PRODUCTIONS AND OPERATIONS MANAGEMENT

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Facilities Location, Design and Layout

Module 005 | Facilities Location, Design and

Layout

For an organization to have an effective and efficient manufacturing unit, it is

important that special attention be given to facility layout. Facility layout is
an arrangement of different aspects of manufacturing in an appropriate
manner as to achieve desired production results. Facility layout considers
available space, final product, safety of users and facility and convenience of
operations.

An effective facility layout ensures that there is a smooth and steady flow of
production material, equipment and manpower at minimum cost. Facility
layout looks at physical allocation of space for economic activity in the plant.
Therefore, main objective of the facility layout planning is to design effective
workflow as to make equipment and workers more productive.

Objectives:

1. Understand the concept of an effective facility layout.

2. Design effective workflow as to make equipment and workers more
productive.

Facility Layout

Facility Layout Objective

A model facility layout should be able to provide an ideal relationship

between raw material, equipment, manpower and final product at minimal
cost under safe and comfortable environment. An efficient and effective
facility layout can cover following objectives:

• To provide optimum space to organize equipment and facilitate

movement of goods and to create safe and comfortable work
environment.
• To promote order in production towards a single objective
• To reduce movement of workers, raw material and equipment
• To promote safety of plant as well as its workers
• To facilitate extension or change in the layout to accommodate new
product line or technology upgradation
• To increase production capacity of the organization

An organization can achieve the above-mentioned objective by ensuring the

following:

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 • Better training of the workers and supervisors.
• Creating awareness about of health hazard and safety standards
• Optimum utilization of workforce and equipment
• Encouraging empowerment and reducing administrative and other
indirect work

Factors affecting Facility Layout

Facility layout designing and implementation is influenced by various factors.

These factors vary from industry to industry but influence facility layout.
These factors are as follows:

• The design of the facility layout should consider overall objectives set
by the organization.
• Optimum space needs to be allocated for process and technology.
• A proper safety measure as to avoid mishaps.
• Overall management policies and future direction of the organization

Design of Facility Layout

Principles, which drive design of the facility layout, need to take into the
consideration objective of facility layout, factors influencing facility layout
and constraints of facility layout. These principles are as follows:

• Flexibility: Facility layout should provide flexibility for expansion or

modification.
• Space Utilization: Optimum space utilization reduces the time in
material and people movement and promotes safety.
• Capital: Capital investment should be minimal when finalizing
different models of facility layout.

Design Layout Techniques

There are three techniques of design layout, and they are as follows:

1. Two or Three Dimensional Templates: This technique utilizes

development of a scaled-down model based on approved drawings.
2. Sequence Analysis: This technique utilizes computer technology in
designing the facility layout by sequencing out all activities and then
arranging them in circular or in a straight line.
3. Line Balancing: This kind of technique is used for assembly line.

Types of Facility Layout

There are six types of facility layout, and they are as follows:

1. Line Layout
2. Functional Layout
3. Fixed Position Layout
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Facilities Location, Design and Layout

4. Cellular Technology Layout

5. Combined Layout, and
6. Computerized Relative Allocation of Facility Technique

Facilities Planning

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.

The facility must be properly managed to achieve its stated purpose while
satisfying several objectives.

Such objectives include producing a product or producing a service

• At lower cost,
• At higher quality,
• Or using the least amount of resources

Importance of Facilities Planning & Design

Manufacturing and Service companies spend a significant amount of time and

money to design or 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

Disciplines involved in Facilities Planning (FP)

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

Within the engineering profession:

• Civil engineers,
• Electrical engineers,
• Industrial engineers,
• Mechanical engineers are involved in FP

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Additionally,
• Architects,
• Consultants,
• General contractors,
• Managers,
• Real estate brokers, and
• Urban planners are involved in FP.
Variety of Facility Planning (FP) Tools
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 both
traditional and contemporary concepts.
Applications of Facilities Planning
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 activity’s objectives.
• What is the objective of the facility?
• How the facility achieves that objective?
In the case of a manufacturing firm:
Facilities Planning (FP) involves the determination of how the manufacturing
facility best supports production.
In the case of an airport:
Facilities Planning (FP) involves determining how the airport facility is to
support the passenger-airplane interface.
In the case of a hospital:
Facilities Planning (FP) for a hospital determines how the hospital facility
supports providing medical care to patients.
Facilities Planner considers the facility as a dynamic entity. Therefore
continuous improvement is an integral element of FP cycle.
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Facilities Location, Design and Layout

