Space Determination and Area Allocation: Factors for consideration in space planning, receiving, storage, production, shipping, tool room and tool crib, other auxiliary service actions, establishing total space requirement, area allocation factors to be considered, expansion, flexibility, aisles column, area allocation procedure, the plot plan. Construction of the Layout: Methods of constructing the layout, evaluation of layout, efficiency indices, presenting layout to management.

1. Space Determination, Area
Allocation and Construction of
the Layout
Module 3
Rashmi S
Asst. Professor
Dept. of IEM, JSSATE-B

2. Content
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 Factors for consideration in space planning
 Area allocation factors
 Construction of the layout
 Methods of constructing the layout
 Evaluation of layout
 Efficiency indices
 Presenting layout to management

3. Factors for consideration in space planning
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4. Contd…
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 The service activities are divided in 4 categories:
 Production
 Physical Plant
 Administration
 Personnel

5. Contd…
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 Production: Activities that serves the productive
function
 Physical Plant : services that are primarily concerned
with the needs of the physical facilities (building,
equipment, utilities)
 Administration: Functions that serve the entire plant
consisting of general office area and related activities
 Personnel: services required for serving or handling
the needs of the people.

6. Factors considered in Space Determination
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 Receiving : getting material, supplies etc to facilities
 Storage : safe keeping and issuing of material before and using
the production operations
 Warehousing: Safekeeping of finished goods
 Shipping: Issuing and distributing finished goods to customers or
other destinations.

7. Receiving
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 Receiving is concerned with the orderly receipt
of all materials and supplies coming into the
facility and their proper storage and disposition.
 Includes responsibilities such as:

8. Receiving
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9. Receiving and
Planning Sheet
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10. Production
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 Determining the space required for production activity is
dependent on individual work places.
 Proportional relationship to the sum of the area of individual
work places
 Allowances is added to provide for aisles, non productive areas.
 It includes workplace design, work area, methods of design &
material flows, work area planning, planning an efficient
workplace, material handling and others.

11. Shipping
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 Determination of space needs for the shipping
activity is closely related that for receiving
activity.
 Space needed must be determined by referring
to previous information on receiving an using it
as necessary to accommodate the slight
differences between both.

12. Storage
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13. Auxiliary and service activities
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 Most of the medical, food, lavatory, locker rooms,
tool room, tool crib, maintenance area
requirements etc…
 Cot, screens, lavatory, examining table, desk
chair, supply cabinet etc…

14. Area Allocation
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 Activity interrelationship and space
requirements are integrated in area allocation
process.
 Objective of area allocation process is to design
an efficient arrangement of the space units
required for each activities into an integrated
whole.

15. Factors for consideration in Area Allocation
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16. Construction of layout
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 Steps in construction of layout for manufacturing facilities are:
1. Select the scale
2. Decide the method of representation
3. Obtain the layout plan supplies /hardware/software
4. Locate all the permanent facilities on the layout plan
5. Locate all the exterior wall that includes receiving function
6. Locate the columns
7. Locate all manufacturing departments and equipments
8. Locate all personal and plan services
9. Audit the layout plan
10. Finalize the layout plan

17. Methods of representing layout plans
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1. Drawings – handmade
 Serves as a rough sketch of an area
 Quick and conveniently made to illustrate the alternative
layout plan
 It is the best approach for layout plans of small area
 Handmade drawings are expensive to produce and to
alter for use as final layout plan for large areas
 Can be used either as rough sketches or final layout
plans for small areas only

18. Manual drawing
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19. 2. Templates and tapes
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 Most often used methods (1990 for creating layout plans)
 Templates are either handmade or purchased and are made up of cardboard, Mylar,
adhesive backed Mylar or magnetized plastics.
 Templates may be blocked or contour templates
 Blocked – it is simply a labeled rectangle representing the length & width of the
equipments.
 Contour – It illustrate the contour and clearances for movable portions of the machines
 Tapes: wide and broad ranges of tapes are available for representing the walls,
partitions, belt conveyors, roller conveyors, windows, overhead monorails and aisles.

20. Contour adhesive backed Mylar
templates
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Magnetic templates

21. 3. Computer-Aided Drafting (CAD)
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 CAD, is technology for design and technical
documentation, which replaces manual drafting with
an automated process.
 A CAD system consist of:
 Input terminal -keyboard, mouse, monitors),
 Central processor - convert instructions from layout
planner into graphics layout and stores the
templates and symbols used in constructing the
layout
 Output peripherals – printers, plotters etc…

22. Advantages of CAD
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 The CAD systems are user friendly. The work can be completed very
quickly. This results in reduction of labor and time.
 The computers work very accurately, giving better quality drawing.
 The drawings can be stored and recollected when ever needed.
 The corrections and modifications can be done quickly and easily.
 Different design ideas can be tried having single basic drawing.
 Visual modeling of any object or component can be done.
 When the same component is needed in many places, the same drawing
can be
 inserted in the required places, instead drawing it again.
 It helps to visualize how the final product will be by using colour
graphics.

23. Contd..
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 Three methods of establishing 3D models are:
1. Scale models
2. Modular block models
3. Computer models

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25. Methods of constructing layout
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 Four common methods
1. Drawn in the conventional drafting manner on drawing paper or
tracing
2. Constructing with 2D templates –cut-outs, to scale, representing
shape and size of each place/equipment.
3. Constructing with 3D scale models in place of templates
4. Constructing combination of scale model and templates for ease
of reproduction.

