Industrial Engineering Departement – ITS, 2011

INTRODUCTION TO FACILITIES
Facilities Planning

PLANNING
 Facilities Planning as one of Strategic Planning

 Business owner will invest a big money on the

project
 Developing and procuring several long-term
capital assests, such as: building, machines,
equipments, etc.
 Treat with uncertainty of demand on business
market
 Long term maintenance process of production
facilities.
 The Overall Planning Process. Planning should
Facilities Planning

cover the input-process-output circle of

production.

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 Scopes

Facilities Location

Facilities Planning Facilities Design

Building Structural Design

Facilities Planning

Facilities Lay Out Design

Material Handling System Design

 Objectives of Facilities Planning

 Support the organization’s vision through improved

material handling, material control, and good
housekeeping
 Efectively utilize people, equipment, space,and energy
 Minimize capital investment
 Be adaptable and promote ease of maintenance
 Provide for employee safety and job satisfaction
Facilities Planning

Tomkins,et.all, 1996
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 Overall Design

FACILITIES DESIGN
“The overall design of enterprise”

•FINANCIAL ANALYSIS
•LOCATION OR ALLOCATION PLANNING
•PROCESS AND PRODUCTION LINE BALANCING
•PEOPLE ARRANGEMENT
Facilities Planning

•WAREHOUSE DESIGN
•SUPPORTIG FACILITIES
•ETC

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 Typical Design Problem in Automated Manufacturing
Systems

Layout of Inventory &

Facility Location Machine of Cells
Machines Cells Distribution

Layout of
Type and Volume Overall System
Tools and Fixture Equipment
of Products Design
within Each Cells

Material
Manufacturing
Process Planning Handling Scheduling Jobs
Process
Methods
Facilities Planning

Design of Type & Qty of Type & Qty of Flow of Products

Component Equipment MHD and People

(Heragu, 1997)
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 Systematic Planning on Facilities Planning
Market
Process Design Product Management
Survey
Design Policy andProjection

Location and Cost Financing

Cost Analysis
Layout Planning CUSTOMER

Building Machines/Equipment
Development Procurement 1
Sales &
2 Marketing
Manufacturing Process

Warehousing &
shipping
Material PRODUCTION
Receiving & Raw
Material Storage
Facilities Planning

Procurement Distribution

Assembly

Packaging
Production
Human resources, Process
1 Management Process
Energy, IT
2 Process Planning

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 It’s time to relax…
Facilities Planning
 Facility is...
In General, Facilities are include Employee, Material,
Machine, and other Equipment.
Facility could be apply for any tranformation of
tangible value of product in production plant and also
on creating a service.
Arranging the facilities become so important to reduce
the operational cost, utilize the capital, minimizing
the manintenance cost, and increase the safety of
works.
Facilities Planning
 6 Principals on Facilities Design

Total Integration
Minimizing the distance of flow
Flow of operations
Space utilization
Employee Safety and Satisfcation
Flexibility
Facilities Planning
 Some problems in Layout Design

• Space Availability
• Flow of Material
• Material Handling
• Flexibility (demand and variation
of products)
Facilities Planning
 Engineering Design Process

Define the
problem

Implement the Analyze the

design problem

Generate
Select the
Facilities Planning

alternative
preferred design
designs

Evaluate the
TOMKINS, et.al (1996) alternatives
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 10 General Steps of Facilities Planning Process

1. Define or 2. Specify primary 4. Determine

3. Determine the
redefine objective and support space
interrelationships
of the facility activities requirements

6. Evaluate 5. Generate
8. Implement the 7. Select a facilities
alternative alternative
plan plan
facilities plans facilities plans
Facilities Planning

Maintain and Redefine the

adopt the facilities objective of the
plan facility

TOMKINS, et.al (1996)

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 10 Steps of Facilities Planning Process : Manufacturing

2. Specify the
1. Define or redefine the 3. Determine the 4. Determine space
manufacturing
product to be interrelationships requirements for all
processes required to
manufactured among department activities
produce the product(s)

6. Evaluate alternative 5. Generate alternative

8. Implement the plan 7. Select a facilities plan
facilities plans facilities plans
Facilities Planning

Maintain and adopt the Redefine the objective

facilities plan of the facility

TOMKINS, et.al (1996)

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 10 Steps of Facilities Planning Process : Hospital

2. Specify the 4. Determine

1. Define or 3. Determine the
medical services space
redefine the interrelationships
required to satisfy requirements for
health needs for all services
the health needs all services

6. Evaluate 5. Generate
8. Implement the 7. Select a hospital
alternative alternative
plan plan
hospital plans hospital plans
Facilities Planning

Maintain and Redefine the

adopt the hospitak objective of the
plan hospital

TOMKINS, et.al (1996)

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 It’s time to relax…
Facilities Planning
 Plant, Factory & Pabrik ?

 Plant, factory, production & manufacturing

activities.
 Proses fabrikasi & perakitan (assembly)

• Raw Material,
• Production
Spare parts, etc. Process
• Finished
• Machines and • Goods Product
Facilities Transformation • Services
of Physical • Waste
• Employee
Facilities Planning

product and
• Energy value of product • Information
• Information, etc.

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 Types of Factories

 Raw Material/Primary
Industries
 Manufacturing Industries
(Producer/ Consumer Goods)
 Distribution/Transportation
Industries
 Service Industries
Facilities Planning

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Type Factories based on product flow

Downstream
Industries
• Medium/Low Tech
• Finished Goods,
Consumer Goods
• Labor Intensive
Upstream Industries
• High Tech
• Capital Intensive
• Semi-Finished Goods,
Producer Goods
• Basic processing of material
(metal,chemical,electronic,etc)

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 Type of Production Process
Characteristics Mass Production Job Order Project
1. Final Product Similar Several Product Single/Spesific
2. Quantity Huge numbers Small numbers Only One
3. Type of equipments Specific and Complex General Purposed General Purposed
4. Layout arrangement By Product By Process By Process

5. Material Handling Conveyor Removeable MH and Portable MH and Big

Big Capacity of Loader Capacity of Loader
6. Inventory Level Low High High for main materials

7. Labor Skill Low Moderate High

8. Diffuculity of Jobs Easy Hard Very Hard

9. Flexibility Very low High High

10. Price of per product Low High Very High
Facilities Planning

Examples : Car Production Machinary Workshop Bridge Construction

Textile production Tools Workshop Highway Construction

Sugar Cane Prduction Apartement Construction

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 Supply Chain of a Typical Mfg Industry

3rd Parties
Manufacturing (Warehouse,
Suppliers Retail Consumer
Company Dealer,
Distributor)
Facilities Planning

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 Strategic Alliances – Horizontal and Vertical

Joint Venture Links

Supplier Links Distribution Links

Raw Manufacturing End

Customers
Materials Firm
Facilities Planning

Joint Venture Links

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