It is important to recognize that we do not use the term facilities planning as

a synonym for such related terms as facilities location, facilities design,
facilities layout, or plant layout. It is convenient to divide a facility into its
location and design components.
Facilities Planning ≠ Facility Location
Facilities Design
Facilities Layout
Plant Layout

Facilities Planning Hierarchy

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Facilities Location (Macro Aspect of FP)

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

suppliers, and other facilities with which it interfaces.

Facilities Design (Micro Aspect of FP)

Design components of a facility consist of the facility systems, the layout and
the handling systems.

• 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. For instance, a manufacturing system:
o Facility Systems – the structure (of building), power, light, gas,
heat, ventilation, air-conditioning, water and sewage needs.
o Layout – the production areas, related support areas,
personnel areas.
o Handling Systems – the materials- personnel, information, and
equipment to support manufacturing.

Significance of Facilities Planning (FP)

To understand the significance of Facilities Planning (FP) considers the

following questions:

• What impact do facilities planning have on handling and maintenance

cost?
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Facilities Location, Design and Layout

• What impact does 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 their capital once invested?
• What impact do facilities planning have on the management of a
facility?
• What impact does facilities planning have on facility’s capability to
adapt to
• Change and satisfy future requirements?

Objectives of Facilities Planning (FP)

Objectives of Facilities Planning (FP) are to plan a facility that achieves both
facilities location and design objectives.

Objectives of Industrial Facility Location

Objective of Industrial Facility Location is to determine the location which, in

consideration of all factors affecting deliver-to-customers cost of the
products to be manufactured, will be minimized.

Typical Facilities Design Objectives

1. Support the organization’s 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. Provide for employee safety and job satisfaction.

Facilities Planning Process

Although facility is planned only once, it is frequently reviewed to

synchronize the facility and its constantly changing objectives. Planning and
Review are linked by the continuous improvement FP cycle.

Facilities Planning (FP) is not an exact science, but it can be 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:

1. Define the problem,
2. Analyze the problem,
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 3. Generate alternative designs,
4. Evaluate the alternatives,
5. Select the preferred design,
6. 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.

An Organization’s Model of Success:

Experience has shown that in order for the facilities plan to be successful, not
only a clear understanding of the vision is needed, but also the mission, the
requirement of success, the guiding principles, and the evidence of success.

Five elements that form an organization’s model of success:

1. Vision: a description of where you are headed.
2. Mission: how to accomplish the vision.
3. Requirements of success: the science of your business.
4. Guiding principles: the values to be used, while pursuing the vision.
5. Evidence of success: measurable results that will demonstrate when
an organization is moving towards their vision.

Glossary
Facility Location: The right location for the manufacturing facility.
Facilities Design: An important component of a business's overall
operations, both in terms of maximizing the effectiveness of the production
process and meeting the needs of employees
Optimum: Best or most favorable
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Facilities Location, Design and Layout

References
Online Supplementary Reading Materials:
1. Facility Layout - Objectives, Design and Factors Affecting the Layout;
http://www.managementstudyguide.com/facility-layout.htm ; April
12, 2017
2. Facilities Planning and Design;
http://ie302.cankaya.edu.tr/uploads/files/file/LectureNotes/IENG4
41%20Facilities%20Planning%20and%20Design%20%20Lecture%
20Notes.pdf ; April 12, 2017
3. Location Planning and Analysis;
https://ids355.wikispaces.com/Ch.+8+Location+Planning+and+Anal
ysis; April 12, 2017
Online Instructional Video:
1. Facility Planning Process and Layout;
https://www.youtube.com/watch?v=TG7kzh2Uz08 ; April 12, 2017
Books and Journals:
1. Jay Heizer & Barry Render (2011); Operations Management (10th
Edition); New Jersey; Prentice Hall PTR

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