Planning. References. Location: An Analytical Approach. operations management. 3. Daniel Kitaw, Industrial Management and Engineering Economy.

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1 Systematic Layout Planning References 1. Richard L. Francis, Facility Layout and Location: An Analytical Approach 2. S.K. Sharma, Industrial engineering and operations management. 3. Daniel Kitaw, Industrial Management and Engineering Economy. 4-1

2 SYSTEMATIC LAYOUT PLANNING (SLP) The most popular approach used in designing plant layout. The procedure has been applied to production, on, transportation, on, storage,, supporting services, and office activities, among others. 4-2

3 Information gathering Flow analysis + Activity analysis Relationship diagram Space consideration + Relationship diagram Space relationship diagram Modifying consideration + Practical limitation CONT D Anumberofalternativelayouts are designed and evaluated 4-3

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5 INFORMATION GATHERING Information is required pertaining to the product, process, and schedule. Data regarding product design decisions s can affect the layout significantly. sgnfcanty. The product design decisions can directly or indirectly affect the layout. 4-5

6 CONT D Basic product design data can be obtained form photographs of the product, exploded drawings, engineering drawings of individual parts, parts lists, bill of materials and assembly charts. 4-6

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9 Company open-close valve company Prepared by Jhon Mc Francies Product gate valve Date October 31, 19xx Part No. Part Name Drawing No. No. Unit Materials Size Make Buy 0105 Nut Brass Buy 0204 Washer Aluminum 0.8 odx0.22 idx0.01 thick Buy 0303 Handle Zinc, die casting 2.0 x0.6 Make 0501 Cap Brass, hex bar stock 0.75 x0.40 Make 0601 Packing Rubber 0.58 odx0.25 idx0.25 Buy 0702 Ferrule Brass, tube 0.4 x0.2 Make 0802 Stem Brass, rod 3.0 x0.375 Make 0901 Bushing Bronze x Mk Make 1001 Gasket Rubber 1.4 odx1.17 idx0.025 Buy 1101 Gate Bronze 1.2 x0.96 x0.55 Make 1305 Body Bronze 1.4 x1.9 x2.125 Make 1402 Box Cardboard x2.125 x4.25 Buy 1503 Staple Aluminum Buy 1603 Label Adhesive backed paper 2.0 x1.0 Buy 4-9

10 Company open-close valve company Product gate valve Prepared by Jhon Mc Francies Date October 31, 19xx Level Part No. Part Name Drawing No. No. Unit Make Buy Comments Pipe valve Make Bottom assembly Make Top assembly Make Nut Buy Washer Buy Handle Make Paint oz. Buy Cap Make Packing Buy Ferrule Make Stem Make Bushing Make Gasket Buy Gate Make Grease oz. Buy Body Make Box Buy Staple Buy Label Buy 4-10

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12 The assembly chart is an analog model of the operations and inspections required in assembling a product. Assembly chart shows graphically which parts must go into(or be assembled to) other parts. The assembly chart is the basis for the layout of the assembly department or assembly lines. 4-12

13 Process design decisions determine whether a part will be purchased or produced,, how the production of parts will be achieved, what equipment will be used, and how long it will take to perform the operation. Such information is typically summarized on an operation sheet or route sheet. 4-13

14 Company open-close valve company Preparedby Jhon Mc Francies Product gate valve Date October 31, 19xx _ Part name Bushing Part Number 0901 _ Material Bronze casting Production Quantity 1500 _ Op. No. Op. Description Machine type Tooling an d supplies Setup time (hrs) Op. time 05 Cast: using green sand mold with 50 bushings per mold; pour, cool, cut off gates and risers Bench mold Band saw T- shaped dry sand core for each bushing Clean: grind, as needed to remove flashing, Bench or pedestal A-24-M-8-V type and tumble grinder; tabling barrel grinding wheel Drill hole:3/16 x1/2 Turret lathe 3/16 drill o 08 Bore hole: 7/16 x1/4 Turret lathe 7/16 bore Turn: small end to 5/8 large end to 3/2 and then large end to 5/4 Turret lathe Round-nose turning tool, cut-off tool and right-hand hand facing tool Thread: small and large ends (5/8-16 UNC- 2A and 5/4-16 UNC-2A threads) Turret lathe Stationary, self-opening die heads for 5/8 and 5/ Total Comments: Operations 7 through 10 are performed on the same turret lathe, using one setup. The operating times given include rechecking the work piece. The operations are performed as follows: chuck large end; drill, bore, turn, thread, and cutoff small end to length; chuck small end, grip hexagonal surface; turn large end to 1.50 over length, cutoff to length, turn large end to 1.25 over 0.25 length, retaining 1.50 diameter over 1.25 length. 4-14

