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Fundamental Principles of Facilities Planning and Design
Raw material Manufacturing Warehouse Retailers Customers

suppliers facility distribution
1 1 1 1
2 2 2 2
I J K L
Information flow
Material flow
Cash flow
FIGURE 8
Supply-chain network.
chain [1]. These versatile tags provide important information about the product (such
as location, inventory turns, processing costs, even quality information) to many manu-
facturing and service industries. Although not without critics of its cost in time and re-
sources, it appears to be a significant step to providing timely information about
products in the supply chain.
The purpose of manufacturing—manufacturing from an ideal point of view—is
to make life in society better (remember the GE commercial: “We bring good things to
life.”) through the production of functionally desirable, aesthetically pleasing, environ-
mentally safe, economically affordable, highly reliable, top-quality products. A manu-
facturing system can be divided into the following essential functions:
앫 Product design
앫 Process planning
앫 Production operations
앫 Materials handling and transportation flow/facilities layout
앫 Production planning and control
Product design is responsible for taking input from marketing and for building a
product. Process planning includes specification of operational sequences needed to trans-
form raw material into finished product. Manufacturing operations are generally classified
as forming (shapes are changed), treating (characteristics are changed), and assembling
(material is added). Material handling is related to systems for moving parts, tools, and
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scrap. Facilities layout is concerned with the physical location of the production processes
within each facility. Production planning and control is responsible for integrating marketing
information, production capacity, and current inventory levels to determine production lev-
els that will allow a firm to run smoothly and efficiently.
6 TYPES OF BASIC MANUFACTURING LAYOUTS

Typical morphological layouts are described below. Most manufacturing layouts can be
classified as either product or process layouts, or a combination of them.
앫 Fixed-position: material or major components brought together in a fixed location.

앫 Product: low number of part types and high production volume.
앫 Cellular (group technology): medium number of part types and medium produc-
tion volume.
앫 Process (job shop): high number of part types and low production volume.
Three things can happen to material in the making of a product: it can be formed,
treated, or assembled.
The classic types of layouts are the layout by fixed position, the layout by process,
and the production line. During the last two decades, a fourth type has become impor-
tant: the cellular layout (also known as the group technology layout).
The fixed-position layout is one where the material or major component remains
in a fixed place to which tools, machinery, people, and other pieces of material are
brought together. Fixed-position layouts are used, for example, for airplanes, locomo-
tives, ships, and other heavy machinery.
Fixed-Position Layout
Figure 9 is an example of a fixed-position layout for the manufacture of gas turbines,
steam engines, or airplanes. Here, we have compressed eight fundamental activities
a = 1a, b, c, d, e, f, g, h2 associated with making a large gas turbine into one specific
location. Obviously, the weight of the product is such that it is more efficient to move
materials, machines, and engineers to work on the units than to move the turbines to
various workstations throughout the plant.
Product Layout Process

The product layout (or production line) places one operation immediately adjacent to
the next; the equipment needed is arranged according to the operational sequence.
Figure 10 illustrates an example of a series of production lines for a high-volume pro-
duction facility. The eight different production activities defined previously are associ-
ated with the eight different workstations along each of the product lines 1, 2, Á , N.
Since the desired volume of the products is normally very high, and given this demand,
dedicated production facilities with conveyors and other automated material handling
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Employees / supervisors
Raw materials Equipment
abcd
efgh
Waste and recycling
Energy systems
FIGURE 9
Fixed-position layout. Packaging and shipping
devices are necessary in order to meet the production requirements.
Process Layout Process

In the process layout, all operations of same process or type are grouped together along with
the equipment for performing a common function. Figure 11 represents a job shop or cus-
tom shop where large metal rolls are moved from one department (grinding, lathes, welding,
and so on) to the next in order to complete the fabrication of the metal rolls. Each letter of
our alphabet represents a different department (grinding, lathes, welding, and so on).
a b g h Product 1
a b g h Product 2
a b g h Product 3
a b g h Product N
FIGURE 10
Product layout alternative.
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a
f
h
b
d FIGURE 11
Process layout alternative.
Cellular Layout Process

