FACILITIES PLANNING & DESIGN

Alberto Garcia-Diaz
J. MacGregor Smith

CHAPTER 4
Layout Planning Procedures

1. Introduction
2. Systematic Layout Planning
3. From-to Program
4. Flow Planning & Patterns
5. Layout Planning Chart
6. Space Requirements
7. Facility Layout Program (FLAP)

1
 Introduction

Workstation
It consists of fixed assets needed to perform specific
operations. It can be considered as a facility itself. It
includes space for equipment, materials, and
personnel.

Planning Department
Planning departments are groups of workstations put
together in a plant layout.

2
Types
(a) Production line departments
(b) Fixed materials location departments
(c) Product family departments
(d) Process departments

3
7

4
 9

Guidelines for Combining Workstations in

Planning Departments

10

5
Activity Relationships
• Organizational
• Flow
• Control
• Environmental
• Process

Success in grouping workstations to form

planning departments greatly depends on the
ability of the planners to recognize all
important inter-departmental relationships
11

Conceptual Illustration (Figure 4.1)

Space Planning
Units Block Layout

Affinity
Diagram

Affinities
Space
Requirements

Constraints
12

6
 Systematic Layout Planning

Input Data: P, Q, R, S, T and Activities

From-To-Chart 1. Flow of Materials 2. Activity Relationships Relationship Chart

3. Relationship Diagram

4. Space Requirements 5. Space Available

6. Space Relationship
Diagram

7. Modifying Considerations 8. Practical Limitations

Plan X Plan Y Plan Z

9. Evaluation

Selected Layout Plan

13

Relationship Chart
Closeness Relationships
A = absolutely necessary
E = especially important
I = important
O = ordinary closeness acceptable
U = unimportant
X = not desirable to be close
1
Receiving (1) 2
E 3
Milling (2) O 4
U I 5
Press (3) E O 6
U I U 7
Screw Mch. (4) U I U
I O U 1
Assembly (5) U U 2
A U 3
Plating (6) I 4
E 5
Shipping (7) 6
7

14

7
 Flow Patterns
Within Workstations
Motion studies & ergonomics
Within Departments
Ring: Fig. 4.9 (a)
Spine: Fig. 4.9 (b)
Tree: Fig. 4.9 (c)
Random: Fig. 4.9 (d)
Between Departments
Straight line: Fig. 4.10 (a)
L-shaped: Fig. 4.10 (b)
U-shaped: Fig. 4.10 (c)
S-shaped: Fig. 4.10 (d)
Circular: Fig. 4.10 (e)

15

Flow Planning

Flow Planning = Flow Principles + Aisle Widths

1. Maximize direct flow paths (no

intersections, no backtracking)
2. Minimize flow (work simplification)
3. Minimize flow costs.

See Table 4.2 , p. 91 for guidelines on aisle widths

16

8
 FACTORS AFFECTING AISLE WIDTHS

Use of the aisle: material, personnel,

handling equipment, machinery, and
other equipment

Frequency of use: volume of traffic (at

peak loads)

Speed of travel permitted or desired

One-way traffic or both

Possible future conditions of these points

17

SUGGESTED AISLE WIDTHS

1. For personnel only (2 persons 30" minimum

to pass)
2. For two-wheel hand truck (no 30" minimum
passing or turning with load)
3. For stock truck (where trucker 20" plus width of truck
must pass around it)
4. For stock truck (where other 38" plus 2 times truck width
trucks and workers must pass)
5. For hand-operated fork truck, 5 to 8' depending on load size
pallet transporter, semilive skid
and jack
6. For 2,000-pound fork truck 8' to 10'
7. For 4,000-pound fork truck 10' to 12'
8. For 6,000-pound fork truck 12' to 14'

18

9
 Measuring Flow

1. Quantitative Flow Measurement

From-To-Chart (large volumes
moved)
2. Qualitative Flow Measurement
Relationship Chart (low volumes
but intensive communication &
organizational relationships)

19

From-To-Chart
Product A: 1-2-3-4 Production volume = 10
Product B: 3-4-2-1-2 Production volume = 20

1 2 3 4

1 2 3 4
- 10+20 - -
1 = 30

20 - 10 -
2
- - - 10+20
3 = 30

- 20 - -
4

20

10
Assumption
Component B is twice as large as Component A & moving 2 units of A
is equivalent to moving 1 unit of B

1 2 3 4 1 2 3 4
- 10+20 - - - 10+40 - -
1 = 30 1 = 50

20 - 10 - 40 - 10 -
2 2
- - - 10+20 - - - 10+40
3 = 30 3 = 50

- 20 - - - 40 - -
4 4

Using Component A as the

reference product

21

Assumption
Component B is twice as large as Component A & moving 3 units of A
is equivalent to moving 1 unit of B
1 2 3 4 1 2 3 4
- 10+20 - - - 5+20 - -
1 = 30 1 = 25