15 The operation process chart is often used to supplement the route sheet; in a sense, it is a pictorial representation of the route sheet. Its an expansion of the assembly process chart in that it includes all operations and inspections performed on the product. The basis for the layout of a manufacturing plant. 4-15

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17 A precedence diagram establishes the prerequisite assembly steps that must be completed before performing a given gvenassembly step. 4-17

18 Schedule design decisions tell us how much to produce and when to produce. Production schedules are given using an analog model called Gantt chart. 4-18

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20 Most information sources available portray yesterdays and, possibly today s data. We are interested in tomorrow's data, since we are developing a solution to be used tomorrow. Data sources emphasizes the interrelationships i among product, process, schedule, and layout design. The layout must support the objectives of the facility. 4-20

21 The effective arrangement of personnel and equipments depends on accurate information regarding g product, process, and schedule requirements. When such requirements change rapidly, it is important for the layout to accommodate changes in requirements. 4-21

22 FLOW ANALYSIS AND ACTIVITY ANALYSIS Flow analysis concentrates on some quantitative measures of movement between departments or activities. Activity ty analysis s is concerned with wth the non- quantitative factors that influence the location of departments or activities. 4-22

23 Basic data have been obtained concerning the process, product and schedule, the layout analyst is in position to analyze the flow of materials, equipment, and personnel. 4-23

24 Factor that affect the flow pattern given by Apple: CONT D 1. External transportation facilities 2. Number of parts in product 3. Number of operations on each part 4. Sequence of operations on each part 5. Number of subassemblies 6. Number of units to be produced 7. Necessary flow between work areas 8. Amount and shape of space available 4-24

25 9. Influence of process 10. Types of flow pattern 11. Product versus process type of layout 12. Location of service areas 13. Production department location 14. Special requirement of departments 15. Material storage 16. Desired flexibility 17. The building CONT D 4-25

26 Types of Flow Patterns Flow patterns can be classified either horizontal or vertical. There are at least five basic types of horizontal flow patterns. 4-26

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28 Vertical flow pattern exist both in single-story and multistory buildings. Utilization of overhead space has focused great attentiononthedesign of vertical flow pattern. 4-28

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30 Types of layout The choice of layout type is the factor affecting the flow pattern. There are four general types of layout categories: 1. Product layout 2. Process layout 3. Fixed position and, 4. Combination layout 4-30

31 Flow analysis approach Flow process chart Multiproduct process chart Flow diagram From-to-chart 4-31

32 Flow process chart 4-32

33 Multiproduct process chart 4-33

34 Flow diagram 4-34

35 From-to-chart 4-35

36 ACTIVITY RELATIONSHIP ANALYSIS Flow analysis tends to relate various activities on some quantitative basis. Typically, y, the relationship is expressed as a function of transport cost or material handling cost. There might be other qualitative aspects of layout design that might be important. 4-36

37 Relationship chart A: Absolutely necessary A relationship chart is a triangular matrix E: Especially important whose elements represent the relationships among plant layout departments. I: Important O: Ordinary closeness OK Letter codes areu: also Unimportant used to represent desirable or X: Undesirable undesirable levels of closeness between departments. 4-37

38 The activity relationship chart (REL chart) was developed to facilitate the consideration of qualitative factors analytically! The REL chart replaces the numbers in the Travel chart by a qualitative closeness rating. All pairs of relationships are evaluated, and a closeness rating (A,E,I,O,U,and X)is assigned to each pair. 4-38

39 With the exception of U rating, the reason for the assigned rating is indicated using a numeric code. Closeness ratings represent an ordered preference for closeness. 4-39

