Introduction

TI4103 Facility Layout Design

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TI4103 Facility Layout Design | Introduction to Facility Planning

Tujuan & Prasyarat
• Tujuan Instruksional Umum
⚬ Mahasiswa mampu merancang tata letak fasilitas sistem
manufaktur, yang meliputi mesin, tempat kerja, dan gudang
serta sistem pemindahan materialnya.

• Tujuan Khusus
⚬ Memahami kerangka umum perancangan fasilitas

TI4103 Facility Layout Design | Introduction to Facility Planning 3

Hierachy for Facility Design
Q. Lee, IIE Solution, 1997
Layout or space planning involves five levels -from the global maps
of site location to engineering drawing tools and workstations

Level 1: Global Site Location

Level 2: Supra-space Plan

Level 3: Macro-space Plan

Level 4: Micro-space Plan

Level 5: Sub-micro-space Plan

The picture can't be displayed.
TI4103 Facility Layout Design | Introduction to Facility Planning 09
Level 1: Global Site Location

• The firm decide where to locate facilities and

determine their missions
• The most strategic impact
• Major considerations: labor rates, tax break, labor skill
and attitudes, supporting services, politics, etc.
• Appropriate planning results in facilities optimized
for the markets and located near the most important
resources

TI4103 Facility Layout Design | Introduction to Facility Planning 10

Level 1: Global Site Location

Figure: Toyota Worldwide

TI4103 Facility Layout Design | Introduction to Facility Planning 11

Level 1: Global Site Location

Figure: Toyota Indonesia

TI4103 Facility Layout Design | Introduction to Facility Planning 12

Level 2: Supra-space Plan
• Site planning, including number, size, location of buildings, as well
as roads, water, gas, and rail
• Involve a series of drawing showing past, present and future
configurations
• Planning still has long-term and far reaching consequences.

TI4103 Facility Layout Design | Introduction to Facility Planning 14

Level 2: Supra-space Plan

Figure: Toyota, Karawang Regency

Source: Google Maps
TI4103 Facility Layout Design | Introduction to Facility Planning 13
Level 2: Supra-space Plan

Golf
Course

River
Roads &
Transportation

Park
Figure: TMMIN Karawang
Source: Apple Maps TI4103 Facility Layout Design | Introduction to Facility Planning 16
Level 3: Macro-space Plan

• A macro-layout, plans each building, structure, or sub-

unit of the site
• The designers define and locate operating
departments and determine overall material flow.
• Easier to correct than site level decisions
• A poorly planned facility can bring high handling cost,
confusion, and inflexibility

TI4103 Facility Layout Design | Introduction to Facility Planning 17

 Level 3: Macro-space Plan
Container Figure: Plant 1 - 3
Yard TMMIN, Karawang

Finished Car
Parking Lot

Taman

Supplier

Plant

Plant & ATM Office Mosque TI4103 Facility Layout Design | Introduction to Facility Planning 18
Source: Google Earth
Level 4: Micro-space Plan

• Department or cell layout

• Location of specific equipment is determined
• Emphasis shifts from gross material flow to
personal space and communication
• Socio-technical considerations dominate

TI4103 Facility Layout Design | Introduction to Facility Planning 19

Level 4: Micro-space Plan

Source: Brigita Gajsek, 2015

TI4103 Facility Layout Design | Introduction to Facility Planning 20
Level 5: Sub Micro-space Plan

• Workstation design
• Workstations are designed for efficiency,
effectiveness, and safety
• Tools-jig and fixture
• Location of materials
• Appropriate material handling aids

TI4103 Facility Layout Design | Introduction to Facility Planning 21

Level 5: Sub Micro-space Plan

Source: Human Centered Solutions.

Source: Plastics Today, 2011

TI4103 Facility Layout Design | Introduction to Facility Planning 22

Level 5: Sub Micro-space Plan

Source: Industry Week, 2020

TI4103 Facility Layout Design | Introduction to Facility Planning 23

Facility Planning
Tompkins, et. al. 1996
• A facility represents the tangible fixed assets associated with
a locus of economic activity.

• Economic activities are those activities associated with the

production, distribution, and consumption of goods
and/or services.

• Examples of facilities – manufacturing plants or factories,

warehouses, distribution centers, retail stores, hospitals,
offices, airports, universities/schools.
TI4103 Facility Layout Design | Introduction to Facility Planning 24
Facility Planning
• FP involves determining the type, quantity, arrangement, and
location of tangible fixed assets to best achieve the
objectives of the economic activity.
• For example: A factory that enables low cost production of
a product can be utilized to maximize the profit of a firm.
• For an airport: enables the passenger-airline interface
• For a hospital: supports providing medical care to
patients.

TI4103 Facility Layout Design | Introduction to Facility Planning 25

Facility Planning

Lokasi
Fasilitas

Perencanaan Desain
Fasilitas Struktur

Desain Desain
Fasilitas Tata Letak

Desain Sistem
Pemindahan Material

TI4103 Facility Layout Design | Introduction to Facility Planning 26

Facility Planning Scope
Divided into into two general areas: Facility desing and Facility
location
• Facility location: Determine where facilities should be located to
best support the production and distribution of of goods
and/or services.
• Facility design: Determine how the components of a facility
should be configured to best support the production and
distribution of goods and/or services, where the components
of the facility consist of the structure, the layout, and the
material handling systems.
TI4103 Facility Layout Design | Introduction to Facility Planning 27
Facility Planning Hierarchy

• Structural Design: Determine the detailed design of a facility, including the

building and services –e.g. gas, water, power, heat, light, air, and sewage.
• Facility Layout: Determine the arrangement and shape of space-consuming
entities (or “activities”) in a facility, where the activities interact with each
other through flows of materials, personnel, and/or information.
• Material Handling System Design: Determine the process, equipment, and
systems that transfer and manage the transfer of material between activities in
a facility

TI4103 Facility Layout Design | Introduction to Facility Planning 28

Facility Planning (FP)

• FP involves making strategic decisions concerning the

tangible fixed assets used in the production process.
• The difference in the planning horizon for each of the
different levels of analysis used in the production
process listed in Table 1.1.

TI4103 Facility Layout Design | Introduction to Facility Planning 29

Table 1.1: Planning Horizon Associated with
Production Analysis

TI4103 Facility Layout Design | Introduction to Facility Planning 30

Significance of Facility Design

• Material handling costs:

⚬ 30 - 75% of a product’s cost (Sule, 1991)
⚬ 20 - 50% of a manufacturing company’s operating
budget (Tompkins & White, 1994)

• Optimal Layout Design can reduce production costs

TI4103 Facility Layout Design | Introduction to Facility Planning 31