The cellular layout is based on the grouping of parts to form product families based on
common machining requirements (and other aspects, such as shapes, material compo-
sition, and tooling requirements). This layout has a high part flow within cells and low
flow between cells. Figure 12 illustrates a general configuration for a number of work
cells arranged in a gridlike fashion, Figure 13 represents one specific work-cell real-
ization for the manufacture of a small hand tool. The work cell combines both manu-
facturing and assembly operations, so that the it is very efficient, and the quality of
each part is carefully monitored by the individual worker. This type of layout is often
abcd abcd abcd

efgh efgh efgh
abcd abcd abcd

efgh efgh efgh
abcd abcd abcd

efgh efgh efgh FIGURE 12
Cellular layout arrangement.
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TRN HD.
TRN HND. Aisle ⫽ 48" wide
TRN HOLE
PAN ⫽ 21 x 28"
BROACH
AS ⫽ 36 x 36"
ACT-20 AB ⫽ 36 x 36"
ACT-20 TC-2 82"
61" 93" wide
PAN
ST PAN PAN AB PAN AS PAN PAN Turn Body 156"

wx-20
Takamaz
120" x 94"
FIGURE 13
Single-cell layout alternative.
referred to as a “one-piece flow.”

From the point of view of product types and production volumes, the following
generalizations are valid: (a) the production line layout is especially suitable for cases
where the number of part types is low and the production volume for each type is high;
(b) the process layout is especially suitable for cases where the number of part types is
high and the production volume for each type is low; (c) the cellular layout is especial-
ly suitable for cases where the number of part types is neither low nor high and the
production volumes are in the middle (between low and high).
A graphical breakeven-point comparison between the fixed-position, process,
cellular, and product layouts is shown in Figure 14. In part (a) of the figure, both
Fixed-position
High Process
Fixed-position Cellular
Process Product
Costs
Product
variety Cellular
Product
Fixed Process Cellular Product

Low position
Low Product volume High Product volume
(a) (b)
FIGURE 14
(a) Product variety–volume and (b) cost–volume breakeven analysis.
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product-variety relationships and product costs are compared with product volume. In
part (b) we consider production volumes, costs (fixed and variable), and revenues. We
show the total-cost lines, the revenue lines, and the break-even points for the four lay-
outs. As can be seen from this graph, the product layout is preferred for high produc-
tion volumes and the fixed-position layout for low production volumes. If F is the fixed
cost, v the variable cost per unit, and r the selling price per unit, the production level Q
corresponding to the breakeven point can be determined from the relationship
F + vQ = rQ.
7 SERVICE SYSTEMS
Service systems include many different building types. The listing below is not exhaus-
tive but indicates the range and variety of building types in the service arena.
Industrial Commercial industrial parks, public utility buildings, and nuclear

power plants.
Cultural Courthouses, municipal facilities, police and fire stations, detention
and correctional facilities, art museums, houses of worship, water parks, and
aquariums.
Commercial Office buildings, banks, credit unions, department stores, shopping
malls, art galleries, and boutiques.
Recreational Regional and urban park facilities, stadiums, arenas, dance halls,
and nightclubs.
Educational College campuses, research laboratories, high, middle, and ele-
mentary schools, and day-care centers.
Medical Public hospitals, teaching hospitals, medical office clinics, nursing
homes, and pharmacies.
Residential High-rise apartments, condominiums, duplexes, single-family resi-
dences, campgrounds and trailer parks.
Transportation Airports, railway terminals, bus stations, truck transit terminals,
and shipping port terminals.
Notice that we have left out most of the infrastructure, which includes roads,
bridges, walkways, utility systems, water reservoirs, tunnels, and the like. Some civil and
mechanical engineers would refer to these as facilities, but we do not include them
under our rubric of facilities planning.
Many and detailed design problems within these building types go beyond the
scope of this text, and we will not attempt to cover them. For instance, we could write
an entire book on hospitals, which are among the most complicated facilities to plan
and design, owing largely to their myriad building and service system requirements and
sanitary concerns. Even art museums entail special considerations for lighting, heating,
and ventilation, such that expert consultants often assist in their planning and design.
Rather than treat each building type in detail here, we will focus on the general princi-
ples and fundamental methodology used in designing such buildings. In the design of
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service facilities, while one may apply the notions of job shop or product layout, unfor-
tunately there are no standard layout types as there are for manufacturing facilities.
This is simply because of service facilities’ broad scope and diversity of functions. One
convenient categorization in the service sector is public vs. private, yet that does not
provide a useful functional dichotomy.
Figure 15 is a planar graph of activities of a public trial courts complex, where
the key activities involved in trial courts planning have been identified [9]. The plan-
ning problem is very complex because of the number of people who use the facility.
Jury Clerk’s office

