Facility Layout: Eng. Alexander Aragón Ch. M.SC

564201
Facility Layout
Eng. Alexander Aragón Ch. M.Sc.
Department of Operations and Systems - DOS
Faculty of Engineering
Class
2021-03
www.alexanderaragon.co
Art. 57° Res. CA. 666 Dic. 17 / 2020

«Student Regulations»
Art. 9° Res. CA. 6602 Oct. 30 / 2017
«Code of Ethics»
Personería jurídica, Res. No. 0618, de la Gobernación del Valle del Cauca, del 20 de febrero de 1970. Universidad Autónoma de Occidente, Res. No. 2766, del Ministerio de Educación Nacional, del 13 de noviembre de 2003, Acreditación Institucional de Alta Calidad, Res. No. 16740, del 24 de agosto de 2017, con vigencia hasta el 2021. Vigilada MinEducación.
Module 2
Plant Layout Design
Session 5
Factors affecting Plant Distribution – 115

Material Factor – 116
Machinery Factor – 119
Man Factor – 122
Movement Factor – 125
Wait Factor – 129
Service Factor – 133
Building Factor – 138
Change Factor – 141
Discussion examples – 143
Review activity – 145
Assessment activity – 146
Glosary – 147
References Session – 148
114
/-\\ 2021-03. Didactic support material – Eng. Alexander Aragón Ch. (www.alexanderaragon.co) – Universidad Autónoma de Occidente 564201 - Facility Layout
Factors that affect the design of a Plant Distribution
The design of a plant distribution is affected by many factors, which in general terms have been grouped into eight (8)
categories1:
1. Material Factor: That includes design, variety, quantity, operations and necessary sequences (raw materials, in process and finished).
2. Machinery Factor: Equipment for production, tools and their use.
3. Man Factor: The Human Talent employed in production both in supervision, service and of course, directly and indirectly in the
process.
4. Movement factor: both man and materials, transport, handling, inspection.
5. Waiting Factor: Temporary or permanent storage of finished goods, in process or raw materials, delayed for dispatch or processing.
6. Service Factor: Maintenance, inspection, disposal, programming and dispatch.
7. Building Factor: Internal and external characteristics of the constructions.
8. Change Factor: Versatility, flexibility and expansion.
4 5
3 6
2 7
1 8
115
1. MATERIAL Factor
The most important to consider in the distribution of the plant, it is composed
of the following elements1:
What about this Factor in
our campus?
• Raw Materials.
• Incoming material.
• Material in process.
• Finished products.
• Outgoing or packed material.
• Accessory materials (inputs) used in the process.
• Pieces refused, to recover or repeat.
• Recovery material
• Scrap metal, chips, waste.
• Packing material.
• Material for maintenance, workshop or other services.
Identify first
Where are materials of all kinds?
116
1. MATERIAL Factor
And the considerations that, in turn, affect the Material Factor are1:
Physicochemical characteristics Specs
Size, Shape and Volume, Weight, Easy to manufacture and assembly design
Condition (Solid, Liquid, Soft, Flexible), Updated plans and formulas
Fragility, Danger. Quality according to the requirements
Temperature, Lighting, Humidity, Dusts, Bill of Materials (BOM)
Vapors, Vibrations, Floor Loading, etc.
Parts and Production Sequence Quantity and Variety

Order of operations, possibility of No. of different references, Production
improvements, parts and standard Quantity of each one, variation (seasons)
materials (Design) of production
Bill of Materials (BOM), Process Diagram MRP, Planning and Production Control
And all this, for each of the materials involved in the process (or not)
1. Dumper truck. Labs. Industrial Eng.
117
1. MATERIAL Factor
The list of necessary resources will then be:
• Technical Specifications of the products to be manufactured. Bill of Materials (BOM),

