introduction pld

8/13/2019 Introduction Pld

1/6

MENG 5235-FACILITIES PLANNING AND DESIGN

Chapter 1 Introduction

Manufacturing and Service companies spend a significant amount of time and money to designor redesign their facilities. This is an extremely important issue and must be addressed before

products are produced or services are rendered. A poor facility design can be costly and may

result in: poor quality products, low employee morale, customer dissatisfaction.

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.

Facilities Planning (FP) has been very popular. It is a complex and a broad subject. It involves

people

Within the engineering profession: civil engineers, electrical engineers, industrialengineers, mechanical engineers are involved in FP.

Additionally, architects, consultants, general contractors, managers, real estate brokers,

and urban planners are involved in FP.

Facility Planning (FP) tools vary from checklists, cookbook type approaches to highly

sophisticated mathematical modeling approaches. In this course, a practical approach to facilities

planning will be employed taking advantage of empirical and analytical approaches using bothtraditional and contemporary concepts.

Applications of Facilities Planning (FP):

Facilities Planning (FP) can be applied to planning of: a new hospital,

an assembly department,

an existing warehouse, the baggage department in an airport,

department building of IE in EMU,

a production plant, a retail store,

a dormitory,

a bank, an office,

a cinema,

a parking lot,

or any portion of these activities etc

Facilities Planning (FP) determines how an activities tangible fixed assets best support achieving

the activitys objectives. i.e. what is the objective of the facility? How the facility achieves that

objective?

Facilities Planner considers the facility as a dynamic entity. Therefore continuous improvement

is an integral element of FP cycle.


2/6

Facility Location of the facility refers to its placement with respect to customers, suppliers, and

other facilities with which it interfaces.


3/6

Facilities Systems: Consists of the structural systems, the atmospheric systems, the

lighting/electricity/communication systems, the life safety systems and the sanitation systems.

Layout: Consists of all equipment, machinery and furnishings within the building.

Handling Systems: Consists of the mechanism need to satisfy the required facility interactions.

e.g. for a manufacturing system:

Significance of Facilities Planning: To understand the significance of Facilities Planning (FP)

consider the following questions:

What impact do facilities planning have on handling and maintenance cost? What impact do facilities planning have on employee morale, and how does employee

morale impact operating costs?

In what do organizations invest the majority of their capital, and how convertible is theircapital once invested?

What impact do facilities planning have on the management of a facility? What impact does facilities planning have on facilitys capability to adapt to change and

satisfy future requirements?

Objectives of Industrial Facility Location: Objective of Industrial Facility Location is todetermine the location which, in consideration of all factors affecting deliver-to-customers cost

of the products to be manufactured, will be minimized.

Some Typical Facilities Design Objectives are to:1. Support the organizations vision through improved material handling, material control,

and good housekeeping.

2. Effectively utilize people, equipment, space and energy.3. Minimize capital investment.4.

Be adaptable and promote ease of maintenance.5. Build flexibility into the plan.

6. Provide for employee safety and job satisfaction.7. Minimize unit and project cost8. Achieve the production start date.9. Optimize quality10.To increase productivity11.Others like No pilferage.

Facilities Planning Process: Although facility is planned only once, it is frequently replanned

to synchronize the facility and its constantly changing objectives. Planning and Replanning are

linked by the continuous improvement FP cycle (Figure 1). FP is not an exact science, but it canbe approached using an organized and systematic approach.

Traditionally, the ENGINEERING DESIGN PROCESS (EDP) can be applied

(similar to problem solving approach). It consists of following 6 steps: Define the problem,

Analyze the problem,

Generate alternative designs,


4/6

Evaluate the alternatives,

Select the preferred design,

Implement the design.

Applying the engineering design process to facilities planning results in the following process:

1. Define (or redefine) the objective of the facility,2. Specify the primary and support activities to be performed in accomplishing the objective.Requirements in terms of:

Operations,

Equipment, Personnel,

Material flows should be satisfied.

