Facilities Layout and Design Lesson 3

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LESSON PROPER
Let us start your journey in learning more on flow systems, activity relationships space
requirements .
Flow System, Space and Activity Relationships
Activity relationships
 Activity relationships are the key input in facilities design
Flow
 Flow of materials, people, equipment, information, money, etc.
 Flow patterns, flow measuring and graphical analysis of the flows
Space
 The amount of space required in the facility
 Workstation specification, department specification and other space requirements
Activity Relationships
Activity relationships are the key input in facilities design
Defined by:
 Flow relationships
 Organizational relationships
LESSON 3: FLOW SYSTEMS, ACTIVITY RELATIONSHIPS
SPACE REQUIREMENTS
You will know about flow systems, activity relationships space requirements. Specifically,
this module will help you to
 Explain the flow system, space and activity relationships
 Identify flow system, space and activity relationships
 Make a flow diagram for each major HVAC, AMT, CPT, and FSM in A4 size of bond paper
portrait or landscape positions.
EXPECTATIONS

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Materials flow system
Physical Distribution system
 Environmental relationships
 Control relationships
 Process relationships
Materials management system
Logistics System
Flow into a manufacturing facility
Flow within a manufacturing facility
Flow from a manufacturing facility
Costumer
Segments of flow
Vendor

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Flow Patterns
Within the overall flow environment, a critical consideration is the pattern of flow.
Flow within workstations
 Motion studies and ergonomics considerations
 Flow should be simultaneous, coordinated, symmetrical, natural, rhythmical, and
habitual
Flow within departments
 Is dependent on the type of department (product vs. process dept.)
Flow between departments
 Used to evaluate overall flow within facility
Flow Patterns: Flow within Departments
Product departments flow: in a product and/or product family department
Flow Patterns: Flow within Departments
Process departments flow: in a process department
 Little flow between workstations
 Flow occurs between workstations and aisles

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Flow Patterns: Flow within Departments
 Flow within departments with material handling considerations Line flow patterns
Flow Patterns: Flow within Departments
 Flow within departments with material handling considerations Spine, tree and loop
flow patterns
Flow Patterns: Flow between Departments
 Flow within a facility considering the locations of entrance and exit

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flow within workstations.
Effective
flow
between
departments
Effective
flow within department
Effective
flow within workstations
Flow Patterns: Flow between Departments
 Flow within a facility - pattern categories
Flow Planning
 The effective flow within a facility depends on effective flow between departments.
Such flow depends on effective flow within departments, which depends on effective
Signs of a good general flow pattern
 A flow starts at receiving and terminates at shipping.
 Straight and short lines of flow
 Minimum backtracking
 Material is moved directly to point of use
 Minimum WIP
 Flow pattern is easily expandable, new processes can easily be merged in

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Principles of effective flow
Maximize directed (uninterrupted) flow paths
Principles of effective flow
1. Minimize flow
 Deliver materials, information, or people directly to the point of ultimate use
 Plan for flow between two consecutive points of use to take place in a few moments as
possible
 Combine flows and operations
2. Maximize directed flow path
3. Minimize the cost of the flow
 Minimize manual handling (automate or mechanize the flow) ◦ Minimize trips of empty
carriers
Flow process chart
 Flow Process Chart is similar to Operations Process Chart
 It shows assemblies, operations, and inspections, but also material handling and
storage.

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Flow diagram
Is a flow process chart spread over the layout of the corresponding area
From-To Chart - procedure
 List all departments down the row and across the column following the overall flow
pattern.
 Establish a measure of flow for the facility that accurately indicates equivalent flow
volumes.
 If the items moved are equivalent (size, weight, value, risk of damage, shape), the
measure could be the number of the trips
 If the items moved vary, then equivalent items may be established so that the
quantities recorded in the From-To Chart represent the proper relationships among the
volumes of movement.
 Record the flow volumes in the From-To Chart based on the flow paths for the items to
be moved and the established measure of flow.

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Relationship Chart
Measures the flows qualitatively using the closeness relationships values
Relationship Chart
Due to the great variety and multiplicity of relationships involved, it is advisable to construct
separate relationship charts for each major relationship being measured:
 material flow
 personnel flow
 information flow
 organizational, control, environmental, and process relationships, etc.