Assembly Diagrams.
• Technical specifications of the raw materials to be used.
• Technical specifications of the additional materials.
• Safety Data Sheets - MSDS.
• Material Requirement Planning - MRP.
• Process Characterization, Process Diagrams.
A practical and simple tool for creating different types of Diagrams, is available for free.
https://app.diagrams.net/
118
2. MACHINERY Factor
The one that follows in order of importance refers to the equipment and tools
necessary for the process1:
our campus?
• Production machines
• Equipment for treatment.
• Special devices
• Tools, molds, patterns, templates, assemblies.
• Measuring and testing devices and equipment.
• Manual and electric tools manipulated by operators.
• Control boxes
• Spare or inactive machinery.
• Machinery for maintenance, workshop or other services.
Identify first
Where there are machines / tools of all kinds?
119
2. MACHINERY Factor
And the considerations that, in turn, affect the Machinery Factor are1:
Process or Method Machinery and equipment
Previous study of methods, times and Type and number of each class, its
movements, before the distribution of the capacity. Enlistment times.
equipment.
Technical Specifications (Dimensions,
Weight, pipes, drains, insulation, etc.)
Machinery Utilization
Maximum equipment utilization, Machinery and Process Requirements
production planning and sequencing, Benches or tables and necessary
speed change. accessories, shelves, facilities.
And all this, for each of the machines involved in the process (or not)
120
2. MACHINERY Factor
• Technical Specifications of Machines / Equipment / Tools.

• Determination (calculation) of the number of Machines / Equipment needed,
• Man-Machine diagrams.
• Process Diagrams.
121
3. MAN Factor
Human Talent is much more flexible than any material or machinery, as it can be
moved, distributed, trained and adjusted to different distributions, although this
is not desired1: our campus?
• Direct Labor.
• Team leader / section / service.
• Indirect labor:
• Enlistment of machinery. • Security personnel.
• Material Handlers • Administrative staff.
• Gliders, Accountants. • Instructors / trainees / visitors.
• Engineers and Process Technicians. • Cafeteria staff and other services.
• Maintenance staff.
• Cleaning staff
Identify first
Where there are Human Talent of all kinds?
122
3. MAN Factor
And the considerations that, in turn, affect the Man Factor are1:
Work Conditions and Safety Workforce Needs
Risk Factors at Work. Elements of Personal Required skills, No. Of necessary
Protection, Codes and Security workers, No. of Shifts needed.
Regulations.
Use of Man Other considerations

Principles of Study of Movements M.T.M. Compensations, individual and group
incentives, psychosocial risks,
supervision needs.
And all this, for each of the people involved in the process (or not)
123
3. MAN Factor
• Determination (calculation) of the number of workers needed,

• Man-Machine diagrams.
• Process Diagrams.
• Left-Right Hand Diagrams.
• Anthropometric Dimensions / Workstation Design.
124
4. MOVEMENT Factor
And the considerations that, in turn, affect the Movement Factor are1:
Reduction of unnecessary handling Pattern or Circulation Model
An operation ends just where the next Planning of Input and Output of each
one begins. Use of gravitational force material and for each operation.
where possible. Machinery movement.
Men's Movement
Handling equipments
Space for movement
Equipment costs, operation, maintenance,
Corridors, elevated, underground or
capacity, secondary use, safety, efficiency
under jobs, outside the building,
folding equipment, etc.
Combined Handling
Analysis of Handling Methods Management equipment both support or
Knowledge about existing equipment work, storage or operation with time
for material handling. Knowledge of regulator (tape, monorail).
the process itself.
And all this, for each of the movements involved in the process (or not)
125
4. MOVEMENT Factor
• Technical Specifications of the products to be manufactured. Material Explosion (BOM), Assembly Diagrams.
• Technical specifications of the different equipment for material handling.
• Material analytical diagrams
126
4. MOVEMENT Factor
Whenever feasible, you will want to move the material:
• Towards its completion: Without setbacks, crosses in the flow.

• On the same element: No transfers to other equipment.
• Smoothly and quickly: No confusion, delays, unnecessary handling or difficult placement.
• According to the shortest distance: Avoiding long journeys.
• With ease: Without repeating movements or supplementary.
• With security: No danger to operators or materials.
• Conveniently: No physical effort
• Economically: without breaking the batch unit or requiring several trips.
• In coordination with production: Preventing production workers from having to spend extra time or additional efforts.
• In coordination with other handlings: Enabling the integration of different teams.
127
4. MOVEMENT Factor
The aisles must comply with:
• If possible straight: With few angles and avoiding blind corners (without visibility).
• Clear: No protrusions of machinery, equipment, columns, fire extinguishers or drinking fountains.
• Marked: On the ground, for clarity of its limits.
• Minimum distances: Tables and flow charts to identify their proper location.
• With double side access: Corridors to the walls serve only on one side.
• Main aisles: For first order traffic.
• Straight (90°): This requires less space.
• Economic Length: Neither too short or too long. Well calculated.
• Of appropriate width: Following the recommendations of the case.
• Only one way: When the widths are limited.
128
5. WAIT Factor
Related to the flow circuits of the material (its movement), and whose objective
is that the circulation of the material is clear and fast through the plant1. Waiting
costs include: our campus?
• Management costs to the point of waiting and from there to production.

