delivering a product.Typically, 70-80% of the cost of a product is fixed at the design stage.

11. Product Design - Documentation
Once the product design is completed, usually following documents are provided for the facilities planning process as inputs
Exploded assembly drawing – omits
specifications and dimensions
Exploded parts photographs
Component part drawing - detailed

12. Exploded Assembly Drawing

13. Exploded Parts Photograph

14. Component Part Drawing

15. Component part drawing