Facilitiesand Workplace

Design
An lllustratedGuide

by

QuartermanLee

with
Arild EngAmundsen
WilliamNelson
HerbertTuttle

ENcrxeenrNc& MatacereNr Pness

Instituteof IndustrialEngineers
Norcross,Georgia,USA
http:llwww.iieneLorg
@ 1997 Institute oflndustrial Engineers. All rights reserved.
Published by the Institute of Industrial Engineers.
Printeil in the United Statesof America.

No part of this book may be reproduced in any form without written permission
from the Publisher. The views and concepts presented are those of the
contributors. Publication by the Institute of Industrial Engineers does not in any
way constitute endorsementor approvalof the book s contents.
No responsibility is assumedby the Publisher for any injury andlor
damage to persons or ProPerry as a matter of product's liability' due to negligence
or otherwise,or from any use or operation of any methods,Products,instructions,
or ideascontainedin the material herein.

02 01 00 99 98 97 6 5 4 3 2 r

CATALOGING-IN-PUBLICATION DATA
Lee, Qrarterman.
Facilities and workplace design: an illustrated guide/by Qrarterman Lee;
with Arild Eng Amundsen, William Nelson, Herbert Tuttle.
p. cm. -- (Engineersin businessseries;3)
Includes bibliographicalreferencesand index.
ISBN 0-89806-166-0
1. Plant lzyout. 2. Plant engineering. 3. Office layout. 4. Work
environment. I. Amundsen, Arild Eng. II. Nelson, William. III. Tuttle,
Herbert. IV. Title. V. Series.
TSI78.L44 1996
658.2'3--dc20 96-22972
CIP

Director/Engineering & Management Press:Eric E. Torrey

Editor: Forsyth Alexander
Cover by Marty Benoit
Printed by Edwards Brothers Inc.

ISBN 0-89806-166-0

Engineering & Management Press

25 Technology Park
Norcross,GA 30092
 Table of Contents
Preface ............... v
A c k n o w r e o g r " n t r . . . : : . : . . . . : . . . . . . : . : : . . : . : . : . . . : . : : . . : . . . . . : . . . . . . :".i.i. . . . : . . . . . . . . .

Chapter 1 - Facilities in a Changing Environment...............1

Working facilitiesin modernhistory ...............
3
Facilitiesin a changingenvironment..................................
5
Approachesto facilitiesplanning .....................
9
The industrial engineer'srole in facility planning .............t2

Chapter 2 - The Framework for Facilities Design.............13

The levelsof spatialdesign........ .....................
13
The phasingof spacedesign .......2l
The spaceplan elements............... .................
23
Spaceplan ................
27
The designproject........ ...............
28

Chapter 3 - The Macro-Space-Plan ..................

29
Introducing CosmosProducts .... 32
Planningthe project ....................
32
Informationacquisition tasks.......... ................33
Identifyingphysicalinfrastructure.....................................
50
The strategicframework................ ................
52
Key manufacturingtasksand focus opportunities.............54
Identi$'ingoperationsstrategy...... ..................58
Designingthe spaceplan ........... ....................
65
Cosmoscell and processdefinition ................
69
The spaceplan primitive .............88
Constraints ...............
88
 Design of Experiments

Designing macro-space-plans ..... 91,

Identifyingkey materialhandlingissues.........
..................
94
Decidingon the bestspaceplan........... ..........95
Evaluatingthe Cosmosspaceplans ...............
99

Chapter 4 - Macro-Space-Planning
and WorkCellDesi9n................ ... 109
Workcells........... ... 111
Interpretingterminologyand conventions............
..........772
The micro-leveltasks ................
114
Selectingthe products.................
The DiamondEquipmentCompany..............................119
Gator SteelFoundry.............. ....725
Designingthe process ................128
Planningcellinfrastructure .......... .................136
Externalproductioncontrol .......138
Designinga spaceplan........... ....I49
Selectingthe bestplan ........... ....157

Chapter5 - WorkstationDesign:
the Sub-Micro-Space-Plan t67
Allocationof functions ...............162
Motion economy .... 165
Ergonomics ............L66
The workstationspacepIan............ ..............
774

Chapter 6 - Site Planning and Location............................