• Driving costs in the waiting area.
• Costs of the records to track the waiting materials.
• Space costs and overhead.
• Interest on money represented by idle material.
• Costs of protection and care of the waiting material.
• Costs of the containers and / or retention equipment involved.
Identify first
Where are waits for all kinds?
129
5. WAIT Factor
And the considerations that, in turn, affect the Standby Factor are1:
Waiting Point Location

Space for each waiting point Fixed waiting point far or near the flow
Amount of material and storage circuit.
method. In the flow circuit (Buffer).
Waiting time (consumption rate).
Storage Method
Precautions and Equipment Cubic use.
Protection against damage, Outer space. Dimensions of spaces
breakdowns, fire, humidity, corrosion, multiple of those of the material.
theft.
Storage equipment Shelves, stackable
containers, etc.
And all this, for each of the waiting involved in the process (or not)
130
5. WAIT Factor
Therefore, it will be necessary to consider:
• Reception areas for incoming material.

• Raw material storage.
• Storage within the process.
• Delays between operations.
• Storage areas for finished products.
• Storage areas for supplies (supplies), returns, packaging, waste, defective, for maintenance.
• Storage areas for inactive or spare tools, machinery and equipment.
• Empty containers and related equipment.
131
5. WAIT Factor
• Technical specifications of the raw materials to be used.

• Technical specifications of the additional materials.
• Safety Data Sheets (Material Safety Data Sheet - MSDS).
• Material Requirement Planning - MRP.
• Process Characterization, Process Diagrams.
132
6. SERVICE Factor
All those activities, elements and people that serve or support production to
always keep it in productive activity1. Composed by:
our campus?
• Relative to staff:
• Access roads, personal use facilities, fire protection, lighting, heating and
ventilation, offices.
• Regarding the material:
• Quality Control, Production, rejections, lost and waste.
• Related to machinery:
• Maintenance, distribution of auxiliary service lines.
Identify first
Where are all kinds of services?
133
6. SERVICE Factor
Therefore, it will be necessary to consider, in the case of staff:
• Access and circulation corridors according to the number of people.

• Parking, changing rooms, bathrooms, showers, disinfection rooms, smoking areas.
• Waiting rooms, shift control (clocks).
• Boards and notices
• Nursing and first aid.
• Cafeteria, dining rooms, dispensing machines.
• Cleaning equipment
• Personnel, administrative offices,
• Standards lighting, noise, heat, vibration.
Acceso
134
6. SERVICE Factor
In the case of the material:
• Location and equipment of inspectors and quality verifiers.

• Raw material storage areas in quarantine.
• Location and provision of quality control laboratories.
• Location and equipment for the control of rejected or waste, recovery or recycling of materials.
Basuras
Calidad
135
6. SERVICE Factor
In the case of machinery:
• A frequent mistake is not to allocate space for on-site maintenance.

• Equipment and personnel for maintenance.
• Water, electricity, gas, air, data supply networks.
Mantenim.
In Situ
Cuarto
Mantenim.
136
6. SERVICE Factor
• All documentation related to the materials, equipment and people involved that require some type of service.
137
7. BUILDING Factor
Depending on whether it is a new building, or an existing one, the adjustments
that adapt to the production process or services that it intends to house inside1
must be considered. Considers: our campus?
• Special or general purpose building.

• Of a single plant or several.
• Shape
• Basements, mezzanines
• Soils
• Roofs
• Walls and columns
• Lifts, stairs, cargo elevators.
• Access roads.
• Canals or rivers.
• bridges.
• Patios, parking.
• Silos, tanks, landfills, wells.
• Docks, ramps.
Identify first
Where are there special requirements for the building?
138
7. BUILDING Factor
• General purpose buildings are easy to adapt and sell.

