Facilities Planning
Facilities planning determines how an activity's tangible assets best support achieving the activity's objective. Facilities planning can be (a) Planning and design of a new facility (b) Modernization of an existing facility (Continuous improvement). Since 1955, approximately 8% of the GNP has been spent annually on new facilities in the United States. Figure 1 shows typical expenditures for major industry groupings.
Figure 1. Facilities expenditures for major industry groups as percent of GNP.
Figure 2. General hierarchy of facilities planning.
Figure 3. Hierarchy of facilities planning in manufacturing industry.
Figure 4. Hierarchy of facilities planning at an airport terminal.
Figure 5. Hierarchy of facilities planning at hospital facilities.
Figure 6. Planning hierarchy at office facilities.
Who are involved in the Facilities Planning ?
Civil engineers
Architects
Electrical engineers
Industrial engineers
Mechanical engineers
General contractors
Consultants (including specialists in safety, health, environment, fire protection)
Managers (including facility managers)
Real estate brokers
Urban planners *
Local governments *
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* Federal, state, local laws, rules and regulations are involved
What are included in the Facilities Planning ?
Location of the facility
Layout of the facility
Material handling systems
Process equipment and machinery
Structural systems
Safety systems
Sanitation systems
Heating, ventilation and air conditioning systems (HVAC systems)
Personnel requirements
Compliance with safety and health laws
Facilities Design Components
:Facilities Systems
Layout
Handling
Examples for Facilities Systems
:Structural systems
HVAC systems
Enclosure systems (Floors, walls, roof, partitions)
Lighting
Electrical systems
Communication systems
Sanitation
Personnel requirements
Occupational health and safety requirements
Examples for layout systems:
HVAC system layout
Electrical
Equipment and machinery
Communication systems
Personnel areas
Inventory system
Material transportation system
Material storage area layout
Examples for handling systems
:Materials
Personnel
Information
Equipment
Public
Effect of Facilities Planning on Productivity:
Facilities planning has a direct impact on productivity. Continuous improvement of facilities means improved productivity.
In manufacturing industry generally 20 to 50 % of the total operating cost is caused by material handling. In some industries it can be as high as 80 %. Reduction of material handling cost makes significant improvement in the market competitiveness. If we improve the flow of material, we will automatically reduce production cost. The shorter the flow throughout the plant, the better. The cost reduction formula from motion and time study is a valuable technique that can be utilized in plant layout design and material handling system design.
It should also be noted that material handling accounts for more than 50% of all industrial injuries. Any occupational injury means loss of labor time and increase in expenses.
Productivity can be improved by improving the following factors:
Material handling
Personnel utilization
Equipment utilization
Space utilization
Energy utilization
Inventory management (reduced inventory)
Quality (increased quality)
Some of the laws, rules and regulations that affect the investment on new facilities or the alteration of existing facilities:
Occupational Safety and Health Act (OSHAct)
Nuclear Waste Policy Act
Americans with Disability Act (ADA)
Clean Air Act
Hazardous and Solid Waste Management and Recovery Act (RCRA)
Energy Conservation Programs
Application of Engineering Design Process to the Facilities Planning Process:
Define the objective of the facility (or redefine)
Specify the primary and support activities
Determine the interrelationships among all the activities
Generate alternative plans
Evaluate alternative plans
Select a facilities plan
Implement the plan
Maintain and adapt the facilities plan
Redefine the objective of the facility
Figure 7. Facility procurement process.
Recognizing the Facility Problem:
Planning process begins with recognition that existing facilities are inadequate. The need for a new or upgraded facility may result from:
Planning and Budgeting:
Budgeting requires a feasibility study, which may include analyzing the needs and evaluating alternatives for obtaining the needed facility. Planning process includes a risk analysis, (For example, special fire protection features, which include sprinklers, sensors, and alarm devices)
Other requirements that are included in planning and budgeting are ventilation, lighting, emergency power, shielding equipment, safety barrier, etc.)
Predesign:
Once a course of action is selected, there are further details to work on, including preparation of detailed requirements and technical information for design. Examples:
Design:
After compiling detailed requirements, one or more preliminary design concepts are prepared. Analyzing and prioritizing safety requirements will help designers deal with important safety features. The design process must include hazard analysis and designers must select corrective measures and integrate them into the design.
Selection and Procurement of Equipment:
An integral part of the facility planning and design is the selection and procurement of equipment that will be used in the facility. Designers identify hazards associated with the equipment and specify what controls to procure with purchased equipment for the facility project.
Construction and Modification:
After design and funding, the facility project moves to construction or modification of an existing facility. (Generally contractors are used)
Designers develop a quality assurance program to make sure that contractors do not make changes that introduce dangers and that safeguards are correctly constructed and installed.
Occupancy and Use:
After completing a facility project, occupants move in and the facility is put to use. After moving in, the system will be continuously monitored and some fine adjustments and modifications will be made.
Site Considerations:
Climate and natural conditions
Neighborhood and population
Building Considerations:
Equipment Considerations:
Fire protection, overpressure, excess heat, dust control, exhaust ventilation, dangers of flammable liquids, leaks, sensing devices which can report status, and many other safety features must be included in the facility planning process.
Designers need to consider interior access for setup, maintenance and cleaning. Access by stairs, fixed ladders or platforms should be part of equipment selection process.
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Last Update: September 9, 1999 |
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Prepared by : Serdar Z. Elgun |