Chief commissioner Processing
Court
clerk
admini- Courtrooms
strator Judge’s
Public desk Juror entrance chambers
Public Juror processing Library
Clerical reading areas Juror
processing Public
lounge/assembly
circulation
impaneling
spaces
Appellate Court
Administrator
Clerk of Court
Public circulation
Attornies’ lounge
Videotape CCTV spectators Probation Trial Defender
room Day care Appellate Defender
Staff services
Emergency medical Trial
Library Public conveniences prosecutor
Grand Juvenile
Press Probation
jury Justice
room Facility
Court
Attorney–client
Court conference Witness
reporters waiting
Detention
Facility
Jury
deliberation
Courtrooms Short-term
detention
Trial Court
Adminis- Judge’s
trator chambers
Trial Court Facility
FIGURE 15
Typical trial courts complex of buildings.
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As in a manufacturing facility, once one has identified the key activity vector
a = 1a 1, a 2 , Á , a n2, then one has an excellent idea of the organization and eventual
layout plan for the entire facility.
8 RENOVATION OR REENGINEERED FACILITIES

Often a brand new facility is not warranted; a remodeled or renovated facility is more
appropriate. Often, too, a new facility is appended to an existing one.
Reengineered facilities can become more difficult to design than a brand new
facility because of the constraints imposed by the existing facility (e.g., existing loca-
tions of columns, walls, stairwells, and so on). Sometimes the problems of reengineer-
ing are such that it is simply easier to construct a brand new facility from scratch.
Often, too, the building codes that applied to the older facility are outdated and the
new building codes must be respected, which compounds the design problems of
reengineered construction.
9 FACILITIES PLANNING AND DESIGN CONSTRAINTS

In the creation of a facility, many external factors come into play, including the following:
앫 Building Codes and Zoning Ordinances

앫 Fire, Health, and Safety Considerations
앫 Structural and Environmental Constraints
앫 Utility Systems (heating, power, water, and light)
앫 Environmental and Energy System Constraints
Rule books provide explicit constraints on the sizes and shapes of elements within and
outside a facility. Some of these constraints are very helpful, while others are severely
limiting.
10 SUMMARY AND CONCLUSION

This chapter has provided a brief overview of the fundamental principles, concepts, de-
finitions, and basic design processes of facilities planning. In summary, some funda-
mental principles are:
1. Design is an activity.
2. Design problems are wicked problems.
3. The activities of a facility a and its graph realization G(N, A) form the foundation
of the facility layout.
4. The design process has three fundamental hierarchical stages: conceptual design,
parametric design, and detailed design.
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5. A design system is basically an issue-based information system (IBIS).