20 - 10 - 20 - 5 -
2 2
- - - 10+20 - - - 5+20
3 = 30 3 = 25

- 20 - - - 20 - -
4 4

Using Component B as the

reference product

22

11
 Layout Planning Chart
1. Combines the detail of the process with
restrictions of work periods & production
quantity requirements
2. Provides data upon which to base machine,
manpower, material handling & storage
requirements
3. Developed by extending the route sheet to
obtain a flow-process chart

23

Chart Heading
1. Part number, part name, assembly number,
assembly name, material, and material size from
route sheet
2. Pieces/assembly & assemblies /product from
assembly chart
3. Production hours/day depend upon number of
shifts/day, hrs/shift, efficiency

24

12
 Chart Body (Column Headings)
Headings)
1. Step Number (counter)
2. Flow Process (activity at each step)
3. Description of Step
4. Operation Number (for fabrication operations)
5. Department
6. Standard Time
7. Machine Fraction
8. Operators per Machine (crew size)
9. Crew Fraction & Workers Required
10. Material Handling Requirements
11. Remarks

25

Flow Process
1. Fabrication operation (F
F)
2. Move (M
M)
3. Storage (S
S)
4. Inspection (II)
5. Operation number from route sheet
6. Department assignment should be delayed until
after decisions made on departments in final
layout

26

13
 Time Factors
1. Standard time per piece or per lot
2. Lot size included in chart heading
3. Storage & inspection times
4. Material handling time cannot be determined
yet
Standard time = (observed time x % rating) (1 + % allowances)

27

Machine or Equipment Requirements

TP
N=
60 HC
Manpower Requirements (Crews)

TP
Nc =
60 HCc

28

14
 Text, Fig. 6.2, p. 305

20

30

29

Space Requirements
• Calculation Method
• Conversion Method
• Standards Method

30

15
 Conversion Method
• New space estimated from present space
• Done on department-by-department basis
• Determined % change for @ department

Space Standards Method

• Most appropriate for service & storage areas
• Standards are usually per employee
• Determine % change for @ department

31

Route Pt Production Calculation

N=
Sheets ( H − s )p Quantities Method
Machine space including travel (MSPACE)

Operator and maintenance space (OMSPACE) Minimum Op. Space = 24” X 36”

•Input buffer storage

•Supplies & maintenance materials
Storage space (STSPACE) •Tools, dies, fixtures
•Rework, scrap, waste
•Output buffer storage

WSPACE = MSPACE + OMSPACE + STSPACE •Aisles

•Floor level conveyors

TOTAL WORKSTATION SPACE + TRANSPORTATION SPACE

DEPARTMENTAL SPACE + Allowance For Between-Department Aisles

32

16
 Textbook, Section 4.8
A Micro-Computerized Procedure
for Layout Design

33

Cycle of Facilities Design and Management

How can the computer be used to make
this process more productive?

Site Data
Location Overall
Preparation Layout
Analysis

Facilities
Management Computer
Graphics Detailed
Information
System Storing Layout

Comparison
Installation of
Alternatives

34

17
 A Microcomputer Program To Assist in Plant
Layout
„ Program Description

1. The program carries out the transplantation,

selection, and evaluation phases
2. The program uses as input an activity
relationship chart and departmental area
requirements
3. From the relationship matrix, a closeness rank is
calculated for each department on the basis of number
of A,E,I,O and X relationships
4. A selection order is determined on the basis of
relationships and ranks

35

A Microcomputer Program To Assist in Plant

Layout

„ Closeness Ranks

1. From the relationship chart, a closeness rank for each

department is calculated on the basis of the number of
A, E, I, O, X relationships.

2. The department having the largest number of A’s will

receive rank 1 (most important). If necessary, break ties
with E’s, I’s, etc.
3. Subsequent departments having A’s are assigned ranks
equal to 2,3, 4, etc, as the number of A’s decreases. Ties
will be broken as indicated before.
4. Subsequent departments having E’s are considered in a
similar manner. Once they are finished, those with I’s will
be considered, and so on. 36

18
 A Microcomputer Program To Assist in Plant
Layout

„ Selection Order

1. Select the department with rank 1 (most important)

2. Select one department having the highest possible

relationship with the most important department.
If there are ties, break them by choosing the department
with best rank (numerically lower) in the group.

3. Subsequent departments are selected on the basis of the

total number of A’s, E’s, I’s and O’s between departments
not yet selected and those already selected. Ties will
be broken using ranks.