3. Determine the interrelationships among all activities,

4. Determine the space requirements for all activities,5. Generate alternative facilities plans,

6. Evaluate alternative facilities plans (alternative locations and alternative designs),

7. Select a facilities plan,8. Implement the facilities plan,

9. Maintain and adapt the facilities plan,

10. Redefine the objective of the facility.

Plant Design Situationsmay arise due to one or more of the following:

design and erection of a completely new plant design and erection of an addition to the existing plant the facility or plant operations and subsequent expansion restricted by a poor site,

thereby necessitating the setting up of the plant at a new site addition of some new product to the existing range adoption of some new process /replacement of some existing equipment modernization / automation of the existing facility expansion of the plant capacity relocating the existing plant at a new site because of new economic, social, legal or

political factors

Factors that influence layout

Volume, weight of items to be produced. Nature of the service to be provided. Cost of the building to house the operation. The product mix that must have a facility. The fragility of the product or component


5/6

Chapter 2Product planning, Process design and scheduling

Manufacturing is a complex process that begins with evaluating the market and investigating the

demands for a product, and ends with delivery of the actual product. Successful marketing

should take into account the factors that affect current and future demands for a product. Itprovides management with appropriate inputs for decision making and directing resources of a

company toward production of a part that is needed in the market. This sets the stage for productdesign and manufacturing as described in the following sections.

Product Design and Design for Manufacturability

At the product design stage, designers and product engineers generate new ideas and studyvarious aspects of design. Also, production engineers investigate the availability of the resources

and capabilities of the production system. CAD systems are extensively used at this stage for

rapid design and revisions of a product. Designs for manufacturability (DFM) and assembly are

used to emphasize the significance of the links between design of a product and itsmanufacturing. Design for manufacturing focuses on appropriate product design, process

planning, and manufacturing to ensure optimum results. It emphasizes the importance of quality

and its relation with the machines/processes accuracy of machined (produced) parts tolerances,and correction of a product defect at the design stage (as opposed to after production) and its

significant impact on cost of a product.

Manufacturing Process Design

The principal objective of manufacturing process design is to produce an organized plan for

converting raw materials into useful products. It involves the selection of timely and cost-effective methods to produce a product without compromising quality and reliability. As part of

the product development process, good manufacturing process design contributes to the

industrial competitiveness of a manufacturing enterprise, while poor process design contributesto cost and schedule overruns and the delivery of products that fail to meet some or all of the

customers needs.Manufacturing process planning often requires the consideration of severalmanufacturing processes for a specific part. In addition to considering manufacturing costs and

production time, rational planning should also involve evaluation of how well a particularprocess satisfies the design requirements, which are delineated within the engineering drawings

and reference specifications. The suitability of a given process may be based on many factors,

such as

1. The dimensions and geometric precision that can be obtained

2. The surface roughness that can be attained

3. The changes that may be produced in material properties and part performance

Unfortunately, there is seldom much time to conduct an exhaustive laboratory or computer-basedstudy and evaluation of all solution alternatives. A systematic approach to design that provides

fundamental principles for decision-making would facilitate process design while enabling the

designer to consider all important factors.

Metals Processing

Metal shapes and components can be produced by various casting, forming, and metal-removal

processes. In the case of metal removal, process planning involves selecting and sequencing the

appropriate machine tools and operations so as to convert a solid piece part from its initial shape


6/6

to a final, desired geometry. This involves matching machine and tool data to the design

requirements, subject to certain constraints imposed by the manufacturing organization and

facilities. In practice, it consists of five or more steps:

1. Interpretation of the engineering drawing and reference specifications2. Selection of machining operations to form the specified surfaces

3. Selection of machine tools for each machining operation4. Selection of jigs and fixtures to guide or facilitate machining5. Sequencing the machining operations

introduction pld

Documents