Plant Layout and Material Handling Spring 2002

1
Facilities Design The Layout

• Class 13
• March 6, 2002

2
Todays Topics

• Review quiz 12
• Review Class Schedule
• When is what due?
• Class Lecture
• Quiz 13

3
Quiz 12

• Area Allocation
• Questions?

4
Layout

• Introduction
• Plot Plan
• Master Plan
• Plant Layout Procedure
• Evaluation

5
Layout Introduction

• Complex results of data collection and analysis
• Only as good as the supporting data
• Visual presentation of data
• Applies to plot plans and master plans
• Your biggest selling tool

6
Plot Plan

• Shows buildings, parking lots, and driveways
• Start with layout of the property with lot lines.
• Place access roads.
• Sources of water, power, gas, and phones.

7
Plot Plan (Cont.)

• 4.Place building with front facing road and long
  side facing road (for expansion to rear)
• 5.Show shipping and receiving (expansion?)
• 6.Connect receiving and shipping to main road.
• 7.Show employee and public entrances.
• 8.Provide parking for visitors and employees.

8
Example Plot Plan
Power Line
Shipping
Future Parking
Expansion
Receiving
100 X 200
Office
Parking
9
Plant Layout Methods

• Template and tape technique
• 3D models
• CAD (more and more common)
• 10X property than building

10
Master Plan

• The finished product of facilities design project
• Templates
• CAD
• Advanced Computer Systems

11
RP Example Master Plan
2D
3D with Pro-E
12
Rating of Layout Techniques
13
Plant Layout Procedure

• Locate Exterior walls
• Exterior doors, columns, and aisles
• One department at a time
• Equipment
• Facilities
• Consider flow at every step
• Material space

14
Evaluation

• Minimize distance traveled
• Maximize space utilization
• Machine utilization ratio
• Control material handling costs
• JIT ratios
• From-to chart
• Cost evaluation

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Minimize Distance Traveled

• How many feet traveled automatically?
• Gravity movement is free power.

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2. Maximize Space Utilization

• Aisle space (Percent aisle space)
• Cube utilization (Percent cube used)
• Machine space utilization

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3. Machine utilization ratio

• Automatic loading can increase machine operation
  time

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4. Control Material Handling Costs

• Material handling ratios
• Manual moves/operation

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5. JIT Ratios
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6. Flow Techniques

• Strive for quantitative
• String Diagram
• Multi-column process charts
• From to charts

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String Diagram
If we jump a department, place the line above the
circles.
R
A
B
C
S
Backtracking, the line is drawn under the circles
RBACS

Flow lines between adjacent circles will be from
middle of circle to middle of circle
RBS
22
Multi-Column Process Chart
Remember
23
From-to Chart
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7. Cost Evaluation Technique

• Total project cost
• Operation costs
• Etc
• ROI

25
Quiz 13