• The number of floors responds to the needs of the process, to the volumes and weight of the products.
• The shape of the building is preferred square or rectangular that is easy to expand.
• If have basements it's necessary guarantee height, ventilation, foundations, lighting and waterproofing, free of water
leaks.
• Windows provide lighting but also affect the process by the entry of heat (or cold) and dust.
139
7. BUILDING Factor
• The floors must withstand the load of materials, people, machinery and the building itself.
• The roofs must protect the interior of the plant against inclement weather. In some cases, support equipment handling
high materials such as cranes or monorails.
• Steel or reinforced concrete columns are what support the building. However, its configuration can present a huge
restriction in terms of ample usable space.
• The exterior walls are usually of masonry and the interiors of prefabricated panels, if it is viable.
• Location of access docks of cargo vehicles.
140
8. CHANGE Factor
The operating conditions always change, so the distribution will be affected1.
Considerations in this regard include:
our campus?
• Change in design of materials, product, demand, variety.
• Changes in the process (machinery or methods).
• Personnel changes (skills, shifts, supervision).
• Changes in auxiliary activities (services, storage, building itself).
• External changes and limitations due to installation.
Identify first
What possible medium or long term changes can occur?
141
8. CHANGE Factor
• Machinery and movable equipment as the main element of flexibility,

• Easy access service lines.
• Standard equipment (uniforms).
• Future expansion possibilities horizontally and / or vertically.
142
Factors discussion example
Do you recognize this building?
Could you identify the differences?
What can you say about these factors?
1. Material Factor
2. Machinery Factor
3. Man Factor
4. Movement factor
5. Waiting Factor
6. Service Factor
7. Building Factor
8. Change Factor
Year of drawing: 1993

Year of ending: 1999
143
General discussion example
Now, you have concepts about:
• Purposes in page 17,
• Principles in page 19.
• The PQRST Key in page 84.
• Factors in page 115.
How can you relate and consider them in your design?
144
Review activity
Now, we are going to review some concepts using your mobile phone. Scan the QR code or visit www.kahoot.it and wait for the access
code.
145
Assessment activity
For class in week 9, create a mind map of key concepts about this topics:
1. The Distribution Factors.

2. From video Plant Layout Tutorial - Chapter 8: Route Planning.
Remember that you can use this software application online: https://www.mindmaps.app/
Title: Plant Layout Tutorial - Chapter 8: Route planning

Posted by: Invest Northern Ireland
Duration: 3:03
Language: English (you can activate subtitles)
146
Glosary
Incorporate in this Glossary page, at least 5 terms or acronyms used in this session, with their respective definitions. You will need for
incorporating it in the final report.
147
References Session 5:
1. MUTHER, Richard & HALES, Lee. Systematic Layout Planning. Management & Industrial Research Publications. Marietta. GA, USA. 2015. 416 p.
Material compiled by Alexander Aragón Ch. For academic use only.
Copyright notice: This presentation may contain copyrighted material cited in the sources consulted; Other material may conform to the uses allowed under the Multimedia guidelines and exemptions for academic use in Copyright laws in some
countries or under Creative Commons licensing. Use for other pourposes is prohibited.
Images: |
Icons: Graphic Resources SL (www.flaticon.com)
YouTube Videos:
This work is covered under the Creative Commons Attribution-Share Alike 3.0 Unported License. To see a copy of this license, visit http://creativecommons.org/licenses/by-sa/3.0/deed.es.
/-\\ Last Update: September 12, 2021.
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564201

Art. 57° Res. CA. 666 Dic. 17 / 2020

Factors affecting Plant Distribution – 115

Parts and Production Sequence Quantity and Variety

• Technical Specifications of the products to be manufactured. Bill of Materials (BOM),

• Technical Specifications of Machines / Equipment / Tools.

Use of Man Other considerations

• Determination (calculation) of the number of workers needed,

• Towards its completion: Without setbacks, crosses in the flow.

• Management costs to the point of waiting and from there to production.

Waiting Point Location

• Reception areas for incoming material.

• Technical specifications of the raw materials to be used.

• Access and circulation corridors according to the number of people.

• Location and equipment of inspectors and quality verifiers.

• A frequent mistake is not to allocate space for on-site maintenance.

• Special or general purpose building.

• General purpose buildings are easy to adapt and sell.

• Machinery and movable equipment as the main element of flexibility,

Year of drawing: 1993

How can you relate and consider them in your design?

1. The Distribution Factors.

Title: Plant Layout Tutorial - Chapter 8: Route planning

Material compiled by Alexander Aragón Ch. For academic use only.

Icons: Graphic Resources SL (www.flaticon.com)

/-\\ Last Update: September 12, 2021.

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