4. Construct a layout satisfying the selection order and

the closeness relationships.
37

A Microcomputer Program To Assist in Plant

Layout

„ Layout Scoring System

1. Use point values of, for example, 8, 4, 2, 1, 0 and

-8 for the symbols A,E,I,O,U, and X, respectively

2. From the layout diagram identify the

departments adjacent to each department

3. A score is computed by adding the point values of

the closeness relationship between adjacent pairs

38

19
 EXAMPLE 3
pp. 97-100

Departments Area (sq. ft.)

1. Receiving 12,000
2. Milling 8,000
3. Press 6,000
4. Screw Machine 12,000
5. Assembly 8,000
6. Plating 12,000
7. Shipping 12,000

39

RELATIONSHIP CHART
1
2
Receiving
E 3
O 4
Milling
U I 5
E O 6
Press 7
U I U
U I U
Screw Machine
I O U 1
Assembly U U 2
A U 3
Plating I 4
E 5
Shipping 6
7

40

20
 DEPARTMENTAL RANKS

Departments A’s E’s I’s O’s U’s X’s

1. Receiving 0 1 1 2 2 0
2. Milling 0 2 2 0 2 0
3. Press 0 0 0 2 4 0
4. Screw Machine 0 1 2 0 3 0
5. Assembly 1 0 3 1 1 0
6. Plating 1 1 1 1 2 0
7. Shipping 0 1 1 0 4 0

41

Department 6 Î 1A, 1E
Department 5 Î 1A, 0E

Department 1 Î 0A, 1E
Department 2 Î 0A, 2E
Department 3 Î 0A, 0E
Department 4 Î 0A, 1E
Department 7 Î 0A, 1E

Department 1 Î 1E, 1I
Department 4 Î 1E, 2I
Department 7 Î 1E, 1I

Department 1 Î 1I, 2O
Department 7 Î 1I, 0O

Rank 1 2 3 4 5 6 7
Dept. 6 5 2 4 1 7 3

42

21
 SELECTION ORDER OF DEPARTMENTS

1. Department 6 is selected first.

2. Department 5 is selected second.
3. For departments 1, 2, 3, 4 and 7 we have to
find the department that has the best set of
relationships with Departments 5 and 6:

1 2 3 4 7
A’s 0 0 0 0 0
E’s 0 0 0 0 1
I’s 0 2 0 1 1
O’s 1 0 1 0 0

43

Department 7 has 1E and 1I relationships with those

chosen. Note that this is better than department 2’s two I
relationships. Therefore, department 7 is selected third.
As an exercise, the students can verify that the following
selection order of departments is obtained:

Selection 1 2 3 4 5 6 7

Department 6 5 7 2 4 1 3

44

22
 PROPOSED LAYOUT

4
7 2
Screw
Shipping Milling Machine

3
Press
6 5 1
Plating Assembly Receiving

45

LAYOUT EVALUATION

1 2 3 4 5 6 7
1 I O 3
2 E I U 6

3 O U 1

4 0
5 A 8

6 E 4

7 0

Score = 3+6+1+8+4 = 22

46

23
 Documentation for Using the
From-To Program

• This program creates the “From-To” chart for

a given input of flows between departments for
each of the different parts manufactured in the
factory.
• The Excel Spreadsheet for keying the input has
numbered (Red color) steps to follow.

47

48

24
 Repetitive process for each part
number to be input
Button No. 3. Yellow cells are input cells.
• Clear all old values in yellow cells before input.
• Part number to be input.
• Quantity to be produced of that part in the
time period under consideration.
• Batch size used for moving that part between
machines.
• When a value is entered for the “Batch”, the
program computes the no. of trips on its own
using the formula No. of trips = Quantity / Batch
49

Button No. 4. Clear all old values in the yellow

cells before input. Enter the sequence in
which this part moves through different
departments in the yellow cells under “Button
4”. After finishing entering the sequence click
on “Button 4”.
Button No. 5. Click on “Total Part 1” for part
number 1 as we are working on part 1 now.

Button No. 6. Click on “Button 6” (“Total”). The

From To chart gets updated with this part
when you click on this button.

50

25
 Button No. 7. If you want to see the input that
you just gave for this part, click on “Button 7”
(View Table”). This will take you to the next
worksheet named “Operation”. If you want to
return to the input or main menu, then click
on the Menu work sheet.

Button No. 8. Once you are in the Menu

Worksheet, you can follow the same steps
from 3 to 7 to input details for the other
parts.

51

Once all the parts have been input, We need to ask

the program to create the From-To Chart. The
procedure is as follows.

• Scroll down the “MENU” worksheet till you see

the From To Format on the screen.
• Choose the number of Departments that you have
from the set of Radio buttons.
• Click on the “Reset Value After Choosing
Departments Number” button.
• Now choose the number of Departments that you
have from the set of Radio buttons again.
• Click on the “Show From-To Chart” button. This
will update the From To chart for the given data. 52

26
FACILITIES LAYOUT PROGRAM (FLAP)
Textbook, pp. 101-110

53

27