Facility Planning

www.a2zmba.com

Introduction
Facility planning means planning:
for the location of all machines, utilities,
employee workstations, customer service areas,
material storage areas, aisles, restrooms,
lunchrooms, internal walls, offices, and
computer rooms
for the flow patterns of materials and people
around, into, and within buildings

www.a2zmba.com

Objectives of the Layout

Strategy
Develop an economical layout which will meet
the requirements of:
product design and volume (product
strategy)
Process equipment and capacity (process
strategy)
quality of work life (human resource
strategy)
building and site constraints (location
strategy)
www.a2zmba.com

Levels of Facility Planning

I Global (Site Location)
II Supra (Site Planning)
III Macro (Building Layout)
IV Micro (Workcell/Department Layout)
V Sub-Micro (Workstation Design)

www.a2zmba.com

Levels of Facility Planning

Level

Activity

Space Planning
Unit

Environment

I
Global

Site Location &

Selection

Sites

World or
Country

II
Supra

Site Planning

Buildings or Site
Features

Site

III
Macro Layout

Building
Department or
Block Layout

Work cells or
Departments

Building

IV
Micro Layout

Work cell of
Department

Workstations or
Work cell Features

Cells or
Departments

V
Sub Micro
Layout

Workstation
Design

Tool & Fixture

Locations

Workstation

www.a2zmba.com

Location?
Country?
Region?
Locality or

Community?
Exact site?

Raw materials
Labour
Market
Power
Transportation
Civic Amenities
Climate
Government
Existence of Complementary

and Competing Industries

Momentum of an early start
www.a2zmba.com

Facility Layout Planning

Production process routings and flows
Material Handling methods and equipment requirements
Product mix and volumes
Sales growth plans
Capacity planning and management
Traffic, aisles and safety requirements
Special manufacturing process requirements
Workforce and supervisory requirements
Process flexibility and agility requirements
Work-in-Process flow and storage requirements
Part size and storage requirement characteristics
Building and property design constraints
And more!
www.a2zmba.com

Characteristics of the
Facility
Planning
Decision

Location of these various areas impacts the

flow through the system.
The layout can affect productivity and costs
generated by the system.
Layout alternatives are limited by
the amount and type of space required for the

various areas
the amount and type of space available
the operations strategy

. . . more
www.a2zmba.com

Characteristics of the
Facility Planning Decision

Layout decisions tend to be:

Infrequent
Expensive to implement

Studied and evaluated extensively

Long-term commitments

www.a2zmba.com

Requirements of a Good Layout

A good layout requires:
an understanding of capacity & space
requirements
selection of appropriate material handling
equipment
decisions regarding environment and
aesthetics
identification and understanding of the
requirements for information flow
identification of the cost of moving between
the various work areas
www.a2zmba.com

Importance
A properly designed facility is an

important source of competitive

advantage. It can:
Operate At Low Cost
Provide Fast Delivery
Accommodate Frequent New Products
Produce Many Varied Products
Produce High or Low Volume Products
Produce At The Highest Quality Level
Provide Unique Services Or Features
www.a2zmba.com

Steps in Facilities Planning

Product
Analysis

Expected Volume of
Production
Process

Indirect
Labour

Equipment

Direct Labour

Plant Layout
Phase
1
Phase
2
www.a2zmba.com

Building
Design

Facilities

Facility Planning Series

Four

fundamental faci
lity elements
go into every
layout or
spaceplan- Space Planning

Units (aka Activity

Areas or SPUs)
Affinities
Space
Constraints.

www.a2zmba.com

Basic Layout Forms

Process
Product
Cellular
Fixed position
Hybrid

www.a2zmba.com

New Trends in
Manufacturing
Layouts

Designed for quality and flexibility

Ability to quickly shift to different product
models or to different production rates
Cellular layout within larger process layouts
Automated material handling
U-shaped production lines
. . . more

www.a2zmba.com

New Trends in
Manufacturing Layouts

More open work areas with fewer walls,

partitions, or other obstacles

Smaller and more compact factory layouts
Less space provided for storage of inventories
throughout the layout

www.a2zmba.com

World-Class Practice
Strive for flexibility in layouts
Multi-job training of workers
Sophisticated preventive-maintenance
programs
Flexible machines
Empowered workers trained in problem solving
Layouts small and compact

www.a2zmba.com

Featherlite
Two facilitiesChair division (Top Floor)
Furniture division (1st and 2nd floor)
Ground floor used to store Raw Materials such as
boards and other things.
A facility manager for both the facility
Entire facilities are in open space according to line
activities.
Layout is Hybrid based on FMS
Facilities clearly marked out by the board on roof
Well managed facility every machinery and operator
function in the space given and this space is marked
by a yellow line.
Aisles clearly marked out with yellow paint.
www.a2zmba.com

Featherlite
Well designed layout with Offices situated

beside the shop floor of Chairs Division

Movable scrap boxes
Effective dust collection system
Another plant coming up at Hejjala with a
built area of 170000 sqft and with state of
the art technology.
New plant will add to capacity to cater to
the nationwide demand.
Lean Manufacturing System is followed
www.a2zmba.com

M/s. TRIMULA INDUSTRIES PVT LTD

www.a2zmba.com

M/s. TRIMULA INDUSTRIES PVT LTD

The project is proposed to be located at SINGRAULI

(M.P.).
The proposed plant location is surrounded by iron

ore mines from OMC/NMDC

Coal based sponge iron plant.
The present project envisages manufacturing 350

TPD X 3 NOS i.e. 3,15,000 MT of Sponge Iron

Lumps and Fines
www.a2zmba.com

LOCATIONAL ADVANTAGES
Proximity to the sources of iron ore
Coal
Finished product consumer
Ready availability of power
Easiness of management control
www.a2zmba.com

The process flow chart for

manufacturing
sponge iron
The TATA
Direct
Reduction
Process.

www.a2zmba.com

FACILITIES and UTILITIES

Day Bins
Rotary Kiln and

cooler
Off Gas System
including waste heat
power generation
Product processing
facilities and product
storage bins.
www.a2zmba.com

ELECTRICALS
Power Supply and

Distribution
Emergency Power
Supply

PLANT AUTOMATION

(PLC)
Instrumentation
Control Desk

FUTURE PLAN
The heat generated from the gas can be used

to generate steam.
This steam generated, will be used for captive
power generation of 8.0 MW.
With the result, the unit becomes a considerable
net exporter of electricity, with consequent
economic benefits to the overall steel making
facility.

www.a2zmba.com