40 Specifically, A and X ratings are considered to be most important ratings. Hence, any layout must satisfy A and X ratings. Thus, A and X > E > I > O > U,where > means more important or higher ranking than. 4-40

41 Rule of thumb: CONT D Very few A and X relationships should be assigned. (no more than 5% of the closeness ratings to be anaa and X). No morethan 10% should be ane. E No more than 15% to be an I. No more than 20% to be an O. Which means that about 50% of the relationships should be U. 4-41

42 Block plans, or block layouts are developed d first by determining the sizes, shapes and relative locations of departments or other designated activities. Next, detailed layouts are designed for each department. Thus different REL charts are needed for designing block plans and detailed layouts. 4-42

43 The process of constructing an activity relationship chart can be complicated by the presence of multiple relationships that will influence the design of the layout. 4-43

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45 The relationship chart and the numerically weighted ratings, assigned to the closeness values, are the basis s for the order and placement in which departments enter the layout. The ratings assigned for AEIOUand A,E,I,O,U X are used to calculate the Total Closeness Rating (TCR) for each department. 4-45

46 TCR i = n j= 1 V( r ij ); i = 1... m Where TCR j = Total Closeness Rating for department; V(r ij ) = Numerical value assigned to the closeness value for department i and j. n = Total number of departments. 4-46

47 The first department to be placed in the layout is assigned by taking the department with the greatest TCR. Next, the relationship chart is scanned to see if there is any department t thatt has an A value with the department already placed. 4-47

48 If no A value exists, a check is made for E value, and if no E value appears, a check is made for I value, followed by O value. If ties develop, the department having the greatest TCR is chosen. This processis continually used until finally all departments are placed in the layout. 4-48

49 Example Numerical values A = 10,000; E = 1,000; I = 100; O = 10; U = 0; and X = -10,

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52 REL Diagram CONT D From REL chart, we construct activity relationship diagram (REL diagram). The purpose is to depict spatially the relationships of the activities. The basic premise is that geographic proximity can be used to satisfy particular relationships. 4-52

53 For example, when the activity relationships reflect the magnitudes of material flows, pairs of activities having the greatest pair wise flow are located next to each other. Similarly, il l pairs of activities iii having an A rating are located adjacently. 4-53

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55 SPACE REQUIREMENT AND AVAILABILITY The bases for determining the space requirement: i. Production rate ii. Equipment requirement iii.employee requirement 4-55

56 Commonly used methods of determining space requirement: i. Production center method Consists of a single machine plus all the associated equipment and space required for its operations. Work space, maintenance space, and storage space are added to space requirement for the machine. 4-56

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58 ii. Roughed-outout layout method CONT D Templates or models are placed on the layout to obtain an estimate of the general configuration and space requirements. iii. Space standards method Industry standards can be used to determine the space requirement. 4-58

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60 DESIGNING THE LAYOUT Designing i thespacerelationship diagram The over all layout is designed by first combining the space consideration with the REL diagram. For each activity, a space template is constructed, to scale, to represent the size and shape of the activity. 4-60

61 Example 4-61

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63 After construction the space relationship diagram, the space templates are modified and adjusted and the relative locations of the activities are shifted as necessary to accommodate practical limitations and other considerations. The block plan is a scaled diagrammatic representation of the building normally shows the locations of internal partitions and columns. 4-63

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65 Presenting the layout A number of alternative component designs, a number of alternative overall designs, or a number of alternative detailed designs should have been generated. 4-65

66 There are three methods of visually representing layouts Drawing or sketches Two-dimensional iconici models Three-dimensional iconic models 4-66

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68 Selection, implementation and follow-up Select the design from alternatives which best meets your objective. The design selected must be specified, all concerned must be sold, and the layout must be installed, observed, and periodically evaluated in an operating environment. 4-68

SECTION COMMON WORK RESULTS FOR FIRE SUPPRESSION

SECTION COMMON WORK RESULTS FOR FIRE SUPPRESSION SECTION 21 05 00 COMMON WORK RESULTS FOR FIRE SUPPRESSION PART 1 - GENERAL 1.1 SUMMARY A. This section supplements all sections in this division, including pipe, fittings, valves, and connections for sprinkler