6. The facility plan depends on the dynamic resolution of the IBIS planning is-
sues over time.
7. Most manufacturing layouts are either a product, process, fixed-position, or cellu-
lar layout, or a combination of these.
11 EXERCISES
1 Give a definition of design (in your own words) as it relates to your factory design project.
2 List and explain (in your own words) the ten key characteristics of wicked problems.
Please related these characteristics to your own factory design layout problem.
3 What are the basic objectives of facilities planning?
4 What are the four different types of layouts for a factory? Visit a local manufacturing fa-
cility, take a plant tour with your classmates (if possible), and try to characterize the layout
into one of the four basic layout types. If it does not exactly fit one of these types, describe
the differences and similarities to the four basic types of layouts.
5 For the factory project, what type of layout discussed in this chapter do you think would be
most appropriate for your factory?
6 Visit a local fast-food restaurant, coffee shop, or donut and pastry shop. What are some de-
sign, contextual, and performance variables that underlie the design of the service enter-
prise? List at least seven items in each category.
7 Shown here is an example layout of a factory plan with ten different departments. Each
department is denoted by a letter and occupies the cell it is in, except that “J” occupies two
cells. Draw the planar graph representation of the layout, then develop a new layout alter-
native by moving department J in such a way that no arcs cross one another. Then gener-
ate a new plant layout. This is referred to as “topological juggling” of the planar graph. Do
not worry at this point about the scale and size of the areas of the departments.
A B C
2 J
D E F
1
G H I
0
0 1 2 3 4
8 Visit a local post office or fast-food restaurant and identify the way customers enter and
leave the facility and interact with the service staff. Create a process flow diagram “planar
graph” and identify any problems that occur in the service process—unusually long delays,
excessive queuing, crossing of traffic patterns, backtracking, and the like. Suggest some
simple improvements to the layout by moving certain stations or changing the way people
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move through the facility and interact with the staff. Develop a revised layout of the facil-
ity based on your analysis.
9 Make a floor plan of your dorm room or apartment on a scale of 14 inch = 1 foot. You may
use AutoCAD or a similar layout tool to help you. Using a suitable grid will also help you
to scale the plan and make sure the dimensions are correct. (In a dorm room or apartment,
inches can be crucial.) Identify and make paper cutouts of the furniture and equipment in
the room that is movable. Identify the design, contextual, and performance factors that
you consider crucial to the success of the layout, and develop at least two alternative
arrangements. Based upon your analysis, which plan should you implement?
10 You are working on the preliminary layout of a small factory where they make 1000 units
of a certain product per day. This product has five parts 5A, B, C, D, E6. One unit requires
the assembly of 4A’s, 3B’s, 2C’s, 1D, 1E. The routings for the production of the 1000 parts
are given below:
Part Department Sequence

A 1-2-3-5
B 2-5-2-3-4
C 1-3-2-4-3
D 4-3-5-1-2
E 3-4-5
The from–to chart, or flow matrix, provided below shows the volume of parts as they flow
through the plant.
Area of Department
Departments 1 2 3 4 5 Total (square feet)
1 ** AD C
(flows from 1) 5000 2000 7000 1500
2 ** AB C B
(flows from 2) 7000 2000 3000 12,000 2000
3 C ** BE AD
(flows from 3) 2000 4000 5000 11,000 3000
4 CD ** E
(flows from 4) 3000 1000 4000 2000
5 D B **
(flows from 5) 1000 3000 4000 1500
Total 1000 10,000 12,000 6000 9000 38,000 10,000
Suggest two alternative layouts for this plant, using cutouts of the departments (as square
as possible) and a grid layout scheme on a sheet of paper. Based upon the data given in the
problem and what you feel would make the most sense, justify your layout.
11 Shown below is a grid layout of a facility complex where there are four existing depart-
ments around a central courtyard or circulation space area for material handling and setup
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Copyright © 2014. Pearson. All rights reserved.

Fundamental Principles of Facilities Planning and Design

Raw material Manufacturing Warehouse Retailers Customers

Fundamental Principles of Facilities Planning and Design

6 TYPES OF BASIC MANUFACTURING LAYOUTS

앫 Fixed-position: material or major components brought together in a fixed location.

Product Layout Process

Fundamental Principles of Facilities Planning and Design

Raw materials Equipment

devices are necessary in order to meet the production requirements.

Process Layout Process

Fundamental Principles of Facilities Planning and Design

Cellular Layout Process

abcd abcd abcd

abcd abcd abcd

abcd abcd abcd

Fundamental Principles of Facilities Planning and Design

ST PAN PAN AB PAN AS PAN PAN Turn Body 156"

referred to as a “one-piece flow.”

Fixed Process Cellular Product

Fundamental Principles of Facilities Planning and Design

Industrial Commercial industrial parks, public utility buildings, and nuclear

Fundamental Principles of Facilities Planning and Design

Jury Clerk’s office

Fundamental Principles of Facilities Planning and Design

8 RENOVATION OR REENGINEERED FACILITIES

9 FACILITIES PLANNING AND DESIGN CONSTRAINTS

앫 Building Codes and Zoning Ordinances

10 SUMMARY AND CONCLUSION

Fundamental Principles of Facilities Planning and Design

5. A design system is basically an issue-based information system (IBIS).

Fundamental Principles of Facilities Planning and Design

Part Department Sequence

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