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Relationship Diagram
It is a transformation of the proximity relationships to a spatial organization of departments.
Relationship Diagram – systematic procedure
 Place the departments among which there is “A” relationship
 Add the departments among which there is “E” relationship to the previously placed
departments. Rearrange.
 Add the departments among which there is “X” relationship to the previously placed
departments. Rearrange. Add the departments among which there is “I” relationship.
Rearrange.
 Add the departments among which there is “O” relationship. Rearrange.
 Add the rest of the departments. Rearrange.
 Verify if all the departments are placed and if the important relations are respected
Space Requirements
 Perhaps the most difficult determination in facilities planning is the amount of space
required in the facility!
 Space requirements should be determined:
-for individual workstations
-department requirements

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Workstation Requirements
Equipment space
 The equipment
 Machine travel
 Machine maintenance
 Plant services
Materials space
 Receiving and storing materials
 In-process materials
 Storing and shipping materials
 Storing and shipping waste and
Scrap
 Tools, fixtures, jigs, dies, and
maintenance materials
Personnel area
 The operator (motion & ergonomic study)
 Material handling
 Operator way in and way out
Departmental Specification
 Once the space requirements for the workstations have been determined, the
department space requirements should be defined.
Departmental area:
◦ Sum of areas of workstations
◦ Equipment maintenance
◦ Tooling, dies, plant services
◦ Storage area
◦ Spare parts etc.
◦ Material handling within department
◦ Aisle space

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Departmental Specification
The total area required for the department is determined on Departmental Service and Area
Requirement Sheet

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FLOW DIAGRAM
Direction: Make a flow diagram for each major HVAC, AMT, CPT, and FSM in A4 size of
bond paper portrait or landscape positions.
Name: Date:
Course/Year/Sec: Professor:
Example: FLOW DIAGRAM IN BAKESHOP RESTAURANT
ACTIVITIES

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Facility layout and design is 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. The basic objective of layout is to ensure a smooth flow of work, material, and
information through a system. The basic meaning of facility is the space in which a business's
activities take place. The layout and design of that space impact greatly how the work is done,
the flow of work, materials, and information through the system. The key to good facility
layout and design is the integration of the needs of people (personnel and customers),
materials (raw, finishes, and in process), and machinery in such a way that they create a single,
well-functioning system.
FACTORS IN DETERMINING LAYOUT AND DESIGN
Small business owners need to consider many operational factors when building or renovating
a facility for maximum layout effectiveness. These criteria include the following:
Ease of future expansion or change-Facilities should be designed so that they can be easily
expanded or adjusted to meet changing production needs. "Although redesigning a facility is a
major, expensive undertaking not to be done lightly, there is always the possibility that a
redesign will be necessary," said Weiss and Gershon in their book Production and Operations
Management. "Therefore, any design should be flexible'¦. Flexible manufacturing systems
most often are highly automated facilities having intermediate-volume production of a variety
of products. Their goal is to minimize changeover or setup times for producing the different
products while still achieving close to assembly line (single-product) production rates."
Flow of movement- The facility design should reflect a recognition of the importance of
smooth process flow. In the case of factory facilities, the editors of How to Run a Small
Business state that "ideally, the plan will show the raw materials entering your plant at one
end and the finished product emerging at the other. The flow need not be a straight line.
Parallel flows, U-shaped patterns, or even a zig-zag that ends up with the finished product back
at the shipping and receiving bays can be functional. However, backtracking is to be avoided in
whatever pattern is chosen. When parts and materials move against or across the overall flow,
personnel and paperwork become confused, parts become lost, and the attainment of
coordination becomes complicated."
Materials handling-Small business owners should make certain that the facility layout makes it
possible to handle materials (products, equipment, containers, etc.) in an orderly, efficient—
and preferably simple—manner.
Output needs-The facility should be laid out in a way that is conducive to helping the business
meet its production needs.
REMEMBER

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References
1. http://users.encs.concordia.ca/~andrea/indu421/Presentation%206%20(Flow%20II).pdf
2.https://www.google.com/search?q=flow+diagram+in+facilities+layout+and+design&sxsrf=AL
eKk01K9muUuo79c0Gxjsr8oU07RxST6w:1600671858106&source=lnms&tbm=isch
3.https://www.inc.com/encyclopedia/facility-layout-and
design.html#:~:text=Their%20goal%20is%20to%20minimize,importance%20of%20smooth%20
process%20flow.