26. Comparison of basic layout methods
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27. Plant layout Tools and techniques – Materials
used
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28. Contd…
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29. Evaluating Layout
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 Why evaluation ?
1. Evaluation of existing layout for the purpose of
finding improvement opportunities
2. Evaluation of alternative layout under
consideration for a single problem or project area.

30. Basis for evaluation of
layout
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31. Qualitative techniques
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 It is the simplest approach
With rating factors such as
 Perfect -10
 Ideal -9
 Excellent – 8
 Very good -7
 Good – 6
 Fair -5
 Average – 4
 Poor-3
 Unsatisfactory -2
 Unacceptable -1

32. Facility layout evaluation form
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33. The symptoms of bad layout are listed below:
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 Poor utilization of space.
 Long material flow lines.
 Congestion for movement of materials and men.
 Large amount work-in-progress.
 Long production cycles.
 More frequent accidents.
 Difficult to supervise and control.
 Spoilage of products during handling.
 Production line bottlenecks.

34. Graphical Techniques used for
evaluating layout
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 Assembly chart
 Operation process chart
 Multi-product process chart
 String Diagram
 Process chart
 Flow diagram
 Flow process chart
 From to (Travel) chart
 Procedure chart

35. Efficiency Indices
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1.Index of Indirect material handling =
a/b
a = Sum of distances that a part moves automatically from machine to machine
with out external material handling
b = Total actual distance that a part travels on the production route from raw
stores to finished stores.
 This index is found to be consistent and accurate
 It is recommended as a good measure of the efficiency of production
route wrt mechanized material handling

36. Contd…
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2. Index of Direct Material Handling = b
It represents the exact distance a part or piece is
required to travel during production (it is no. of
feet)
 This is a good measure of efficiency with which the
production route is laid out
 It is used to compare the plant/areas manufacturing
the same type of product
 It is the more accurate than any ratios investigated

37. Contd…
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3. Index of cavity Utilization = d/e
d = Sum of vertical distance that gravity feed is used in a
multi-storey plant
e = Total vertical distance up or down that a part moves,
involving either machine or human efforts from layout
area entrance to layout area exit of multi-storey plant

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4 . Prime index of Automatic machinery loading = f/100g
f = Sum of percentages of machine down time from all cases where individual
percentages of down time are equal to or less than 50% of individual work cycles
Down time = portion of work cycle in which m/c is loaded or unloaded
g = Total no. of operators on these machines

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5.
Secondary Index of Automatic machinery loading =
h/100g
h = Sum of % of m/c down time from all cases where the
individual % of down time are greater than 50% of
individual work cycles

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6. Index of production line flexibility = j1/k1
j1 = No. of m/c or work stations performing operations on the part under
consideration, so designed that they can be moved to new location in
the same production line in 1working shift
k1 = total no. of m/c. or work stations performing operations on the part
under consideration in production line

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6b. Index of Work station Flexibility = j2/k2
j2 = No. of m/c. or work stations within the area under consideration so
designed that they can be moved to any other location in one working
shift.
k2 = Total no. of m/c. or workstations with in the area under
consideration.

42. 7. Index of floor area loading density
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8. Index of Aisle space = r/q
r = total aisles area
q = total layout floor area
9. Index of storage space = (q-u)/q
q = Total layout floor area
u = Total floor area occupied by temporary or controlled storage
of material, tools and equipments needed to modify this
material

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 10. Index of Storage volume utilization = v/w
v = Volume occupied by raw material/finished
goods at the normal maximum level of storage
w = Total volume available for storage of raw
material or finished goods

45. Presenting the Layout to Management
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 Visual presentation
 An oral report
 A written report

46. Visual Presentation
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• The layout itself
• Supplementary details and facts
• Supplementary charts and displays
The supporting and pertinent data includes:
1. Final layout
2. Flow diagrams
3. Evaluation forms or tabulations
4. Cost comparison sheets
5. Summary of intangible benefits

47. Formal Written Report
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A. Title page
B. Letter of Transmittal
C. Table of contents
D. Discussion of Project
E. 1. Introduction
a. Purpose of the project and presentation of the problem
b. Basic facts about facility – as necessary
-Product
-Production methods
-Annual sales
-Number of employees
- Plant size
-Building construction
-Plant Location

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2. Condensed statement of proposal
3. Discussionof major activities
a. Receiving and shipping
b. Storage
c. Maintenance, tool crib etc
d. Employee facilities
e. Office
f. Production –discussionon each activity
g. Others as appropriate
4. A statement of costs for installing the layout
5. A statement of expected savings
6. A statement of expected increases in operating expenses
7. A cost analysis and engineering economy study summarizing the effects of the proposals and comparing the proposals with present conditions.
8. Recommendations for improvements in related areas
9. Schedule of installation
10. Procedure of re-layout or re-arrangement
11. Conclusions – a) General Comments and Observations b) Recommendations
12. Appendix

49. Contents in Appendix
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a) Production data and related information
- Sales forecast
- Drawings
- Bills of material
- Production calculations
- Routings
b) Material Flow design
- Assembly chart
- Operation process chart
- Flow diagram
c) Other items as necessary
- Activity relations chart and diagram
- Production area determination
- Storage and warehousing area determination
- Service area space determination
- Area Allocation diagram
- Plot plan
- Final Layout
- Indices of layout efficiency or other evidences of layout evaluation

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Thank You

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References
 Facilities Planning, Third Edition By JAMES A. Tompkins
 Plant Layout And Materials Handling By James M. Apple
 Facility Planning & Layout Design by Chandrashekar
Hiregoudar, B Raghavendra Reddy