183
Sitelocationand acquisition.............. ..........184
Siteplanning................ .............
188

Chapter7 - OfficeSpacePlanning ...................203

Approachesto office planning .. 204
The officelayoutteam .......... .... 207
The layout project .. 207

ChapterS -A Final Note ..................215

Gfossary ...........277
Bibliography
.................. ........227
fn d e x ...............225
Aboutthe authors .......,.,.,.,.,.231
..232
 Preface

Modern factorylayoutbeganmost notably at Highland Park, Michigan.

There, Henry Ford and CharlesSorensenfirst put large-scaleflow line
production into place.Layout, the arrangementof equipmentwithin
the building space,was the most striking featureof Ford production.
The layout of Ford factorieswas so noticeable,it disguisedrhe more
intangibleelementsof Ford and Sorensen's highly integratedandwell-
thought-out manufacturingsystem.As a result,manyfactorymanagers,
businessexecutives,and engineersstill try to replicate eady Ford
layouts.Theseimitationsoften areill-suited to their businesspurposes.
Evenwhen managersdo not copyFord layouts,they continueto believe
that layoul is the heart of efficient production.
And so it is, but only as the culmination of a rational design
process:aprocessthat movesfrom globallocationto workstations,from
policy to operations.It is a processthat includesthe entire range of
tangibleand intangibleelements.The resultis a designthat integrates
products,service,people,information, and technology.
Our facilitiesplanning approachbuildson the pioneeringworkof
RichardMuther andKnut Haganas,both ofwhom delelopedsystematic
layoutplanning (SLP) and systematichandling analysis(SHA). These
conceptsremainvalid after almostthirty-five years.Our approachuses
contemporarylanguageand examples.Data acquisition is stressed.
Perhapsmost importantly, we integrate manufacturingstrategyand
manufacturingfocus,conceptsfirst put forth byWickham Skinnerand
first recognizedas connectedby William Wrennall.
This is more than a manufacturingbook, however.The concepts
originally developedfor industry now apply to services.Products and
 FacilitiesPlanning

servicesmeld togetherin almosteveryviableenterprisein today'sworld.

"business
The conceptof process"coversall productivehuman activity.
Government, education, the professions,and industry are simply
variationson a few centralideas.Therefore,the planning ofa government
facility or an idea fzctory follows the sameprinciples and approach as
the planning of an automotive factory.The planning of a hospital
follows the samecourseas the planning of a textile mill.
Under its
A facility projectoften is the catalystfor new strategies.
guise,managementmayopena strategicdebatethat bringstogetherthe
many disparatefunctionsand elementsof the enterprise.It canprovide
the structurefor analysisand discussion. The projectthen translatesthe
resultsinto steeland concrete.In this way, facilityplanning becomesa
large-scalereengineeringproject rather than an exercisein template
shuffling.
Our purposein writing this book is to help practicingindustrial
engineersnew to facility planning. We intend it to be practicalwith
manyexamples,forms,diagrams,andvisualaids.Visualapproaches are
especially important for facility planning. The human mind is usually
more creativein avisualmode.Illustrations,graphs,andchartseffectively
representcomplexspatialarrangements that havemanylevelsof detail.
Also, data is more significantfor most of us when we can seeit.
A plant layout is the product ofthousandsofdecisions,both past
andpresent.It is the physicalmanifestationofthe firm's manufacturing
strategy,whetherde factoor otherwise.Thesedecisionscoverthe entire
rangeof manufacturing-finance, personnel,process'product design,
and many, many other topics.We cannot possiblydo justice to all of
theseissues.We hope, however,to alert industrial engineersto their
existenceand importance.We hope to point the way to more rational
and strategicallyorientedfacility design.
 Acknowledgments

t{e this_opportuniryto thank others who helped with this book.

[e
Margie and curtJennings producedmuch of the aitwork. sandraLee
helped with research,data entry and proofing. Maura Reeves,Ellen
snodgrass,Eric Torrey, Forslth Alex"nd.r, anJ the staffat the Institute
of Industrial Engineershavesupportedus and helped make this final
product readable.